Research Papers

Using Morphing Techniques in Early Variation Analysis

[+] Author and Article Information
Ola Wagersten

Department 91360, PVÖSN 35,
Volvo Cars,
Göteborg SE-405 31, Sweden
e-mail: ola.wagersten@volvocars.com

Björn Lindau

Department 81720, PVÖSE 101,
Volvo Cars,
Göteborg SE-405 31, Sweden
e-mail: bjorn.lindau@volvocars.com

Lars Lindkvist

Department of Product and
Production Development,
Chalmers University of Technology,
Göteborg SE-412 96, Sweden
e-mail: lali@chalmers.se

Rikard Söderberg

Department of Product and
Production Development,
Chalmers University of Technology,
Göteborg SE-412 96, Sweden
e-mail: rikard.soderberg@chalmers.se

Contributed by the Design Engineering Division of ASME for publication in the JOURNAL OF COMPUTING AND INFORMATION SCIENCE IN ENGINNERING. Manuscript received August 22, 2013; final manuscript received August 30, 2013; published online January 22, 2014. Editor: Bahram Ravani.

J. Comput. Inf. Sci. Eng 14(1), 011007 (Jan 22, 2014) (9 pages) Paper No: JCISE-13-1163; doi: 10.1115/1.4025719 History: Received August 22, 2013; Revised August 30, 2013

Today, in order to be competitive in a fierce global car market, higher demands are placed on the perceived quality (PQ) of the products. The end customer's visual impression of fit and finish are one of several factors influencing the overall PQ. When assessing the PQ of split-lines, the assumed geometric variation of the ingoing parts is an important prerequisite for trustworthy visualization and for correct judgments. To facilitate early decision making in conceptual phases, new demands are set on virtual tools and methods to support the engineers. In this study, a method for early evaluation of the impact of geometrical variation on PQ of split-lines is proposed. Starting from an exterior styling model, mesh morphing techniques have been used to distort the exterior model according to measurement data acquired in running production. Morphing techniques have also been used to adopt previous structural design solutions onto the new styling, in order to make an early assumption of the assembly stiffness. The used method is described and adopted in an industrial case. The study shows that the presented technique can be used to create continuous and correlated datasets. Non-rigid part behavior can be included in early PQ evaluations, even if the final detailed engineering design models do not yet exist.

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Fig. 1

Contributing factors to perceived quality of split-lines

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Fig. 2

(a) Rigid variation simulation and (b) non-rigid variation simulation based on FEA

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Fig. 3

Available data for early judgment

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Fig. 4

Assembly variation analysis

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Fig. 6

Example of preparation of contour shapes in the styling model

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Fig. 7

Morphing to guess part deviation

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Fig. 8

Morphing to guess shape of structural part

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Fig. 10

Morphing direction divided into surface (white) and edge (black) components

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Fig. 11

Distribution of the handles along the edge contour

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Fig. 12

Part deviation modeling

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Fig. 13

Color plots describing hood exterior part deviation after morphing

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Fig. 14

Cumulative percentage of variation

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Fig. 15

Result PCA-representation (a) Part normal mean and (b) part normal variation

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Fig. 16

Color plots of unit displacement disturbance: (a) Morphed model and (b) engineering model

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Fig. 18

Simulated range versus production measurements

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Fig. 17

Rendered visualization model for PQ assessment



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