Geometric variation simulation and robust design for flexible cables and hoses

Abstract

This article presents how to do stability analysis, variation simulation and tolerance envelopes for deformable cables and hoses. In this way, the well-established methods for analyzing and minimizing the propagation of geometric variation are extended from rigid and sheet metal assemblies to large deformations of slender parts. This extension is highly motivated, not at least, by the increased amount of cables and hoses in electrified and hybrid solutions in the automotive industry. To secure the geometric correctness of the analysis, we use a nonlinear rod approach in the implementation of a simulation model of flexible cables that accounts for large deformations and supports a wide range of common cable clip types, cable joints and branches. A selection of measures and visualizations that reflect the spatial effects of geometric variation in deformable cables is incorporated in established variation analysis techniques. In particular, the concept of tolerance envelopes for rigid parts has been extended to also handle system of slender parts such as cables and hoses. This article extends previous research on robust design and variation simulation to cables subject to large deformations and has been successfully applied on two typical industrial cases: a wiring harness attached with various types of clips to a static surrounding and a cooler hose subjected to a high-frequency sampled engine motion

A review: virtual assembly of flexible cables based on physical modeling

“…An example of the cable-assemblyprocess planning and strain-strength check was provided to validate the model. Hermansson et al (2013) proposed a simulation model for cable geometry of vehicle doors based on Cosserat theory, considering cable connector constraints; the centerline position was calculated by the principle of energy minimization. , simulated a deformation process in a virtual environment on the basis of Kirchhoff theory; cable was discretized into center points and cross-sections.…”

Mechanisms and coherences of robust design methodology: a robust design process proposal

“…Schleich et al (2012) use skin models to incorporate manufacturing data to increase the detail and accuracy of geometric variation simulation. Other studies seek to extent geometric variation simulations by for example including the influence of welding on the final assembly (Pahkamaa et al 2012) or by regarding deformable, slender parts like cables and hoses (Hermansson, Carlson, and Bjo 2013).…”

Toleransi dimensi dan geometri-Analisis rantai variasi dalam proses perakitan produk

“…Contoh lain perakitan benda non-rigid adalah perakitan sebuah kabel yang fleksibel [Hermansson et al 2013]. Gambar 15 memperlihatkan bagaimana proses analisis variasi kabel tersebut dilakukan untuk memperbaiki disain kabel tersebut.…”

“…Gambar 15: (a) simulasi zona variasi sebuah kabel dimana ada resiko tinggi untuk menyentuk batang vertikal sebelah kiri, (b) besarnya zona variasi pada kabel tersebut dengan representasi warna dan (c) simulasi zona variasi dengan disain kabel yang baru [Hermansson et al 2013].…”