Variation is a universal aspect of manufacturing that adds complexity to the production process. It can affect all parameters, leading to differences in the form and size of produced parts, which may affect the whole product. To tackle these challenges, researchers at Wingquist Laboratory are developing new methods to manage variation. One outcome of their research is the well-established RD&T software.
Inconsistencies in manufacturing can lead to significant problems throughout product development. They can cause assembly difficulties or functional defects, which results in additional costs and delays. Moreover, these variations can impact perceived quality, such as visible gaps between doors or hoods, which affects the overall impression of the product.
“Every process that goes into creating a product has some degree of variation. To make sure these differences do not compromise quality or increase costs, it is important to really understand and manage them well,” says Rikard Söderberg, Director of Wingquist Laboratory.
The Geometry Assurance and Robust Design research group at Wingquist Laboratory develops advanced methodologies and tools aimed at minimizing geometric variation in products. These efforts contribute to enhancing product quality, reducing costs, and promoting sustainable production practices.
By predicting and managing variation in critical dimensions, we can make product concepts more robust from the start.
Using Simulations to Improve Product Quality
One key outcome of their research is the development of statistical variation simulations used in the RD&T software, a spin-off project from Wingquist Laboratory. This tool allows designers to analyse how variations in manufacturing and assembly processes might affect a product, enabling them to visualise variations and potential issues, and make informed decisions early in the design process, before physical prototypes are made.
“By predicting and managing variation in critical dimensions, we can make product concepts more robust from the start. For instance, when multiple parts are assembled, variations can propagate through the contact points. Optimizing these contact points enhances the robustness and reliability of the final product,” says Rikard Söderberg.
The research also acknowledges that no part is perfect, whether dealing with sheet metal or plastic components that might bend or deform. It also identifies which tolerances are most critical, allowing designers to determine where tight tolerances are necessary and where they can be relaxed.
Adoption in Industry
The research has seen broad implementation across various industries over the years. Companies like Volvo Cars are leveraging these research-driven insights through the RD&T software to meet strict requirements and maintain high quality standards.
"The software helps us determine feasibility and ensure stability throughout the process, identifying when we fall outside the tolerance range, based on the placement of locators and tolerance allocation," says Johan Stabeck, Senior Engineering Manager of Robust Design and Tolerancing at Volvo Cars.
By incorporating the research from Wingquist Laboratory, companies can identify potential issues early and optimize processes to meet high-quality standards and tight production timelines.
“From concept through to the project phase, the software has been an important enabler in supporting our product development. The insights we gain strengthen our global development and manufacturing efforts, ensuring our products consistently meet all geometry requirements," says Johan Stabeck.
Utilized by Industry Partners
RD&T has been used in the automotive industry for over 20 years. In addition to Volvo Cars, the RD&T software is utilized by companies such as Volvo Group Trucks Technology, GKN Aerospace Engine Systems, Saab Aeronautics and Scania CV.
Research at Wingquist Laboratory
Learn more about the research at Wingquist Laboratory, and our research groups.
RD&T Technology
RD&T Technology is a spin off company from Wingquist Laboratory.
- Full Professor, Product Development, Industrial and Materials Science