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"Virtual Modeling" |
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"Virtual Modeling" |
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Inside view of interior seat side shield |
Interior seat side shield surface modeled |
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The Lear Corporation, based in Detroit, is among the world's leading suppliers of automotive interior systems. The company's Advanced Math Modeling Group has solved many thorny design problems for major auto manufacturers, including Chrysler, Ford, Mazda, and Toyota. Design challenges have ranged from troubleshooting a faulty visor clip, to a complete revamping of a minivan interior. Not long ago, a Japanese automaker asked the Advanced Modeling Group to complete an ashtray assembly design -- in three weeks. Using a conventional NURBS-based system, this project would normally take up to six weeks because of the differences in surface development. This time, instead of a traditional CAD system, the Advanced Modeling Group used a Class A surface-modeling product called ICEM Surf from ICEM Technologies of Arden Hills, MN. "We not only met the deadline, we gave the customer a fully surfaced CAD model -- Class A and back side," said Rich Blue, manager of Lear's Design Business Unit. The automaker was then able to generate a functional stereo lithography model prior to tooling the component. "We were used to the standard, conventional CAD modeling systems where you build curves first and then build surfaces around those curves," said Matt Pyzik, head of Lear's CAD modeling team. "With ICEM Surf, you create surfaces first. When I have a complex surface with a conventional CAD system, the opportunity for surface imperfections is much greater." ICEM Technologies is a division of Parametric Technology Corporation, and was formed in 1995 to develop advanced software solutions for computer-aided product design and manufacturing. ICEM Surf allows what the company calls "global modeling" by enabling users to modify many surfaces together, working both the Class A (finished side) and Class B (back side) surfaces of the material. According to the company, ICEM Surf allows surfaces to be generated, diagnosed, visualized, and modeled dynamically in real time. All work can be performed directly on an accurate 3D surface model that can be rotated and positioned. Stylists can use this model as if it were made of virtual clay; surfaces can be manipulated and stretched in real time. As changes are made, the highlight reflections, section curves, shaded displays, and surface textures are dynamically updated. What the designer sees onscreen is exactly what will be produced during machining. Changing the Rules The traditional design process typically has included building a clay model, scanning it, surfacing the scan data, creating a proveout model of the surface, review and surface modifications, proveout model changes, and the cutting of a tool. Recently, when Lear's team received engineering data outlining all sections needed for certain interior components, the stylist used the information to generate a "treasure map," calling out fillets, radii, and a general shape. By using ICEM Surf to design Class A and B surfaces, Lear was able to eliminate the clay model for one component and the proveout model for another. In a job for a minivan producer, the Advanced Math Modeling Group was asked to make extensive changes in an interior to accommodate a new AC system, packaging of a different window mechanism, and a new automatic sliding door. From rough scan data supplied by the client, Lear was able to create a millable surface for the entire interior within a few weeks. Lear also has used ICEM Surf for troubleshooting designs, such as a visor clip that malfunctioned on a particular truck model. The Advanced Math Modeling Group compared laser scan data from the tool with the original CAD data, recreated both sides of the part in ICEM Surf, and collaborated with the engineering team to make the part fit correctly. "The ultimate goal of all automakers is to eliminate the expensive and time-consuming process of prototyping," said Blue. "Lear already has shown how we can help them do that. In fact, the combination of our top-quality staff and our ICEM Surf design system makes us one of the best resources for design services." For more information, contact ICEM Technologies, 4201 Lexington Ave. North, Arden Hills, MN 55126-6198; Tel: 800-799-3932. |
