Abstract:
A tooling and part design method automatically detects tooling and machining interferences with a desired part design. A user selects a mechanical component. Data indicative of the mechanical component, such as a part template, is determined and displayed to the user. The user selects one or more design parameters of the mechanical component to modify. Any necessary tooling and/or machining functions are embedded in the data, and performed automatically on the mechanical component when the user modifies a design parameter. Any interferences caused by the modification are automatically identified to the user.

Description:
FIELD OF THE INVENTION 
     The present invention relates to tooling automotive components, and more particularly to concurrently modeling automotive components and the tooling thereof. 
     BACKGROUND OF THE INVENTION 
     Manufacturing tooling capabilities for mechanical parts may be limited due to the complexity of the parts. This is especially true in automotive applications. Spatial limitations can cause difficulty during initial design, manufacturing, and tooling of the parts. 
     In particular, it can be difficult to perform actions associated with machining, handling, and assembling of the part due to interferences between the part and the particular tool being used. For example, although it may visually appear that an appropriate tool can be used at a particular location on a part, actual performance may result in permanent damage to the part. 
     SUMMARY OF THE INVENTION 
     A tooling and part design method comprises selecting a mechanical component. Data that is indicative of the mechanical component is determined. The data is modified in order to alter one or more dimensions of the mechanical component. A tooling function to perform on the mechanical component is selected automatically. Interference between the tooling function and the mechanical component is identified automatically. 
     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
         FIG. 1  is an automated tool and part modeling algorithm according to the present invention; 
         FIG. 2  illustrates a part template according to the present invention; 
         FIG. 3  illustrates a tooling template according to the present invention; 
         FIG. 4  illustrates a machining template according to the present invention; and 
         FIG. 5  illustrates a part template showing interferences between a tooling or machining template and the part template. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
     An automated tool and part modeling algorithm  10  is shown in  FIG. 1 . At step  12 , a user selects a part and the algorithm  10  loads the part template. In the preferred embodiment, the user selects the part at a graphical user interface. The part template may include any suitable reference information indicating the dimensions of the part. For example, the part template may include, but is not limited to, parametric tooling data and the geometry of the tool and/or part. The part is displayed three-dimensionally to the user at the graphical user interface at step  14 . At step  16 , the user selects and changes a parameter in order to modify a particular feature or dimension of the part. For example, the user may change a location of a fastener, such as a bolt. The graphical user interface redisplays the part, reflecting the modified feature or dimension, at step  18 . The part modeling algorithm automatically selects appropriate tools and/or operations to apply to the part at step  20 . Alternatively, the user may remove, modify, or add additional operations such as drilling, cutting, or grinding to perform on the part. The tooling and/or machining data necessary for this process is embedded in the part template. The user may have the option of modifying the tooling or machining data, but it is not required. Because the tooling and/or machining data is embedded in the part template, it is not required that the user have any knowledge of the operations required to manufacture and process the part as designed. In this manner, the user is able to make changes to a part design without further knowledge of the tooling and/or machining required. 
     At step  22 , the results of the tooling and/or operation of the part are displayed to the user. At this step, the user is able to determine if the modification at step  16  resulted in interference between the tool and the part. For example, the graphical user interface may display the interaction between the tool and the part. Alternatively, the algorithm  10  may perform a Boolean removal operation on the part to visually subtract the area of the part that the tool interferes with. The graphical user interface indicates the subtracted area of the part to the user. Additionally, the graphical user interface may indicate the interference to the user using other suitable means, such as a textual message or audio alert. 
     A user selects an automotive component and a part template  30  of the component is displayed at a graphical user interface as shown in  FIG. 2 . A part template  30  of a steering knuckle  32  is displayed at the graphical user interface. The user can change one or more parameters of the steering knuckle  32 . For example, the user can reshape or resize the steering knuckle  32  and the graphical user interface automatically displays the changes to the steering knuckle  32 . Parameters may include, but are not limited to, size and or angle of one or more bolt holes  34  and  36 . In other words, the user can change the angle of the axis  38  of the bolt hole  34  in reference to an axis  40  of the part template  30 . 
     The user selects a machining or tooling function as shown in  FIGS. 3 and 4 . The graphical user interface displays a tooling template  42  or a machining template  44  applied to the part template  30 . The tooling template  42  includes a tool head  46  and one or more socket heads  48 . Associated tooling information and geometry is embedded in the part template  30 , so that the position and size of the tooling template  42  automatically changes when the geometry of the part is changed due to the user modification of the parameters. For example, as shown in  FIG. 3 , the angle of the bolt hole  34  is changed. The position and/or size of the tooling template  42  changes accordingly in order to accommodate the changes to the bolt hole  34 . Similarly, in  FIG. 4 , the angle of the bolt hole  36  is changed. The machining template  44  includes one or more cutting or grinding elements  50 . The position and/or size of the machining template  44  changes accordingly in order to accommodate the changes to the bolt hole  36 . 
     In one aspect of the invention, the user is able to visually discern any interference between either the tooling template  42  or the machining template  44  and the part template  30  at the graphical user interface. As shown in  FIG. 3 , the modified bolt hole  34  caused the angle of the tooling template  42  to change in such a manner that an anterior portion of the tool head  46  interferes with a portion of the part template  30 . As shown in  FIG. 4 , the modified bolt hole  36  caused the angle of the machining template in such a manner that the cutting element  50  interferes with a portion of the part template  30 . 
     In another aspect of the invention, the graphical user interface identifies interference regions  60  and  62  directly on the part template  30  as shown in  FIG. 5 . Interference between the tool head  46  of  FIG. 3  and the part template  30  resulted in interference region  60 . Similarly, interference between the cutting element  48  and the part template  30  resulted in interference region  62 . 
     In this manner, tooling and machining interferences can be detected in the early stages of part design. In the preferred embodiment, this modeling technique is used on a CAD system capable of parametric design as is known in the art. The part structure, as well as any machining, assembly, or handling tooling can be modeled concurrently in the same parametric model of the part. 
     The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.