Nissan building capability in virtual engineering

Citation

(1998), "Nissan building capability in virtual engineering", Assembly Automation, Vol. 18 No. 4. https://doi.org/10.1108/aa.1998.03318dab.007

Nissan building capability in virtual engineering

Nissan building capability in virtual engineering

Keywords Computer-aided engineering, Virtual reality

Nissan has completed its first development programmes using computer-aided production engineering (CAPE) software tools from Tecnomatix Technologies Limited. The Nissan European Technology Centre network, based in Cranfield, is using Tecnomatix DYNAMO software to construct virtual reality simulations showing how vehicle components relate to each other. The information is then carried forward for validation within a 3D virtual reality factory, using ROBCAD to plan the production process.

By complementing its existing CAD-CAM investment, the introduction of CAPE facilities has helped Nissan engineers to achieve dramatic reductions in the development lead times for two new models, the Primera estate variant now in production, and a replacement for the Almera, due to commence production at Nissan's Sunderland factory in the year 2000.

CAPE technologies speed up the prototype development process by allowing engineers to look at different aspects of the vehicle design simultaneously. Once a component design has been generated by traditional CAD methods the solid model data can be used to develop complex 3D layouts on the computer screen. These can be used to analyse the optimum sequence of assembly operations, highlighting any problems at an early stage to ensure that the actual hardware will fit "right-first-time".

The 3D images can be projected on to large screens allowing specialist engineers or suppliers' representatives to review the design, discuss potential problems and use their collective expertise to arrive at the most efficient solutions. Any changes to the component database are promulgated immediately to other departments which may be using the same data.

ROBCAD, for example, uses the component design data to validate the manufacturing process within the virtual factory. Specific manufacturing operations are constructed within a 3D simulation representing all the production resources required to complete the operation. This covers every aspect from floor space to material handling, conveyors and any standard automation such as robots and tooling. ROBCAD guides the production engineer through decisions concerning approved methods, the allocation of existing resources and any unusual tooling problems which will need to be resolved.

Manual operations can be assessed by using the Tecnomatix ergonomics package ROBCAD-MAN. This provides a means for evaluating repetitive manual tasks which may have Health and Safety implications. The virtual worker can be used to achieve best posture for a wide range of tasks, from simple jobs such as clipping-in a carpet, to more complex operations which may require mechanical assisters to support the weight of heavy components.

The main benefit delivered by CAPE tools is that problems which were previously discovered during the assembly of actual hardware can now be resolved much earlier, and at a less expensive stage of the development process. This not only reduces costs, it is helping Nissan to reduce the time taken to design and launch new models ­ giving them a crucial advantage in today's increasingly competitive markets.

NETC is currently upgrading its computer-aided design system to provide state-of-the art analysis for effective ­ and rapid ­ working. The eventual aim is to reduce the lead time for new vehicle designs by about 30 per cent to around 16-20 months. According to Andy Palmer, General Manager of Vehicle Design and Test for Nissan, interoperability with existing computer-aided engineering facilities was a crucial factor in choosing Tecnomatix software.