RPS System

Definition and Applications

Presentation

RPS System
Definition and Applications
Reference Point Systematics

Sist. Local

Sist. Global
RPS System
Definition and Applications

1.0 - Vehicle Coordinate System

The concept of the Reference Point Systematics is

based on the definition of a coordinate system in
piece.

A convention determines that a car will have its

dimensions characterized from a coordinate system
global, whose origin is at the center of the front axle of the vehicle.

From this coordinate system, lines are drawn

parallel to each of the coordinate axes (equidistant from
approximately 100 mm), forming a network. These lines
of the network facilitate the definition of the position of any point of the
car, in addition to serving as a reference for contour lines.
RPS System
Definition and Applications

1.1 - Global Coordinate System and Coordinate System

Local in Vehicle
The coordinate systems
places are obtained from
a translation and/or rotation of
global system

All coordinate systems

locations, defined in a certain
request, maintains a direct relationship with the

global coordinate system

(car coordinate system).

The origin of local systems is

determined from a point
fixed well defined (RPS point
as it will be seen ahead).
RPS System
Definition and Applications

2.0 - Concepts of RPS and Functional Mass

There is, over the automotive industry, an increasing demand
customer's preference for quality and low price, in addition to competition,
that seeks to satisfy customer needs with products each
see better.

Thus, everything that is important to the client must be considered

during the development and manufacturing of the product.

The Client desires:

Security
Reliability
Execution of functions
Assembly guarantee on adjustments
RPS System
Definition and Applications

2.1 - Why the RPS System?

Greater demand from customers for quality and low price !!!!!
To reduce costs, one of the main points is
reduce rework !!!!!

The causes of rework are:

- low dimensional quality of the parts (individual pieces and welded groups);
- difficulty in positioning/fixing the parts during the process of
manufacturing and measurement;

the composition (addition) of tolerances during the various stages of

process, mainly caused by the change of reference during the
manufacturing and measuring processes
RPS System
Definition and Applications

2.1 - Why the RPS System?

•In turn, the main causes that lead to deviations

dimensions are :

Incorrect definition of the fixation points

Changes of references during manufacturing and measurement

Lack of guidelines (standards) for positioning the points

of fixation
RPS System
Definition and Applications

2.1 - Why the RPS System?

The Problem of the lack of guidelines for definition

of the fixation points (Manufacturing and measurement)
RPS System
Definition and Applications

2.2 - What is RPS System?

The RPS points are the basis for unifying the fastening of the
parts during manufacturing and measurement.

They provide an unequivocal result about the

dimensional characteristics of the part throughout all
stages of manufacturing.
RPS System
Definition and Applications

2.3 - The Question of Reference Change

One of the main causes of the introduction of tolerances (errors)

in the process, it is the change of reference during manufacturing and
measurement.

Example:
Consider the task of executing the drills
B and C, so that the pins serve
in the holes. Another hole D is still
necessary. in a next step, the
the plate will be fixed from the hole already
existing in A.
RPS System
Definition and Applications

2.3 - The Issue of Changing the Reference

Step 2:
The piece is fixed from
Step 1: do furo D (mudança de
reference) and the hole C is
The part is fixed starting from the executed.
hole A and holes B and D are The tolerances
executed. achieved are:
The achieved tolerances are:
A B = 0.1 mm
A B = 0.1 mm A D= 0.1 mm
A D= 0.1 mm D C= 0.1 mm
-----------------------
B C= 0.3 mm
RPS System
Definition and Applications

2.3 - The Question of Changing the Reference

The same part can be manufactured without changing the reference,
through the following procedure:

Step 2:
The part is fixed starting from the
Step 1: the hole A again and the hole C is
executed.
The part is fixed from the The achieved tolerances are:
hole A and holes B and D are
executed. A B = 0.1 mm
The achieved tolerances are: A C = 0.1 mm
-----------------------
A B = 0.1 mm
B C= 0.2 mm
A D= 0.1 mm
RPS System
Definition and Applications

2.3 - The Question of Changing the Reference

These examples aim to show how, through change of
Reference, unnecessary tolerances are added to the process.

The definition of the fixation point (reference) should already be made during the
project. As the number of changes decreases
references, the sum of tolerances is reduced and the quality of
product.
To reduce the number of reference changes, it is necessary to
that in the posts/cells the manufacturing and measuring operations are
referenced to the same points, that is, the same master hole must
to be used both during manufacturing and during measurement.

And finally, to reduce reference changes, the same holes

the master pins should be used in the largest number of steps during the
process.
RPS System
Definition and Applications

2.3 - The Issue of Changing the Reference

Two production lines: in the first there was no concern in the
definition of the fixation points and the second one uses philosophy
RPS.
RPS System
Definition and Applications

2.4 - Definition of Degrees of Freedom

In order to fix or position in a way

unique (unequivocal), six degrees of
freedom (possible forms of
movement - 3 translations and 3
Rotations must be prevented.

Six elements/devices of
fixation, arranged as shown in the figure,
they fulfill the function of ensuring the
correct positioning of the part:

3 devices in the z direction;

2 devices in the y direction;
1 device in the x direction.
RPS System
Definition and Applications

2.5 - Parallelism to the Coordinate Axes

The RPS points must be parallel to the

coordinate axis system of the part.

If there are no parallel surfaces in the part

to these axes, the project must be changed from
way to have them.

Non-parallel surfaces to the system of

Axes are very difficult to measure.
RPS System
Definition and Applications

2.5 - Parallelism to the Coordinate Axes

2.5.1 - Use in All Stages of the Process

The reference points will be used during the various stages of

process, from manufacturing to assembly and control.
For this reason, the RPS holes are:

defined in the piece as holes or surfaces as early as

possible;
defined in such a way that they guarantee a simple and stable attachment
of the piece;

that the same fixation can be repeated throughout the process

(up to final assembly and control).
RPS System
Definition and Applications

2.7 - The 3-2-1 Rule

A body has six possibilities.

of motion (degrees of freedom)
in three-dimensional space.

There are three rotational movements.

(indicated in gray) around the
coordinate axes and three of
translation (indicated by the arrows
greens).
RPS System
Definition and Applications

2.8 - The 3-2-1 Rule

In order to fix a body in space (preventing any
movement), all 6 degrees of freedom need to be
"blocked". This can be implemented as per the example
below
RPS System
Definition and Applications

2.8 - The 3-2-1 Rule

The choice for the distribution of points depends on the shape of the piece.

Preferably, 3 are placed over the largest projected surface.

RPS points, 2 points for the second largest and 1 point for the smallest.
point.
The six attachment points could also be distributed as
in the figure below:

The most important thing in distribution

of the points RPS is that it must be followed by
3-2-1 rule, because only then the
the correct fixation of the part will be
possible !!!
RPS System
Definition and Applications

2.9 - The 3-2-1 Rule

In order to achieve the greatest possible stability of fixation the
RPS points should be distributed as far apart from each other as possible.
The best way to secure a part should not consider
not only its form, but also its function.
Six RPS points are required whenever it is not possible.
to drill holes in the part for the purpose of fixing. A hole (as per
shown below) can "lock" two degrees of freedom. For this
the reason that in the example there are only 5 RPS points
RPS System
Definition and Applications

2.10 - The 3-2-1 Rule

The 3-2-1 Rule applies to any type of part, regardless of its
shape. However, pieces that are not very "stable", like large
stamped parts and coatings need fastening points
auxiliaries.
To avoid confusion regarding the names of the points, definitions were made.
rules by the Konzern for the naming of RPS. There are a maximum of 6.
main RPS devices, sequentially numbered: RPS 1, RPS 2 ...
RPS 6. Auxiliary RPS points are denominated in an analogous way, although
the numbering starts from 7. Considering the form of fixing,
the following letters were defined:

H - for holes and pins;

F - surfaces and edges.
RPS System
Definition and Applications

2.11 - The 3-2-1 Rule

Positioning and naming of RPS points

RPS System
Definition and Applications

2.12 Auxiliary RPS Points - Sets

RPS System
Definition and Applications

2.13 Auxiliary RPS Points - Sets

The device must comply with the 3-2-1 rule.

RPS System
Definition and Applications

2.14 Product Measurement Plan - PMP

Section A-A

Pos. 1.2 RPS 1 Hxz RPS 2 Hxz

Theoretical 1 2 3 4 5 1 2 3 4 5 Tol.
X= +/-0.0
Y=
Z= +0.0
Point positioned Point positioned as per
according to detail detail
17
RPS System
Definition and Applications

3.0 - Quotation
With the use of the car's global coordinate system, the position
Any and all pieces can be defined unequivocally.
In the listing with the help of the global coordinate system and the Network,
quotas are usually not presented as direct measures. The
levels are indicated with reference to the lines of the Network. These measures are
tolerated. The derived quotas have greater tolerances

In the example, the measure AB

it has a tolerance of ± 0.4 mm
because A and B have a
tolerance of ± 0.2 mm in
relation to the lines of the Network.
RPS System
Definition and Applications

3.1 - Quotation

Through the RPS system, each piece receives a system of

own coordinates, referred to as local. Normally this local system
consists only of a translation, parallel to the axis(es) of the system
global coordinates. In some cases, a rotation is also necessary.

For the x, y, and z axes, 3 coordinates of the main RPS points are
zeradas, defining the origin of the local system.

The origin of the local system is not tolerated in relation to the global system.
once the translation carried out is theoretical. The pricing of a part is
referenced in relation to this origin.

For the quotation of a part, the global system is no longer used. The
reference is defined based on the RPS that are located in the parts
but more stable of the part.
RPS System
Definition and Applications

3.2 - Quotation

•By direct quotation, the measure

RPS 1Hxy B has tolerance of
just 0.2 mm.

The definition of a quota (its origin) is always made considering the

function of the part. Important measurements (that characterize a function
(important part) are presented through direct quotation,
characterizing a functional measure.
The example illustrates this situation: the distance between the holes is
importante para permitir a montagem dos pinos de uma tampa. Já a
the distance of the holes to the reference point does not compromise the function
of the group of holes
RPS System
Definition and Applications

3.3 - Quotation

Drilling Group (Important Dimension)

The example of the illustration is this
+- 0.2
situation: the distance between the
holes are important to allow
the assembly of the pins of a
tampa.
RPS1 Hxz
The distance from the holes to
reference point no
compromises the function of the group
of holes
RPS System
Definition and Applications

3.4 - Quotation

•Special attention must be given to the form of

quotation. Care must be taken not to
forgetting to characterize the importance of the
measure (appropriate tolerance), that is,
measures that influence function
they should normally have smaller tolerances.

However, they should not be attributed

unnecessary tolerances to measures that do not
have great functional importance.
RPS System
Definition and Applications

3.5 - Quotation

The figure characterizes the quotation using

as a reference the lines of the Network.

In this example, the tolerances are

the holes may not comply
its function (to hold the lid pins).
The distance between the holes can be
very big.

Usando esta forma de cotagem, este efeito só será minimizado

if the tolerance regarding the network lines is decreased !!!
RPS System
Definition and Applications

3.6 - Quotation The example shows another way of

quotation: the mixed quotation.

Even using the referenced quote in

regarding the network lines, the direct pricing
it can also be used.
The important dimensions can be
assigned tolerances that ensure that the
The request fulfills its function.

However, this form of quotation presents

the inconvenience of assigning in parallel
smaller tolerances to measures that perhaps
don't need that.

In the example, a relatively unimportant measure assumes

the standard tolerance. Even with a larger tolerance range, the
function would be fulfilled.
RPS System
Definition and Applications

3.7 - Quotation

The distance from a point to the origin of

the coordinate system of the part is
called "RPS function measure" (or
Functional Measurement - RPS.

Functional masses are characterized

through an absolute value obtained by
simple subtraction.
RPS System
Definition and Applications

4.0 - Example

In the example: the origin of

coordinate system of the
the item is in the global system
(Rede) the following coordinates
x = 400, y=-65 e z =100.
•
The RPS point 4 Fz has in the
global system (Network) as
coordenadasx=550, y=-95,
z=100.
RPS System
Definition and Applications

The functional measures of point RPS 4 Fz are, therefore:

4.1 - Example ORIGIN RPS 4 FUNCTIONAL MEASURE
X = 400 550 150
Y = -65 95 30
Z=100 100 0

Functional measures represent

the differences of points at the origin of
coordinate system (value ).
In technical drawing, the same
information is given through a
quota.
The question revolves around measures,
not coordinated. That's why the
functional measures cannot be
negative.
Once the system of
the coordinates of the piece are obtained from

global coordinate system by

translation, the Functional Measures -
RPS can be calculated by
simple subtraction.
RPS System
Definition and Applications

4.2 - Example

The Point RPS1 Hxy sets two degrees of

freedom (x and y). The points 2Hy, 3Fz,
4Fz and 5Fz set the other degrees of
freedom.
These are the These are the These are the Functional Measures-
RPS points, coordinates of RPS. As a Functional Measure is
as per RPS points in introduced the distance from the point to the
defined by regarding the Network. coordinate system of the part.
rule 3-2-1. A Functional measure has the
the same meaning as a measure
direct (quota) in a technical drawing.
That is why the Functional Measures-RPS
are placed as values
absolutes
RPS System
Definition and Applications

4.3 - Example

The origin of the system of

the coordinates of the part are
recognized through the
null values assigned to
Functional Measures
(Function measures)
RPS System
Definition and Applications

4.4 - Example

The coordinates x, y, and z of point A in relation to

global system are respectively, 400, 700 and
100

A The respective function values are zero, once

the coordinates are at the origin of the system
of local coordinates.

The tolerance of the function measures is also zero.

for the same reason.
RPS System
Definition and Applications

5.0 - The Parallelism to the Network Lines

The fastening devices for the pieces to be measured or to be
manufactured should be designed in such a way that the results
generated in the process are unequivocal, that is, they allow for errors
can be easily identified and tracked.

The design of devices that have the RPS parallel to the lines of
Network is very important in this task
RPS System
Definition and Applications

5.1 - The Parallelism to the Network Lines

However, observe what happens with non-conforming pieces (n.i.O). Consider-
if now two equally non-conforming parts are assembled on the
devices below:
•No primeiro caso a peça desliza até encontrar o apoio mais à esquerda. Este desvio
In the X direction it is easily identified and measured (without causing doubts).
In the case on the right, the piece slides to the left and down simultaneously.
consequence is a change in the magnitude of the deviation in X and the generation of a false
deviation in Z.
RPS System
Definition and Applications

5.2 - The Parallelism to the Network Lines

This bias always leads to false results, having

the following consequences regarding the process:

The piece may be considered scrap when in fact it is not;

Modifications can be made to the tools in both directions.

when in fact only one direction has problems;

The fastening devices will be incorrectly modified;

Generation of scrap due to future errors.

RPS System
Definition and Applications

6.0 - RPS x Simultaneous Engineering

The RPS points (type and position) are defined by a team of

simultaneous engineering, bringing together members from various
factory departments:

Project and development

Quality Assurance
Manufacturing
Manufacturing planning
Suppliers.
RPS System
Definition and Applications

6.1 - RPS x Simultaneous Engineering

It is important that there is participation from various areas, where each one
contribute with your experience. Remember that the goal is to define the
RPS in such a way as to:

simplify the manufacturing and measurement process,

ensure product quality,

avoid changes to fixation points as much as possible (i.e., an RPS

it should be usable throughout as many stages of the process as possible,
consider the function of the component,

to facilitate the identification and correction of the component's deviations.