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Process Assessment and Visualisation

The main purpose of the Process Assessment and Visualisation module is to provide an industry compatible platform to verify and validate the experimental methods and tools to current industrial standards and to apply these methods and tools to the Pilot Build of an existing industrial case study and demonstrate Application
Readiness (TRL 6)
(i) Industry compatible platform.
(ii) Verify and validate the experimental methods and tools developed in the Work Packages
2, 3, 4 & 5 to current industrial standards.
(iii) Apply these methods and tools to the Pilot Build of an existing industrial case study.
(iv) Test the output of the Pilot Build using industry approved standards and methods.

The Process Assessment and Visualisation moduleaims at demonstrating the viability of RLW Navigator
toolkit against performance measures defined by industrial standards. Demonstration test-bed has
been built by using inputs from simulations and then software packages have been verified and
validated and their performances have been checked and improved. The L538 front RH door has been
selected as case study and simulation and experimental work has been developed under this case
study. It has been agreed by IAB that the car door test case would be sufficient to prove the robustness
of the developed software modules against complex industrial application. All software modules have
been tested using RLW workstation demonstrator except for System Configurator. System
Configurator and its components have been compared to commercially available solutions and a
significant computational speed has been observed.
The robot program and work-piece placement, generated by Workstation Planner and OLP software,
have been used in demonstrator and tested. In addition, RLW Process Optimiser software modules
have been validated both using coupons trials and door assembly experiments. Using the same
experiments, Weld Quality Performance Evaluator and Eco-advisor software have been tested and

The software modules and tools need to be tested in order to: (i) verify their performances and
provide feedback to optimise the process; and, (ii) ensure that results are in accordance with
industrially accepted standards. The Demonstrator provides a Test Bed for the above tasks, providing
all the hardware equipment to carry out the welding trials, dimensional measurement fixtures and
measuring facilities, weld quality monitoring and measurement and strength performance
measurement equipment. The RLW demonstrator comprises of various equipment which have been
assembled within the final demonstrator (refer to Fig.1).


Figure 1. RLW Workstation Demonstrator: (i) in-process laser monitoring system; (ii) RLW welding fixture; and (iii) RLW dimpling fixture.


To develop a demonstration test-bed to prove the robustness and reliability of simulation tools against industrial standard.


  • Part and weld monitoring.
  • Dimpling and welding operation.
  • Destructive and non-destructive tests.


  • Verify simulation tool’ performances.
  • Ensure that results are in accordance with industrially accepted standards.


(i) RLW Eco Advisor Simulation Tool;

(ii) Product, Process and Resource Costing (PPRC) for RLW Simulation Tool;

(iii) System Evaluation and Visualization Interface (SEVI) Simulation Tool;