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MANUFACTURING GOES VIRTUAL
Section: Feature manufacturing
CAD-like technologies are being widely used for design and simulation of manufacturing processes, equipment, and facilities.
There's a great deal of information wrapped up in today's 3D CAD models, so the push is on to leverage this asset throughout the enterprise. Perhaps no where is this effort so evident as in virtual manufacturing, which can be defined as the use of software to design, simulate, visualize and optimize discrete-parts manufacturing operations, processes, and facilities.
Put another way, virtual manufacturing is to manufacturing processes what today's 3D CAD/CAM/ CAE systems are to products: a way to model, evaluate, and refine a complex system entirely in the computer, before time and money are spent on the real thing. As with most emerging technologies, virtual manufacturing goes by many names: digital factory, digital plant, digital manufacturing, virtual factory, and others; some experts feel the term computer-aided production engineering (CAPE) is perhaps best.
Whatever you call it, this technology is swiftly gaining momentum, and the widespread use of CAD in product development is just one of the factors fueling its growth. The technology has its roots in the automotive industry, where the need to shorten time to market, reduce costs, and improve product quality are especially acute, and today is being widely used in the world's leading automobile manufacturers. Other industries are now jumping on the bandwagon as they see the benefits of technology. Indeed, customers of virtual manufacturing vendors include most of the world's leading manufacturers in the aerospace, automotive, electronics, and heavy machinery industries. Of course, the falling cost and increasing performance of computers has helped accelerate the use of this technology as it depends on systems that can efficiently handle complex 3D models.
Why Go Virtual?
The business reasons for investing in virtual manufacturing technology are much the same as for CAD/CAM/CAE. "Faster market response times and lower production costs are bottom line benefits to user companies. Lose the race on either of those fronts, and you are left behind; dead before you know it," says Bob Brown, president of Deneb Robotics Inc., a developer of virtual manufacturing software.
Tecnomatix, another maker of virtual manufacturing software, also makes the point that while CAD and CAE have drastically improved product design, and factory automation equipment has vastly improved shop floor operations, the middle


IP属地:新疆1楼2014-04-20 09:12回复
    also be tested without requiring the use of the actual robots themselves, again reducing production down time.
    Most robot simulation software uses libraries of robots from major manufacturers. There is a move underfoot to more closely align the robot simulation and programming software with the robot control systems. For instance, Prosolvia has a partnership with ABB Flexible Automation, a maker of robots, while Silma is owned by Adept Technologies, another robot manufacturer.
    5 Assembly simulation/mockup.
    In the design realm, digital mock-up (DMU) is a specialized application that can bring in 3D models from various CAD systems and assemble them into a final product. DMU systems are used to ensure that the various components, which are often designed independently of one another, fit together and to check for interferences and proper clearances.
    Assembly simulation/mock-up tools in the context of virtual manufacturing operate on the same principle as DMU (and often, the same software can handle both tasks) but with a different objective. Here, the goal is to ensure that the parts can be assembled in the factory and to study the assembly process for efficiency. The system can also be used to study maintenance and disassembly procedures. It's sometimes used with human modeling to understand ergonomics and safety concerns. Another difference between assembly simulation for virtual manufacturing and DMU for design is that assembly simulations may also need to include jigs, fixtures, etc., in short, the entire environment in which the assembly will be built.
    These systems can also create animations of the assembly process. Some assembly simulation products have realistic dynamics capabilities provided by software such as ADAMS from Mechanical Dynamics Inc. In addition to helping to understand and finetune the assembly process, these animations can be used for training purposes.
    Again, the big benefit is that these considerations are made early on, often while there is still time to change the design to accommodate the assembly. Indeed, some of these systems provide facilities to communicate problems and changes back to the CAD system.
    Assembly simulation can be handled by a variety of software. It could be done with traditional CAD systems, as these often provide the ability to work with very large assemblies. Increasingly, however, assembly simulation is accomplished with software made for the task, as these programs can work with a variety of CAD model data. Most of the major virtual manufacturing vendors provide assembly simulation software.
    6 Human modeling.


    IP属地:新疆4楼2014-04-20 09:13
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      There are some reports that 70% of all manufacturing is still done with human labor. As a result, a virtual manufacturing system that does not account for humans is probably not complete. What's more, manual labor has special considerations, such as meeting safety and government regulations.
      Human modeling is offered by several vendors in the virtual manufacturing area. The software allows 3D models of humans, typically drawn from a database, and placed into factory processes and assembly situations to study reach, field of view, lifting characteristics, and other factors.
      7 NC programming, simulation, and verification.
      Also called computer-aided manufacturing (CAM), these tools are normally considered to be part of CAD/CAM systems. But the technology can also play a role in virtual manufacturing as machine tools are really just another type of production workcell that must be considered in the overall operation of a factory. Indeed, several of the vendors of virtual manufacturing systems offer NC verification software as part of their portfolio. Other vendors, such as CGTech and Lightwork Design Ltd. provide NC verification software as well.
      8 Quality control.
      This broad category includes tolerance analysis applications and programming of coordinate measuring machines (CMM). Tolerance analysis, which helps users define and analyze part tolerances, is often closely associated with CAD but must also take into account the capabilities of available manufacturing processes. It can also be used to create off-line inspection programs for CMM machines.
      9 Viewing and markup.
      Improved communications is also a hallmark of the digital factory, and one tool that helps in this regard is viewing and markup software. Viewing software permits design engineers to understand changes that might be required to make the product easier to manufacture. Or, factory personnel can view 3D animations to understand how to assemble the product. Several of the virtual manufacturing vendors offer their own 2D and/or 3D viewing and markup software; numerous other companies provide similar software that could be used in virtual manufacturing environments.
      10 Service and support.
      Creating a virtual manufacturing environment and integrating all of the many pieces into a coherent whole is no small task. As such, most of the vendors in this market say that service and support is an integral part of their business. As well, they will often partner with customers to deliver a truly virtual simulation of their factories.
      CAE LINKS
      Mechanical Dynamics Inc. -- www.edams.com
      CGTech -- www.cgtech.com


      IP属地:新疆5楼2014-04-20 09:14
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        Unigraphics Solutions Inc., makers of the Unigraphics CAD/CAM/CAE software and IMAN PDM system, has a strategic partnership with Tecnomatix for virtual manufacturing. It has also recently struck up a deal with Engineering Animation Inc. for digital mockup and viewing software.
        CAE LINKS
        Dassault Systemes -- www.catia.com
        IBM Corp. -- www.catia.ibm.com
        Parametric Technology Corp. -- wwwNaNc.com
        SDRC -- www.sdrc.com
        Unigraphics Solutions -- www.ugsolutions.com
        FEA for Manufacturing
        Finite-element analysis (FEA) is usually thought of as a tool to analyze parts and assemblies and to guide design decisions. The technology, however, can also be used to accurately simulate complex manufacturing processes, taking into account the physics of the problem. As such, it's a technology that fits nicely into the notion of virtual manufacturing. Processes that can be simulated with FEA include sheet metal forming and forging. Another application is plastic injection molding, which is simulated by specialized programs from vendors such as C-Mold (wwwNaNold.com) and Moldflow Inc. www.moldflow.com). Examples of vendors offering FEA software for manufacturing applications include:
        Altair Computing is maker of engineering simulation software. It provides two sheet metal forming tools: Optris and HyperForm. Both tools allow users to simulate and refine processes in the computer rather than trying them out on the actual machine itself.
        Optris, which the firm calls "The Virtual Press," is software that uses an incremental method, providing a step-by-step simulation of the stamping process that starts with the sheet metal blank. The process progresses in stages, taking into account all necessary parameters. This method allows the entire history of part deformations to be reviewed so that sources of formability issues are understood and resolved. Altair says this method significantly decreases the time and reconfiguring costs associated with die tryouts and late part revisions due to unformable part shapes, provides automatic meshing and allows user to select materials from a database. Users then define press parameter kinematics such as blankholder forces, drawbead positioning, tool movements, and friction between the blank and tools.
        The firm also offers HyperForm, which is a combination of its HyperMesh finite-element modeling software with finite-element code for sheet metal forming. In contrast to Optris, HyperForm uses an inverse method that begins with the part geometry. The nodes are then projected to the original blank surface and, using the change in element length in the meshed geometry, stresses and strains are calculated. By varying the node positions along the blank surface, an inverse


        IP属地:新疆7楼2014-04-20 09:14
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          tool. IGRIP and Ultra products hahdie programming and simulation of robotic workcells; the firm claims to offer the largest robot library. Virtual NC is an NC simulation and analysis tool. QUEST (The QUeing Event Simulation Tool) provides discrete event simulation that operates independently or with Deneb's other products. Deneb/Review is an interactive viewer. Its products support most forms of virtual reality hardware as well. Deneb Robotics Inc., 248-267-9696; www.deneb.com
          Engineering Animation Inc. (EAI)is a maker of engineering visualization software. In the last 18 months, the company has acquired several companies to bolster its virtual manufacturing offerings. These include Cimtechnologies, Transom Technologies, Variation Systems Analysis, Inc. (VSA), and Rosetta Technologies.
          Its main line of products for virtual manufacturing now go under the name VisFactory. FactoryCAD is a CAD system developed to work with AutoCAD Release 14 specifically for drawing and modifying factory layouts in 2D or 3D. Its claim to fame is the use of "smart factory objects," which are said to simplify the task and provide more intelligence in the resulting model. FactoryFLOW integrates facilities drawings and material flow paths with production and material handling data. FactoryPLAN uses qualitative factors plus flow intensity data to create relationship diagrams that convey the important activity relationships on the production floor. FactoryOPT automatically generates a near optimal block layout based on FactoryPLAN relationship and/or FactoryFLOW intensity data. FactoryVIEW is viewing software to allow users to pan, zoom, and fly through a rendered 3D factory model. FactorySIM uses material handling data plus the factory CAD model to generate a series of equipment and part locations. FactoryBROWSER provides access to factory model drawings via Microsoft Internet Explorer or Netscape Navigator.
          Other EAI products also come into play in virtual manufacturing applications. VisMockUp is software that combines 3D visualization with assembly analysis and collaboration tools; it integrates with a number of high-end CAD systems. Transom Jack provides human modeling, while VSA-3D and VSA-GDT provide tolerance analysis software. Engineering Animation Inc., 515-296-9908; 800-3247-7760; www.eai.com
          Prosolvia provides interactive simulation software and services. Its "Digital Plant Technology" offerings go under the name [PS-ENGINE], and its claim to fame is that this software runs exclusively on Windows NT, providing a common user interface and integration with office applications. The software provides translators for most high-end CAD systems and integrates with MRP and PDM systems. Prosolvia has a partnership with ABB Flexible Automation, a leading maker of robots and other automation equipment. Its products link to most CAD systems, either directly or through standard interfaces.


          IP属地:新疆10楼2014-04-20 09:15
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            [PS-ENGINE]-PlantDesign handles logistics and process design and provides both continuous and discrete simulation. [PS-ENGINE]-Assembly provides for assembly and disassembly simulation. [PS-ENGINE]-Layout is a plant layout-optimization product. [PS-ENGINE]-Review, provides 3D visualization and design communication and works with a variety of CAD data. [PS-ENGINE]-RobotStudio handles simulation and off-tine programming of robots. Prosolvia Inc., 248-649-1200; www.prosolvia.com
            Silma is a maker of simulation and programming software for a variety of manufacturing systems. It's a division of Adept Technology, a manufacturer of robots.
            Silma's products include CimStation Inspection, a 3D simulation and programming tool used to create and optimize programs for Coordinate Measuring Machines (CMMs). It generates CMM programs, detects collisions and interferences. After a part program has been run on the CMM, the inspection results can be displayed in CimStation Inspection to compare the measured geometry to the nominal geometry. CimStation Robotics aids in design, simulation, and off-line program robotic workcells. Soft Machines is a software machine tool used by NC programmers to verify post-processed machine code data. Soft Assembly is a visualization and verification software tool to view and manipulate assemblies of CAD parts. Slime, A Division of Adept Technology, 408-432-1260; 800-34SILMA. www.silma.com
            Tecnomatix is one of the early entrants in virtual manufacturing and is perhaps best known for its efforts in the automotive industry. The company plans to continue to move into other markets, including aerospace and electronics. Tecnomatix puts an emphasis on CAD-independence, but to ensure a close connection with CAD, it recently introduced the CADLinked and Embedded Objects (CLEO)technology for creating a live link between CAD and its digital factory applications. This technology works with Pro/ENGINEER, CATIA, CADDS, Unigraphics, and I-DEAS Master Series and is said to eliminate the need to translate or duplicate CAD information.
            Tecnomatix provides several products and product lines. ROBCAD handles robot simulation and off-line programming. It comes in several versions for specific types of robotic processes, from spot and arc welding to painting and drilling. One module, ROBCAD/Man, handles simulation of manual operations and includes a human models and kinematic analysis capabilities. VALISYS handles the definition, measurement, and analysis of manufacturing tolerances. PART generates machining process plans and toolpaths. DYNAMO provides for digital mock-ups for product packaging, assembly process planning, and maintenance procedures. SIMPLE++ provides for design, simulation, and optimization of entire manufacturing plants, systems, and processes. FLOW is a new program that provides 3D modeling, layout, kinematic, and data management for the conceptual design of automotive body


            IP属地:新疆11楼2014-04-20 09:15
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              assembly workplaces. EXALINE simulates assembly line stations for printed circuit boards. Tecnomatix Technologies Inc., 248-471-6140; www.tecnomatix.com
              Circle 289
              PHOTO (COLOR): The virtual factory. Integrated suites of software such as [PS-ENGINE] from Prosoliva are permitting production engineers to create simulations of entire factories.
              PHOTO (COLOR): Top to bottom. Via integration of various applications, software suites such as the Tecnomatix Digital Factory allow a manufacturer to design, simulate, and optimize a complete factory, its production lines, and its processes.
              PHOTO (COLOR): Forging ahead. Formation of a connecting rod from an initial dumbbell preform is analyzed with MARC/AutoForge 2.2 nonlinear finite-element analysis software. The number of elements increases at each stage to capture the high curvature of the tool.
              PHOTO (COLOR): Smart factory. FactoryCAD from Engineering Animation Inc. provides "smart factory objects" that allows users to quickly draw and modify factory layouts.
              By Robert Mills & Barbara Schmitz
              Robert Mills is editor and Barbara Shmitz is Associate Editor of Computer-Aided ENGINEERING


              IP属地:新疆12楼2014-04-20 09:16
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