Dr Antony Robotham - Executive Director EWG-DSS Liverpool April 2012

Transcription

1 Dr Antony Robotham - Executive Director EWG-DSS Liverpool April 2012

2 THE VALUE OF SIMULATION AND IMMERSIVE VIRTUAL REALITY ENVIRONMENTS TO DESIGN DECISION MAKING IN NEW PRODUCT DEVELOPMENT DR A J ROBOTHAM & DR F SHAO

3 Virtual Engineering Centre Virtual Engineering Virtual Engineering Across the Product Lifecycle Examples Scenarios and Case Study with Bentley Motors Conclusions Content

4 VIRTUAL ENGINEERING CENTRE

5 Located in North West region of UK Largest manufacturing region in the UK by GVA Manufacturing generates 20% of the region s GVA Employs 400,000 people in the region Virtual Engineering Centre Virtual Engineering Centre

6 A Centre of Excellence in Virtual Engineering VE best practice demonstration VE business development and research VE education and skills development providing VE support to the aerospace supply chain and other high valued added manufacturing sectors Virtual Engineering Centre

7 Project Partners University of Liverpool STFC Daresbury Laboratory NWAA Morson Projects BAE Systems Airbus (Associate) Funding NWDA ERDF VEC Project Partners

8 Virtual Engineering Centre Applied Computing & Engineering Ltd VE Technology Specialists

9 LAN to HPC & Internet CAE Workgroup VR Workgroup VESL Workgroup VEC Technical Facilities

10 HPC Link LAN 100 Mbps Computer Network 3 x DELL T bit 1 x DELL T bit 100 Mbps Ethernet connection Various software applications License Server DELL T bit DS Virtools PTC Division CATIA V6 Server DELL PowerEdge 10 Gbps via Fibre Optic Stereo Projection System NVIDIA Quadro 5800 Graphics 2 x WUXGA Active Stereo projectors 6.0m x 2.1m screen 3390 x 1200 resolution single image 3.6 million pixels in total Virtual Touch System Haption Virtuose Haptic Device 6 x Degrees of Freedom Force feedback VRPN communication protocol Head Mounted Display NVIS nvisor SX111 HMD NVIDIA Quadro 4800 Graphics 2 x 1280 x 1024 eye displays 102 o Horizontal Field of View Passive Stereo - 50 o Binocular HFOV Magnetic/Infrared Tracking Virtual Reality Workgroup Optical Tracking System 12 x Vicon Bonita Infrared Cameras 100 Mbps Ethernet connection Vicon Tracker software VRPN communication protocol

11 Virtual Reality at the VEC

12 Virtual Product Design CATIA V6 Solid /Surface Geometry Feature Modelling Parametric SolidWorks CAD IGES STEP Geometry Prep SpaceClaim Direct Modelling Parametric OPENFOAM Open Source CFD Pointwise Meshing tool Virtual Engineering - CFD ANSYS Fluent Virtual Documents 3DVIA Composer / Player Optimisation ModelCenter Prep Stage Solve Stage Post Stage ENOVIA PLM HPC Virtual Production - Assembly DELMIA / HAPTION RTI WITNESS Discrete Event Simulation Virtual Reality - Immersion 3DVIA Virtools PTC Division 3DXML OPTIS Physics based rendering CAE Workflow Optimisation isight Prep Stage NASTRAN FEA Modelling ADAMS MBD Modelling Solve Stage Virtual Engineering - FEA SIMULIA Post Stage

13 VIRTUAL ENGINEERING

14 Integration of product and process modelling using digital technologies Virtual Engineering

15 A product model in a synthetic environment En Hu VIRTUAL PROTOTYPE TS Theory of Technical Systems: V Hubka Virtual Prototypes State 0 Transformational State 1 Process TS = Technical System Hu = Human System En = Active Environment

16 A product model in a synthetic environment En Hu VIRTUAL PROTOTYPE TS Flying Air to Ship Landing Landed TS = Synthetic Helicopter Hu = Pilot in Flight Deck En = Synthetic Ship & Air Wake Virtual Prototypes

17 VE enables integration across the product life cycle but requires 1000s of scenarios to be modelled using VPs VIRTUAL ENGINEERING VE across the Product Lifecycle

18 High fidelity VPs support early decision making in NPD VIRTUAL PROTOTYPES VPs across the Product Lifecycle

19 SYNTHESIS Demand Pull EWG-DSS Liverpool 2012 VPs are an effective support to the iterative activities of the Fuzzy Front End of NPD and the systematic development of holistic, integrated solutions DECOMPOSITION Overall Problem Sub Problem Overall Solution Sub Solution Opportunity Identification VPs in support of NPD

20 VE EXAMPLES

21 Requirements Capture: VOC

22 Y ew Sweep et b/2 Y w i MAC yw i xf i t 1 X Geometry CoG lt ct X Structural Model b/10 f i cw bt/2 X Aerodynamic Model Concept Definition: Flight Behaviour

23 Design: Functional Development

24 Manufacture: Process Simulation

25 Assembly: Ergonomic Assessment

26 Development: Ride Qualities

27 Size of Design Space = 2 Size of Design Space = 3 Development: Optimisation

28 Visualisation Environment Hub CFCS Product Model Platform Test & Certification: UAV Mission

29 En u Operations: Flight Handling Qualities

30 Operations: Planning & Training

31 Upgrades: Improved Performance

32 Disposal: Nuclear Decommissioning

33 SCENARIOS

34 The totality of product quality is achieved only when all life cycle phases have been considered all stakeholders are delighted Product Quality

35 A concrete description of activity that the user engages in when performing a specific task A description sufficiently detailed so that design implications can be inferred and reasoned about Scenarios are not formal; they are not scientific in any fancy sense Carroll, JM (1995) Scenarios

36 Multiple scenarios allow us to explore different visions of the future cover the field as much as possible a creative tool that facilitates the leap from observation to invention Verplank, W et al (1993) Scenarios

37 Customers demand more sophisticated, higher quality products Engineering simulations can provide: insight into the behaviour of virtual products a comprehensive coverage of the solution space data and information to make design decisions Scenarios in Virtual Engineering

38 However, engineering simulations only represent a small set of product properties and are limited bound by the fidelity of the underlying physics Therefore, hundreds of different simulation models may be required to represent all the scenarios identified in the product life cycle Additionally, each scenario requires accurate representations of the product, the active environment, and the human operator Scenarios in Virtual Engineering

39 Immersive Virtual Reality enables: interaction with the virtual product in real-time exploration of many different aspects of a scenario assessment of user stimuli on the functionality However, to achieve real-time interaction often requires engineering simulations to be simplified and limited to tasks that can computed quickly Scenarios in Immersive Virtual Reality

40 Case Study with Bentley Motors

41 Case Study with Bentley Motors

42 Case Study with Bentley Motors

43 Case Study with Bentley Motors

44 Case Study with Bentley Motors

45 Working with Bentley Motors is was apparent that immersive virtual reality provides: a collaborative environment for the design team; an information resource shared by all; a means of communication; a means for visualising life cycle events; awareness of stakeholder needs during design; a stimulus for creativity and synthesis; a means to monitor the progress of design work; and a means to support quality assurance in design. Immersive Virtual Reality

46 CONCLUSIONS

47 Virtual Prototypes have an important role to play in NPD Hi-fidelity physics-based models are required of the product and the active environment Exploration of the total design space will be expensive......so it requires efficient software & effective hardware Virtual scenarios demand management Concluding Remarks

48 Thank You