Virtual Simulation Of Systems


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Virtual Simulation Of Systems

  1. 1. Jordan Hites
  2. 2. Course Description <ul><li>Virtual Simulation—Production and Management. Credits: 4.00. Development of advanced virtual simulations of discrete events. Factory layouts and process flows analyzed utilizing state-of-the-art simulation software. Focus on project management, analysis, and class presentations. Into to digital process and resource planning. Industrial project with teamwork and problem solving. </li></ul>
  3. 3. Course Objectives <ul><li>Demonstrate the ability to create, program and operate virtual simulation “worlds” utilizing the QUEST software product for material and process flow. </li></ul><ul><li>Understanding of applications and benefits of virtual simulation analysis and implementations. </li></ul><ul><li>Understanding of digital manufacturing applications for the management of complex production systems. </li></ul><ul><li>Creation and presentation of a comprehensive electronic portfolio of completed work. </li></ul>
  4. 5. Assembled
  5. 6. Disassembled
  6. 7. Collision Analysis
  7. 8. Distance Analysis
  8. 9. Band Analysis
  9. 10. Sectioning
  10. 11. Swept Volume
  11. 12. Measure
  12. 13. Disassembly
  13. 14. Assembly
  14. 15. Engineering Change Requests <ul><li>Redesign cover and/or chassis to better fit together. </li></ul><ul><li>Redesign front shock tower mount and/or front differential to prevent collision. </li></ul><ul><li>Steering and front suspension needs to better mesh together. </li></ul>
  15. 17. Simulation Ergonomics Project and Grading Criteria <ul><li>1.      Make an interesting environment and simulation with at least two manikins of different profiles and appearance. </li></ul><ul><li>2.      Create walks and activities for at least two manikins. </li></ul><ul><li>3.      Create SnagIt video of simulation with view changes. </li></ul><ul><li>4.      Perform at least one of each of the following analysis: </li></ul><ul><ul><li>a. Rapid Upper Limb Assessment </li></ul></ul><ul><ul><li>b.      Lift-Lower Postural Analysis </li></ul></ul><ul><ul><li>c.       Push-Pull Analysis </li></ul></ul><ul><ul><li>d.      Carry Postural Analysis </li></ul></ul><ul><ul><li>e.       Biomechanics Single Action Analysis </li></ul></ul><ul><li>5.      Create PowerPoint with the following: </li></ul><ul><ul><li>a.       Explanation of your simulation activity </li></ul></ul><ul><ul><li>b.      Simulation video </li></ul></ul><ul><ul><li>c.       Screen shots of each of the analysis with an explanation of the results </li></ul></ul><ul><li>6.      Present your ergo project PowerPoint the week we get back from break. </li></ul><ul><li>7.      Grading based on the following: </li></ul><ul><ul><li>a.       Complexity of simulation environment and activities </li></ul></ul><ul><ul><li>b.      Quality of the video and view changes </li></ul></ul><ul><ul><li>c.       Proficiency using the software </li></ul></ul><ul><ul><li>d.      Quality of all the analysis functions above </li></ul></ul><ul><ul><li>e.       Overall quality of the PowerPoint </li></ul></ul><ul><ul><li>f.       Bonus points for creativity or Waku-Waku </li></ul></ul>
  16. 18. Simulation Activity <ul><li>Man moves to ladder. </li></ul><ul><li>Woman moves to ladder. </li></ul><ul><li>Man grabs ladder to steady it. </li></ul><ul><li>Woman climbs ladder. </li></ul><ul><li>Woman dismounts ladder onto ceiling. </li></ul><ul><li>Woman walks to RC car on ceiling. </li></ul><ul><li>Woman picks up RC car. </li></ul><ul><li>Man moves ladder to Woman’s position. </li></ul><ul><li>Woman slides down ladder with car. </li></ul><ul><li>Woman dismounts ladder onto floor with RC car. </li></ul>
  17. 20. Rapid Upper Limb Assessment
  18. 21. Lift-Lower Postural Analysis
  19. 22. Push-Pull Analysis
  20. 23. Carry Postural Analysis
  21. 24. Biomechanics Single Action Analysis (Summary)
  22. 25. Biomechanics Single Action Analysis (L4-L5 Spine Limit)
  23. 26. Biomechanics Single Action Analysis (Joint Moment Strength Data)
  24. 27. Biomechanics Single Action Analysis (Reaction Forces and Moments)
  25. 28. Biomechanics Single Action Analysis (Segment Positions)
  26. 30. <ul><li>As a class we went down to the Robotics lab and took measurements of the mill, robot tables, conveyor, camera sensors, and the end of arm tooling. Once we had the measurements taken we split the work up evenly. </li></ul><ul><li>*All the parts each of us made were designed using CATIA and imported into DELMIA. </li></ul>Simulation Layout
  27. 31. <ul><li>The Robotics lab project is a dry run simulation layout of what our KUKA plant layout. </li></ul><ul><li>We were supposed to make a replica of the robotics lab and actually make a functional simulation of the lab running the way it really works. </li></ul>Simulation Layout
  28. 32. Camera Sensor
  29. 33. Conveyor
  30. 34. End of Arm Tooling
  31. 35. Mill and Robot Table
  32. 36. Robot Tables
  33. 37. Simulation and Simulation Layout
  34. 38. Video
  35. 39. <ul><li>As a class we felt that the project was a good idea itself, but we didn’t feel that it was fair enough that we had no class time to do the project. We did as much as we could with the time allotted for the project. </li></ul>Robotics Lab Analysis
  36. 41. Team Objective: <ul><li>To incorporate the glass cell into the right side door work cell. </li></ul>
  37. 42. Initial Information
  38. 43. Software Used: <ul><li>CATIA V5 </li></ul><ul><li>DELMIA </li></ul>
  39. 44. Team Design: <ul><li>Floor layout (perimeter fencing, exterior stock bins, risers) </li></ul><ul><li>Robot and Fixture positioning </li></ul><ul><li>End of arm tooling </li></ul><ul><li>Physical parts (door parts) </li></ul><ul><li>Robotics (creating I/O’s for simulated movements) </li></ul>
  40. 45. Gantt Chart: Microsoft Project
  41. 46. Virtual Simulation Of Cell: (Right Front Door)
  42. 47. Hemming and Sealing Operations
  43. 48. End of Arm Tooling:
  44. 49. Glass Run Cell:
  45. 50. Proposal *Robot used KR210
  46. 51. Problems Encountered: <ul><li>Robot 9 maxing out </li></ul><ul><li>DELMIA software bug </li></ul><ul><li>Robots being in singularity </li></ul><ul><li>Robot 7 dual end of arm tooling </li></ul>
  47. 53. Simulation Objective <ul><li>Recreate the MTR process flow in QUEST </li></ul><ul><ul><li>Read process data into QUEST from Excel </li></ul></ul><ul><ul><li>Provide start/completion dates for each activity </li></ul></ul><ul><ul><li>Option to output summary sheet at the end of the run </li></ul></ul>
  48. 54. Given Information & Geometry <ul><li>GDLS Project Proposal </li></ul><ul><ul><li>Process flow maps </li></ul></ul><ul><ul><li>Operation & move cycle times </li></ul></ul><ul><li>Plant layout </li></ul><ul><li>MTR QUEST geometry </li></ul>
  49. 55. Gantt Chart
  50. 56. Generating the Layout <ul><li>A plant layout had to be made in order to begin our simulation </li></ul><ul><li>This layout was imported from CATIA into the QUEST environment </li></ul><ul><li>Each rectangular section represents a different machining operation along the line </li></ul>
  51. 57. Generating the Layout <ul><li>Conveyors were used to link the different machining stations </li></ul><ul><li>Layout was created based upon the information given by the company </li></ul>
  52. 58. GD Plant Layout
  53. 59. Writing the SCL Code <ul><li>We used Simulation Control Language to create the desired results for the Quest simulation </li></ul><ul><li>The documentation provided by Quest was of limited help, therefore outside help was required </li></ul>
  54. 60. Writing the SCL Code <ul><li>In addition, finding example SCL codes proved to be more difficult than expected. </li></ul><ul><li>We were having trouble formatting our code properly </li></ul><ul><li>Reading and writing with a text file was easy, however, linking the code to an excel spreadsheet gave our team a multitude of problems. </li></ul>
  55. 61. Writing the SCL Code <ul><li>Our team reached out to Joe Hugan of Magnys / V-Sim Incorporated for help with the basic formatting of the SCL Code. </li></ul><ul><li>He provided us with the foundation necessary to complete the project objectives. </li></ul>
  56. 62. The Spreadsheet and Code <ul><li>Input Spreadsheet </li></ul><ul><li>SCL Code </li></ul>
  57. 63. Completed Simulation
  58. 64. Conclusion <ul><li>Strengths </li></ul><ul><ul><li>Much knowledge gained with software </li></ul></ul><ul><ul><li>Much hands-on experience </li></ul></ul><ul><ul><li>Large scope of material covered </li></ul></ul><ul><li>Weaknesses </li></ul><ul><ul><li>None </li></ul></ul>