State Of The Art R04

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State of the art of engineering system for pre-engineered metal building system industry

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State Of The Art R04

  1. 1. State of the Art Integrated and Automated CAD/CAM Software for the Metal Building System A. J. Yang | S.E. Yang Shan Shu Yuan Shanghai 20060825
  2. 2. Industry Background 1990-2006
  3. 3. Market: The Target Market for the MBS Industry <ul><li>Manufacturing, </li></ul><ul><li>Distribution, </li></ul><ul><li>Community, </li></ul><ul><li>Religious, </li></ul><ul><li>Sporting Facility, </li></ul><ul><li>Aircraft Hangar, </li></ul><ul><li>Recreational, </li></ul><ul><li>Office, </li></ul><ul><li>Retail, </li></ul><ul><li>Mini-Warehouse, </li></ul><ul><li>Educational, </li></ul><ul><li>Medical Clinic, </li></ul><ul><li>… . </li></ul>
  4. 4. Metal Building System: Members and the System <ul><li>Main Frame, </li></ul><ul><ul><li>Endwall Frame, Crane, Mezzanine </li></ul></ul><ul><li>Secondary Frame </li></ul><ul><li>Wall/Roof Panel System </li></ul><ul><li>Other Wall System </li></ul><ul><li>Building Accessories </li></ul>
  5. 5. Manufacturing Tech.: The Production Process of the Metal Building System <ul><li>Main Frame </li></ul>
  6. 6. Manufacturing Tech.: The Production Process of the Metal Building System (Continued) <ul><li>Secondary Structure & Panels </li></ul>
  7. 7. Manufacturing Tech.: The Production Process of the Metal Building System (Continued) <ul><li>Other Products in the System </li></ul>
  8. 8. The Differences: The Particular Themes Separate the Industry from Others <ul><li>Mass production , repeated procedure for engineering and manufacturing </li></ul><ul><li>Lower price, higher profit </li></ul><ul><li>Faster track engineering, manufacturing and delivery with higher quality </li></ul><ul><li>Unlimited application possible when the above three rules achieved </li></ul>
  9. 9. The Differences: The Particular Themes Separate the Industry from Others (Continued) <ul><li>New Tech. </li></ul><ul><ul><li>The strongest demand (and consumer) for latest CAD/CAM technologies in such a traditional industry </li></ul></ul><ul><li>Single Source Manufacturer </li></ul><ul><ul><li>Products line specification, machinery development, design, detailing, production… </li></ul></ul><ul><ul><li>Highly integration workflow in quotation, design, engineering, production, material stock, PM… </li></ul></ul><ul><li>Special Manufacturing Machinery </li></ul><ul><ul><li>Particular equipments, products line predefined and standardization, punched and coded joints, minimum special holes per case, minimum shop drawing achieved… </li></ul></ul><ul><li>Special Design and Engineering Practice </li></ul><ul><ul><li>Later developed structural analysis theories and optimizing algorithm which is not commonly mentioned in text books and clearly specified in industrial standards and codes </li></ul></ul><ul><ul><li>Laterally braced plate girder frame, lapped purlin, cold formed truss, floor vibration, complex wind load coefficient, … </li></ul></ul><ul><li>Special CAD/CAM Software </li></ul><ul><ul><li>Most sophistic and effective software system developed by internal PRD department, historically and theoretically </li></ul></ul>
  10. 10. Software Architecture Company knowledge based automated design system
  11. 11. Workflow over Teams Sales Engineer Estimator Detailer P. M. Production Buyout Delivery
  12. 12. Software Output <ul><li>Quotation/Sales: </li></ul><ul><ul><li>Cost estimating, foundation data, architecture expression and collaboration with other professions… </li></ul></ul><ul><li>Structural Design: </li></ul><ul><ul><li>A thoroughly and detailed design report </li></ul></ul><ul><li>Details and Production Engineering: </li></ul><ul><ul><li>Erection DWG, Shop DWG and CNC files, Plate Nesting, BOM, labeling, manifest, packing list… </li></ul></ul><ul><li>Remote Teams Collaborations: </li></ul><ul><ul><li>Workflow database, Revising, Remote release… </li></ul></ul>
  13. 13. Modules Targeted Structural Design Detail and Production Engineering Workflow Contract Control ERP Complexity Control Schedule Control Project Spec. Architecture Representation Foundation Design Material Optimizing Purchase Control BOM CNC Buyouts Labeling Manifest Packing List Estimating Quotation File Database
  14. 14. Module : Structural Optimizing <ul><li>Structural system pre-defined </li></ul><ul><ul><li>Rigid frame </li></ul></ul><ul><ul><li>Roof purlin, wall girt </li></ul></ul><ul><ul><li>Endwall frame </li></ul></ul><ul><ul><li>Crane beam </li></ul></ul><ul><ul><li>Bracing </li></ul></ul><ul><ul><li>Mezzanine </li></ul></ul><ul><ul><li>… </li></ul></ul><ul><li>FEA </li></ul><ul><li>Optimizing algorithm </li></ul><ul><li>UI </li></ul><ul><li>Output, revising </li></ul>
  15. 15. Module: Engineering for Details and Production <ul><li>Pre-defined members, products module </li></ul><ul><ul><li>Main Frame </li></ul></ul><ul><ul><li>Secondary structures </li></ul></ul><ul><ul><li>Panels </li></ul></ul><ul><ul><li>Standard accessories </li></ul></ul><ul><ul><li>… </li></ul></ul><ul><li>Design logic => Object relations (lisp or C++) </li></ul><ul><li>Model built </li></ul><ul><li>Visual check </li></ul><ul><li>Collaboration </li></ul><ul><li>Output, revising </li></ul>
  16. 16. Complexity of the model <ul><li>Before the PC </li></ul><ul><li>Present </li></ul><ul><li>Future </li></ul>
  17. 17. Company Knowledge How the Company Knowledge Embedded in a Software System Expert System or Artificial Intelligence Static or Dynamic Details Engineering Logic Object Relations and Predefined Algorithm (Lisp or C++) Predefined Members Predefined Products Module Predefined Rules A Downstream Developing Frame for the Detail and Production Module at proven output format
  18. 18. Software Documentations <ul><li>Getting Started Guide for Novice User </li></ul><ul><li>Software Package User Manual / Software Package Administration Manual Sample Job Detailed Report </li></ul><ul><ul><li>Standard and Complex </li></ul></ul><ul><ul><li>Advised Practice for Cases beyond the Defined Standards </li></ul></ul>User Manual Third party documents (Developing platform, commercial components) Other Development and Maintenance Records References Descriptions of Each Module Source Files with Detailed Comments and References Revising Logs for Maintenance/ Revising Logs for End Users Software Resource Manual for Products Line Definition Manual for Structural Design Manual for Detailed Engineering Practices for Production and Erection Descriptions for static and dynamic linked details Company Knowledge
  19. 19. The Differences Separated them from Others <ul><li>Company knowledge based expert system </li></ul><ul><li>Automated design </li></ul><ul><li>Redundancy data minimized </li></ul><ul><li>Proven output </li></ul><ul><li>Highly integrated to manufacturing </li></ul><ul><li>Frequently updated when any adjustment needed </li></ul><ul><li>Downstream developing method </li></ul>
  20. 20. History The engine of modern PEMB industry
  21. 21. Yearbook: <ul><li>1960’s </li></ul><ul><li>1970’s </li></ul><ul><li>1980’s </li></ul><ul><li>1990’s </li></ul><ul><li>2000’s - </li></ul>
  22. 22. Milestones of the Development: <ul><li>Interface difference from the beginning: </li></ul><ul><ul><li>Minimum key-in </li></ul></ul><ul><ul><li>Highest efficient </li></ul></ul><ul><li>Algorithm: </li></ul><ul><ul><li>Design </li></ul></ul><ul><ul><li>Detailing and modeling </li></ul></ul><ul><ul><li>2D and 3D </li></ul></ul><ul><li>Develop Platform: </li></ul><ul><ul><li>Basic => Fortran => C => C++; </li></ul></ul><ul><ul><li>Lisp, C++ </li></ul></ul><ul><ul><li>3D Modeler </li></ul></ul><ul><li>Features: </li></ul><ul><ul><li>Rigid frame FEA only and beyond </li></ul></ul><ul><ul><li>Automated design when PC and ADS available </li></ul></ul><ul><ul><li>Next generation software </li></ul></ul>
  23. 23. Some Stories & Experiences: <ul><li>Portal Frame vs. Metal Building System </li></ul><ul><li>Pre-Engineered vs. Precision Engineered </li></ul><ul><li>The era before PC </li></ul><ul><li>Autosteel </li></ul><ul><ul><li>Synercom Technologies Inc., 1971,1995 </li></ul></ul><ul><li>Pronto, Advantage… </li></ul><ul><ul><li>BMC, 1989, 1995 </li></ul></ul><ul><li>EDS, XDS </li></ul><ul><ul><li>RCC, 1993, 1999 </li></ul></ul>
  24. 24. Present In-house development vs. Outsourcing
  25. 25. In-house Developed System MBS Manufacturers’ in-house developed CAD/CAM System <ul><li>RCC => NCI </li></ul><ul><li>Zamilsteel </li></ul><ul><li>Butler </li></ul><ul><li>VP </li></ul><ul><li>ABC </li></ul>
  26. 26. Developing Tools <ul><li>Design++ </li></ul>Pride of Finland
  27. 27. Developing Tools (Continued) <ul><li>Lisp Generator </li></ul>y = 3 sin x / 5.0 y = 3 * sin(x) / 5.0 y is 3 times sin(x) over 5.0 y equals three times the sine of x divided by five (setq y (/ (* 3 (sin x)) 5.0))
  28. 28. The Commercial Vendor <ul><li>Questware </li></ul>
  29. 29. The Commercial Vendor <ul><li>MBS </li></ul>
  30. 30. The Commercial Vendor <ul><li>Loseke </li></ul>
  31. 31. Future Company knowledge will be embedded in new platform
  32. 32. New Tech.: Attractive features from contemporary structural analysis programs ( STAAD, RISA, RAM ) <ul><li>Graphic editing capability </li></ul><ul><ul><li>snap-to and many other powerful function </li></ul></ul><ul><li>Complex FE modeling </li></ul><ul><ul><li>Dynamic Analysis </li></ul></ul><ul><ul><li>Real Moving Loads </li></ul></ul><ul><ul><li>Plate Element for Bracing </li></ul></ul><ul><ul><li>… </li></ul></ul><ul><li>Contemporary platform </li></ul><ul><ul><li>… </li></ul></ul><ul><ul><li>… </li></ul></ul><ul><li>… </li></ul>
  33. 33. New Tech.: Challenges to use these commercial structural analysis programs <ul><li>Tapered Member </li></ul><ul><ul><li>No real tapered plate girder correctly specified (e.g. closer outside flange bracing for bigger downloads and looser inside flange bracing for smaller uploads) </li></ul></ul><ul><li>Cold Formed Steel </li></ul><ul><ul><li>No real cold formed purlin correctly specified (e.g. Lap different length to get different rigidness, complex lateral bracing for cold formed section) </li></ul></ul><ul><li>MBS need special optimizing algorithm which is not available in commercial packages </li></ul><ul><li>Typically, no predefined structural system (Exclude RISA Tower…) </li></ul><ul><li>Other limits… </li></ul>
  34. 34. New Tech.: Attractive features from contemporary 3D steel detailing programs ( Tekla Structures, SDS/2, StruCAD ) <ul><li>A visual 3D Surface Model: two point defined a line, a line with section defined a closed surface </li></ul><ul><li>A loose constrain geometry database separate them from other 3D mechanical design system </li></ul><ul><li>Power 3D editing capability of the geometry model </li></ul><ul><li>The model can as complex as you can imagine, not just the standard unit </li></ul><ul><li>Define the whole model in one database, define each member/part as an independent geometry and mapping the 2D drafting directly from the 3D model </li></ul><ul><li>Typically wider consumer market targeted, more programmers and support engineers involved in developing and maintenance and better procedure quality control, new technologies can be adopted faster </li></ul>
  35. 35. New Tech.: Challenges to adopt these commercial 3D detailing programs <ul><li>They are all end products for general (and conventional) applications, not a development platform </li></ul><ul><li>No tapered plate girder can be correctly specified </li></ul><ul><li>No lapped purlin/girts can be defined correctly </li></ul><ul><li>No metal panel can be defined efficiently </li></ul><ul><li>Typically, standard building accessories cannot be integrated or linked in the 3D model efficiently, </li></ul><ul><li>As each the geometry are independent, two many redundancy data output are typically generated by the 3D detailing system. </li></ul><ul><li>The mapping method of the 2D drawing output makes the desired out look of erection and shop drawing very (very!!!) difficult to be setting at the user interface, </li></ul>
  36. 36. Some Considerations on these Affairs: <ul><li>They are all end products for general (and conventional) applications, not a development platform , the fundamental custom development will not be available recently </li></ul><ul><li>A special object as the real tapered plate girder shall be correctly specified (the geometry model of flat welded plate girder is quite complex, the current line-section method cannot be well defined) </li></ul><ul><li>A special object as the real lapped purlin/girts shall be defined correctly with the CNC pre-punch definition </li></ul><ul><li>Typically the joints are standardized and coded for the predefined structural detail </li></ul><ul><li>Geometry database of each system are propertied, standard building accessories cannot be integrated or linked in the 3D model efficiently, some fundamental geometry format shall be revised to be compatible with the current industrial standard surface or solid objects. Pre-engineered details is a tradition in this industry. </li></ul><ul><li>Further, a special object as the metal panel shall be defined </li></ul><ul><li>As each the geometry are independent, two many redundancy data output are typically generated by the 3D detailing system. Maybe going back to organized a group of members defined as the proven product module is a solution. </li></ul><ul><li>The mapping method of the 2D drawing output makes the desired out look of erection and shop drawing very (very!!!) difficult to be setting at the user interface, some fundamental coding to each type of the defined members (if a OEM or customized edition of 3D detailing system for the MBS industry is targeted ) is needed. </li></ul>
  37. 37. A Sample from Finland : <ul><li>Vertex </li></ul>Pride of Finland
  38. 38. <ul><li>Hardware enhanced (Workstation and PC cluster) </li></ul><ul><li>Many tools commercially available: </li></ul><ul><ul><li>3D ACIS Modeler </li></ul></ul><ul><ul><li>True DWG licenses </li></ul></ul><ul><ul><li>VB, VC++ enhanced </li></ul></ul><ul><ul><li>True C++ FEA LIBs available </li></ul></ul><ul><ul><li>Other tools and developing platform </li></ul></ul><ul><ul><li>New collaboration platform (e.g. world wide distributed database..) </li></ul></ul><ul><ul><li>… </li></ul></ul>Tools Ready: Contemporary technologies will enhance the industry The in-house developers seduced by the advance of commercial software each and every day!!!
  39. 39. Look ahead: Something may be really soon <ul><li>3D solid Model </li></ul><ul><ul><li>3D is a better platform for knowledge based system </li></ul></ul><ul><ul><li>Structural Engineering </li></ul></ul><ul><ul><li>Detail and Production Engineering </li></ul></ul><ul><li>Complex Load Definition </li></ul><ul><ul><li>For complex geometry model, the unusual wind load coefficients can be digital modeled in current workstation or PC cluster, the current system typically defaulted at the MBMA standard coefficients </li></ul></ul><ul><ul><li>… </li></ul></ul><ul><li>Complex Structural Analysis </li></ul><ul><ul><li>Flexibility of the structural design module: advanced interface, the more conventional structures can be merged to MBS </li></ul></ul><ul><ul><li>… </li></ul></ul><ul><li>Complex Detailing </li></ul><ul><ul><li>Flexibility of the products line and engineering practice: the more conventional structures can be merged to MBS </li></ul></ul><ul><ul><li>… </li></ul></ul><ul><li>More and more complex application can be assembled with the sophistic and proven standardized products module </li></ul><ul><li>… </li></ul>
  40. 40. Ultimate Target for the Development <ul><li>Company knowledge based automated design </li></ul><ul><li>Low cost development, easy to maintenance </li></ul><ul><li>More and more applications after proven manually design </li></ul><ul><li>Maximum one year schedule of prototype development </li></ul><ul><li>The ability to collaborate with other contemporary platform </li></ul><ul><li>As there’s no limit of the sky, there’s no ultimate target system for the MBS </li></ul>
  41. 41. Considerations for discuss American, China and the business
  42. 42. A Transportable Commodity? These kinds of integrated technologies demanded outside American or not? <ul><li>The situation </li></ul><ul><li>Programs Localization </li></ul><ul><ul><li>Unity check </li></ul></ul><ul><ul><li>User Interface </li></ul></ul><ul><ul><li>Documentations </li></ul></ul><ul><ul><li>Others </li></ul></ul><ul><ul><li>The cost </li></ul></ul><ul><li>Risk </li></ul><ul><ul><li>Run software development as a business </li></ul></ul><ul><ul><li>In-house developed system </li></ul></ul><ul><ul><li>How big the team shall be? </li></ul></ul><ul><li>Imagination </li></ul>
  43. 43. China! Can be an opportunity? <ul><li>Market size </li></ul><ul><li>Team work to enhance the local industrial codes and standards </li></ul><ul><li>Software localization </li></ul><ul><li>For business, service concentrated </li></ul><ul><li>Price policy </li></ul>
  44. 44. Some considerations: <ul><li>1985-1995, a romance era </li></ul><ul><li>Despite the different developing and running platform, the kernel is always the company knowledge accumulated from the manually design ahead </li></ul><ul><li>The in-house developed system advanced a little slower recently for the notable software crisis and the market situation in American </li></ul><ul><li>Contemporary structural design and detailing software educated the next generation integrative software system for MBS </li></ul><ul><li>MBS is also an opportunity for the current 3D steel detailing software vendors to enter, a new and stable market. But some re-architecture development needed. </li></ul><ul><li>Perhaps China is an opportunity for the industry </li></ul>
  45. 45. References <ul><li>Publications </li></ul><ul><li>Other References </li></ul>
  46. 46. Acknowledgement <ul><li>HI UNION </li></ul>
  47. 47. Thank You!
  48. 48. Question? <ul><li>aj_young@yahoo.com </li></ul>Yang Shan Shu Yuan ® 20060825 Modern Steel Construction Library and Laboratories

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