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Virtual Commercial Vehicle: VDC-Whitepaper

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In recent years, a large number of applications of virtual technologies in the commercial vehicle sector have emerged and developed. Due to its peculiarities, the commercial vehicle sector has many boundary conditions and tasks that suggest the use of a digital prototype, the virtual commercial vehicle. This whitepaper gives an overview of the use of Virtual Reality and Augmented Reality for the development, production and operation of commercial vehicles.

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Virtual Commercial Vehicle: VDC-Whitepaper

  1. 1. Whitepaper Virtual Commercial Vehicle Applications, Challenges, Results © Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC) Dr.-Ing. Dipl.-Kfm. Christoph Runde Virtual Dimension Center (VDC) Fellbach Auberlenstr. 13 70736 Fellbach www.vdc-fellbach.de Applications, Challenges, Results
  2. 2. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Environment commercial vehicle Varying laws, rules, environmental requirements Long planning periods, changing requirements and requests Globalisation, language and cultural barriers Very high complexity: Partially enormous sizes Smaller batch sizes (compared to passenger car) Fluctuating batch sizes High amount of variants Changing variants and product types Basics 2 Very high complexity: development, production operation, service Changing variants and product types Varying assembly processes and efforts Image: LumoGraphics
  3. 3. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Virtual development o Styling, design, interieur o Calculation visualization o Ergonomics o Testing assistance systems and human-machine-interface Application fields Training o Driving and operation o Service Marketing & Sales o Variant management Basics 3 human-machine-interface o DMU and Serviceablility Virtual manufacturing o Factory planning o Assembly planning o Manufacturing processes o Variant management o Sales configurators Teleoperations Entertainment
  4. 4. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Photorealistic illustrations Development of alternative product concepts Emphasis on early development stages Early feedback Fast development cycles as an active Styling, design, interieur: Design reviews Image: LumoGraphics Realistic design visualizations Virtual Development 4 Fast development cycles as an active process element Decide on product specifications Realistic1:1-presentation: real dimensions Possibility to compare real vehicle – virtual prototype Image: Volvo Image: Volvo Large Powerwall for 1:1-visualization Hall with the possibility for commercial vehicles to drive in
  5. 5. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Design reviews Virtual Development 5 Image: Hochschule Mannheim Design review agricultural machine John Deere in a CAVE (4 projection sides)
  6. 6. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Design reviews Virtual Development 6 Image: Virtalis Review using a Powerwall and a Head Mounted Display at CNH
  7. 7. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Calculation visualization Representation and interactive analysis of the results of the simulation of CFD (Computational Fluid Dynamics) and FEM (Finite Element Method) data Via VR improved spatial representation and interaction possibility Image: Lauer & Weiss Load calculation gear screw connection Virtual Development 7 and interaction possibility Discussion platform for interdisciplinary cooperation Direct display of data of physical prototypes/ products: Augmented Reality (AR) Image: HLRS Image: HLRS Truck with AR marker Truck with overlaid flow simulation
  8. 8. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Ergonomics Early verification of accessibility and visibility of controls Hedging visibility of safety-relevant operating and display elements Virtual examination of comfort Consideration of ergonomic aspects for Image: HS Mannheim Examination with digital human model plus Motion Capturing Virtual Development 8 Consideration of ergonomic aspects for age groups, percentiles, somato types (hedging product functionality for large sections of the population) Consideration of human as a physical factor Image: ESI – IC.IDO Image: Fraunhofer IAO Inspection of visibility and accessibility with „seat box“ in front of Powerwall Inspection freedom of movement (model´s right arm)
  9. 9. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Testing assistance system and human-machine-interface Harmless testing and optimization of assistance systems (such as brake assitant) Testing novel human-machine interfaces Operator interface: driver´s behavior, driving behavior, machine simulation, environmental simulation Image: ESI – IC.IDO View in driving simulator Virtual Development 9 environmental simulation Design information interface Image: TU Dresden Image: TU Dresden Operation shotcrete machine Information interface in bucket wheel excavator
  10. 10. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Digital Mock-Up (DMU) and Serviceability Construction visualization Geometric overall model including all disciplines (such as electrics, hydraulics..) Checking serviceability and avoidance of special tools Image: Lauer & Weiss Review e-machine, gear, gear housing Virtual Development 10 of special tools Assembly space optimization and simultaneous testing of mountability and serviceability Flexible components (hoses, cables, etc.) can be considered Image: Jaguar-Landrover Image: ESI – IC.IDO DMU review in CAVE Examination of hose behavior in case of tank disassembly
  11. 11. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Digital Mock-Up (DMU) and Serviceability Service Engineering: Verify accessibility visually and manually Check accessibility of assembly units, connecting elements, grease nipples, etc. - visually Virtual Service Review Daimler-VRSC, Brühl Virtual Development Image: ESI – IC.IDO 11 - visually - manually - using a tool All variants can be examined All perspectives and positions can be considered Image: HS Mannheim Image: HS Mannheim Virtual walk through agricultural machine Check serviceability in front of Powerwall
  12. 12. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Digital Mock-Up (DMU) and Serviceability Virtual Development 12 Image: Virtalis Review using a Powerwall at CNH
  13. 13. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Assembly planning • Checking (dis)assembly • Test and evaluation of assembly aids (guide lines, bevelled corners, etc.) for manual assembly • Determination of mounting sequences Collision display acoustically, graphically Image: ESI – IC.IDO Virtual assembly examination of a tank in front of Powerwall Virtual Production 13 • Collision display acoustically, graphically or haptically Image: ESI – IC.IDO Image: Haption Ambidextrous installation/ removal examination in front of Powerwall with tactile feedback Disassembly examination with force feedback
  14. 14. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Factory planning and manufacturing processes Geometric planning of all trades in an overall factory model Simulation and animation Concurrent engineering Virtual walkthrough Internal logistics: additional VDC Image: Fraunhofer IPA View in 3D model shell assembly Virtual Production 14 Internal logistics: additional VDC whitepaper Manufacturing processes: additional VDC whitepaper Image: TU München Image: Visenso Logistics: AR planning of new conveyor technology in existing system Manufacturing process: pressure die-casting tool
  15. 15. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Training – Knowledge management Knowledge types in virtual environments: Position knowledge: what is where? Structural knowledge: how is something related? Behavioral knowledge: how does the system behave? How do I behave? Image: HS Mannheim Training fire brigade using a virtual emergency vehicle Training 15 system behave? How do I behave? Procedure knowledge: which processes cause what? Possibilities of learning in virtual environments: Spatial exploration Conceptual learning Learning motoric abilities Procedural learning Image: HS Mannheim Image: HS Mannheim Training fire brigade using a virtual emergency vehicle Exploration cockpit of an agricultural machine, software ESI – IC.IDO
  16. 16. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Training – Simulators Special vehicle kinematics Special vehicle behavior Big vehicles, high seating positions Unclear vehicle areas Analysis of driver postures and view Image: GlobalSim.com View on workplace crane simulator Training 16 Image: TU Dresden Image: RIF View on excavator on ramp Training: harvester
  17. 17. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Training – Simulators Training tasks oCoping training course oDetection dangerous situations oCorrect communication with endangered persons Avoidance of swinging load, risk of Image: RIF Interactive 3D model harvester Training 17 Avoidance of swinging load, risk of collision Stay of persons in danger zone Surprising entry of people in travels Image: Fraunhofer IAO Image: Fraunhofer IAO Crane: underrun of minimum distance results in visual warning Crane: person in danger zone
  18. 18. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Training – Simulators Glance into driving simulator TU Dresden Training Glance into driving simulator 18 Image: TU Dresden Image: TU Dresden Glance into driving simulator
  19. 19. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Training – Service Maintenance Repair Accessibilities Use of tools Processes, process knowledge, risk of damages Image: ESI – IC.IDO Removal engine of a forklift Training 19 damages All variants, all perspectives Learning Concepts: demonstrate - accompany - examine Online assistants (e.g. with AR) Image: BMW/Arvika Image: BMW/Arvika AR-view on disassembly scenario: assembly units and tools AR-view on disassembly scenario: assembly units and tools
  20. 20. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Variant management Long planning periods - fast technology development Different life cycles of product parts Incremental and iterative development Spontaneous request changes Huge number of combination possibilities Image: LumoGraphics Representation of variants commercial vehicles Marketing & Sales 20 Huge number of combination possibilities Combination restrictions Systematic variant management very important: unsystematic variant management often works initially, but can not be scaled Image: LumoGraphics Image: Volvo Representation of variants commercial vehicles Comparison of variants in front of Powerwall
  21. 21. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Sales configurator Early, possibly anonymous customer involvement Capture customer request Increase customer loyalty in early stages Only product (variants) which are possible are offered Image: LumoGraphics Configurator: outside view Marketing & Sales 21 possible are offered Early statement on availability and delivery date Early statement on price, offer support Image: LumoGraphics Image: LumoGraphics Configurator: inside view Configurator menu
  22. 22. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Teleoperations Tracking the vehicles in control center Logistics, construction site control station Tracking work progress Remote control: Usage where cameras are not possible due to environmental conditions or signal propagation delay Image: Financial Times Projection in control center Rio Tinto Teleoperations 22 conditions or signal propagation delay Projection screen or in case of 2D-3D task (layout + perspective): Planning desk Image: Financial Times Image: Financial Times Warning sign automated mine in Western Australia Unmanned trucks in mine in Western Australia
  23. 23. Training TeleoperationsBasics Virtual Development Virtual Production Marketing & Sales Entertainment Summary Teleoperations Teleoperations 23 /ŵĂŐĞ͗ s Perspectives of planning desk for construction site control station: 2D top view (for desk, left), 3D perspective excavator view (top right) and view from an outside third vehicle (bottom right)
  24. 24. Training TeleoperationsBasics Virtual Development Virtual Production Marketing Sales Entertainment Summary Entertainment First tests on the use of Augmented Reality (AR) in the windscreen for infotainment (also context-sensitive) Use windscreen as a touch screen Games arouse first interest in commercial vehicles Image: Daimler Fading in of information on windscreen Entertainment 24 commercial vehicles Image: Aeon Project Imageer: John Deere/Caterpillar Interaction/ input via windscreen Games arouse interest in virtual commercial vehicles
  25. 25. Training TeleoperationsBasics Virtual Development Virtual Production Marketing Sales Entertainment Summary Summary Various application possibilities along the entire development process chain Many potential benefits Process integration is essential Reusable 3D data is essential Often the extension of the use of VR/ VE to more application areas is possible Summary 25 Image: HLRS
  26. 26. VDC members and partners regarding this topic 26
  27. 27. Thank you very much for your interest! You are interested in this topic and you are looking for contact persons/ implementation partners? Please contact us. © Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC) Virtual Dimension Center (VDC) Fellbach Auberlenstraße 13 70736 Fellbach www.vdc-fellbach.de

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