Content: Environment of special machine construction Styling & Design Virtual Mock-Ups Process simulation Automation technology Training Other topics

1. Whitepaper
Virtual Techniques in Special Machine
Construction
Technologies – Application fields - Benefits
© 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
Technologies – Application fields - Benefits

2. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Content
1. Environment of special machine
construction
2. Styling & Design
Function
Styling
3. Virtual Mock-Ups
5. Automation technology
Prototyping automation concept
Commissioning
Work safety
6. Training
Operation/ Usage3. Virtual Mock-Ups
Collision/ assembly space
optimisation
Reconstruction & dismantling
Usability/ ergonomics
Serviceability
4. Process simulation
Material flow
Clean room application
Operation/ Usage
Service/ Repair/ Maintenance
7. Other topics
Marketing/ Communication
Process support with AR
Teleoperations/ Teleservices

3. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further TopicsEnvironment
Environment of special machine construction
Long-term planning deadlines
Widely varied requirements
Partial enormous sizes
Batch size 1
Environment: The field of special machine construction describes a branch of
mechanical engineering, which manufactures special purpose machines. These
are specially designed and manufactured according to customer requirements.
Worldwide market:
language and cultural barriers
Varying laws, rules and environmental
regulations
High complexity:
development, production,
commissioning, operation, service
Enormous variation
Varying mounting sizes and
operations
Platform strategy

4. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Virtual Engineering (1/2)
Objectives of Virtual Engineering
Fast development cycles as an active
process element
Early feedback of results
Emphasis on early development stages
Environment
Emphasis on early development stages
Development of alternative product
concepts
Deciding on product specifications
4
[Bullinger, 2002]

5. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Virtual Engineering (2/2)
Benefit Virtual Reality
Less physical prototypes are necessary
Higher planning quality and planning reliability,
reduction of iteration loops
Cost savings through error reduction, thus reduction
Environment
Cost savings through error reduction, thus reduction
of consequential costs
Improved internal communication and customer
dialogue
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6. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Styling & Design (1/2)
Photorealistic illustrations, styling evaluation:
geometry, colors, materials
Realistic presentation through real dimensions
Variant analysis, preselection prior to rapid
prototyping
Display in the respective environment (e.g.
Image: ESI
Design-Review
Trumpf TruLaser
Cell 3000
Design
Display in the respective environment (e.g.
factory environment)
Comparison possibility: real system - virtual
prototype
Acceptance tests
Operating tests
Image: Trumpf
Design Review
in the Cave of VRCP
3D-Visualisation of
Trulaser 3030
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Image: TU Chemnitz

7. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Styling & Design (2/2)
Design
Image: BSH
VR system in the design process
at BSH with focus on high image
quality. By means of product
visualisations designers can make
material and shape decisions.
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8. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Virtual Mock-Ups (1/10)
Mock-Ups
Collision / Optimisation of the assembly space
Merging of the different disciplines
(mechanics, hydraulics, electrics, ...)
Optimisation of the assembly space
Avoidance of a double occupancy of the
Image: ESI Analysis for OPTIMA
8
Avoidance of a double occupancy of the
installation space
Collision check in motion
Consideration of inventory by means of laser
scanning: mixed data processing
Image: Scantec 3D
Image: Visenso
Processing of mixed data:
Laser scan (grey) and CAD
(colored) to avoid a
double occupancy of the
assembly space
Virtual Mock-Up:
Deep-drawing press with
process simulation

9. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Virtual Mock-Ups (2/10)
Collision/ Optimisation of assembly space
Mock-Ups
Image: Visenso
Checking
functionality of
casting tool,
kinematics,
collisions, clearance
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10. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Virtual Mock-Ups (3/10)
Collision/ Optimisation of assembly space
Mock-Ups
Virtual Design Review of a textile machine
10
Image: Oerlikon/ESI-IC.IDO

11. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
AR planning in existing system
Trumpf
Virtual Mock-Ups (4/10)
Mock-Ups
Application of Augmented Reality
11
Image: Re‘flekt

12. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Virtual Mock-Ups (5/10)
Reconstruction and dismantling: VR-application
fields
Return of existing system and level of realization
in planning documents, variant consideration
Support of project controlling
Mock-Ups
Image: Scantec 3D Laser scan
Support of project controlling
Change management
Mixed data processing:
scan plus new construction
AR-based scheduling of new geometries in stock
Image: VDC
12
Image: Volkswagen
Discussion in front of a
Powerwall
AR-based planning of
new objects in existing
system

13. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Virtual Mock-Ups (6/10)
Collision/ Assembly space optimisation
Mock-Ups
Image: ESI
Mixed data processing in front of a
Powerwall: Combination
of 3D-models and
laser scan-point cloud
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14. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
AR-planning in existing system:
Conveyor technology
Measuring function
in AR
Virtual Mock-Ups (7/10)
Mock-Ups
14
Image: TU München
Image: Volkswagen
Image: Volkswagen

15. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Virtual Mock-Ups (8/10)
Mock-Ups
Usability / Ergonomics
Usability, visibility
Accessibility (hands, tools)
Strains
User in VR environment or virtual human
Image: OPTIMA
Gripping area analysis
with a Mixed Mock-Up
15
User in VR environment or virtual human
model
Advantage of real users: subjective estimation,
(implicit) expert knowledge
Advantage human model: objective,
statements for large part of the population
achievable
Image: Siemens PLM
Approachability analysis
with a virtual human
model

16. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Virtual Mock-Ups (9/10)
Mock-Ups
Serviceability
Checking accessibility visually and manually
Checking accessibility assembly units,
connecting elements, grease nipples, etc.
visually with hands and tools
All variants, perspectives and positions
Image: ESI Courtesy of Extricom
Virtual disassembly:
Accessibility
16
Image: Industriehansa
Image: Fraunhofer IPA
All variants, perspectives and positions
Testing assembly/ disassembly, assembly
sequences
Test and evaluation of assembly aids (spines,
bevelled corners, etc.) for manual assembly
Memorandum, determination of the incentive
time
Accessibility analysis in a
machining centre
Documentation of the
work steps:
Generation of the
incentive time

17. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Virtual Mock-Ups (10/10)
Serviceability
Mock-Ups
Image: ESI
17

18. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Process simulation (1/4)
Process Simulation
Material flow
Virtual commissioning of
geometric-logical models
of conveyor systems
Dimensioning of buffer, bearing, control
Image: Fraunhofer IPA
Conveyor system
Deutsche Post
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Dimensioning of buffer, bearing, control
concept/ sensor technology
As appropriate linkage with material flow
simulator (e.g. plant simulation)
Image: Fraunhofer IPA
Image: Fraunhofer IPA
Shell assembly
Daimler
Commissioning warehouse
Rhode Schuhe

19. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Process simulation (2/4)
Process Simulation
Design of manufacturing processes
Simulation objective: desired component
properties (geometry, tolerances, thickness,
strength, prevention of cavities) in a optimized
process (process reliability, process speed)
VR applications show the process itself and the
Image: Visenso
Chipping
production
19
VR applications show the process itself and the
result
Cut free specific areas
Take samples
Put particle sources
Temperature profile/ development
Material strain/ stress
Image: Visenso
Image: Visenso
Extrusion:
Simulation
Cooling off
cast part

20. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Process simulation (3/4)
Process Simulation
Image: Fraunhofer IPA
Virtual steel mill:
Simulator combines order sequence
planning with process simulation
(furnace, rollers) and with 3D-
visualisation at SMS DEMAG
20

21. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Process simulation (4/4)
Process Simulation
Cleanroom applications
Flow behaviour in plant
Objective: Guarantee of a uniform laminar
flow
Minimisation of turbulences
Image: Optima
Flow simulation in a
cleanroom
packaging plant
21
Minimisation of turbulences
Minimisation of shading
Image: Optima
Flow simulation in a
cleanroom
packaging plant

22. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Simulation automation technology (1/3)
Automation Technology
Prototyping automation concept
Offline programming
Virtual tests and optimization
Design of sensors, actuators
Avoid collisions, deadlocks
Image: RIF
Simulation model of
automatized working
stations
22
Avoid collisions, deadlocks
Usage/ generation of the real (soft) PLC / robot
control codes if necessary
Image: RIF
Image: Fraunhofer IPA
Simulation model
of two machining stations
with
equipping robots
Simulation model
shell assembly

23. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Simulation automation technology (2/3)
Commissioning
Ramp-up support
by partial simulation
Hardware-in-the-Loop: development and
evaluation sensors, actuators, control
Image: Bathelt
Virtual packaging
machine
Automation Technology
evaluation sensors, actuators, control
Processes, emergency stop, ramp-up,
shutdown
Image: v-fab
Image: RIF
Physical SPS on
3D-plant model
Virtual
control surface
23

24. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Simulation automation technology (3/3)
Automation Technology
Industrial safety
Safety technology, accident prevention
Checking gripping areas
Testing separation systems, barriers, sensors,
processing (security concept)
Image: Fraunhofer IPA
„IPA-Security Cell“:
virtual validation of the
security concept
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processing (security concept)
Image: Fraunhofer IAO
Image: VRMMP
Crane simulator:
danger zone in red
in the case of
unloading
Signage in plant
manufacturing

25. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Image: VRMMP
Place and message of
a display
Training (1/5)
Possible forms of knowledge in virtual
environments:
Knowledge of position
Structural knowledge
Behavioural knowledge
Procedural knowledge
Training
25
Image: Fraunhofer IPA
Image: VRMMP
Function of a process
Operating a virtual
control with a Head-Up-
Display
Procedural knowledge
Possible ways of learning in virtual environments:
Spatial exploration
Conceptual learning
Learning of motoric abilities
Procedural learning

26. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Image: LightShape
Transfer process
knowledge:
stitch types at Groz-
Beckert
Training (2/5)
Operation/ usage
Learning level: explain, accompany, examine
Insertion of documentations
Insertion of simulators
Simulation of scenarios
Training
Simulation of scenarios
Visualisation of the hidden
Image: ESI
Image: RIF
Product presentation at
Gabler
Insight into a machining
centre
26

27. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Training (3/5)
Example high-voltage transformer station
Mediation of all circuits via interactive circuit
diagram
Insulators and contact breakers can be opened
and closed in the circuit diagram
Training
Image: 5DT
3D-view of a transformer
station
and closed in the circuit diagram
In the background, a high-voltage safety
program checks the correctness of all
operations
In a next step, operations are performed via a
simulated operator console
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Image: 5DT
Image: 5DT
Circuit diagram with
spatial assignment
Simulated operator
console

28. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Training (4/5)
Service/ Repair/ Maintenance
Use of tools
Process knowledge, risk of damages
All variants, all perspectivs
Online-assistants (e.g. with AR)
Training
Image: ESI
Tool changer regarding
collision and sliding
conditions
Online-assistants (e.g. with AR)
Image: ESI
Image: VRMMP
Ambidextrous
disassembly simulation
Operator Training
Simulator
(OTS): Fault cause
determination in plant
construction
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29. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Training (5/5)
Service/ Repair/ Maintenance
Training
Image: VRMMP
Screenshot of a distributed,
cooperative training simulator
of Virtual Reality &
Multimedia Park Turin for
Total: a group of employees -
each has its own avatar - has
to solve tasks of fault
diagnosis and fault
elimination jointly.
29

30. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Further topics: Technical documentation
Recording of documentation-relevant
information in the 3D model
Linking and retrieval within a virtual
walkthrough
Linking and correct (relating to position)
retrieval via augmented reality in the presence
Image: Fraunhofer IPA
Interactive
documentation with VR
Further Topics
retrieval via augmented reality in the presence
of the real machine with connection to the
complete documentation system
Acquisition of 3D geometries by laser scanning
for documentation purposes; if necessary,
comparison with existing documentation (older
acquisitions, planned/ target geometries or
planned/ target positions)
Image: Re‘flekt
Interactive
documentation with AR
30
Image: scantec 3D
Documentation of 3D
geometries via laser
scan

31. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Further topics: Marketing (1/3)
Virtual product presentation
Secure common understanding
Complex and big products
Show virtual product in operative mode
o Thereby saving transport costs
Image: ESI Group
VR-fair stand
Motek 2011
Further Topics
o Thereby saving transport costs
Individual presentations; costumer can create
his own specific product
Image: Visenso
VR-fair stand
Knowledge Base
31
Image: Imsys
Customer guidance
Powerwall

32. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Further topics: Marketing (2/3)
Variant management in Sales
Long planning periods – fast technology development
Different life cycles of product parts
Huge amount of combination possibilities,
prohibitions of combination
Recording customer request, increase customer loyalty
in early stages
Image: Schuler
Equipment options of a
press line
Further Topics
in early stages
Offering of only technical possible products
Early statement on availability and delivery date
Early statement on price, offer support
Incremental and iterative development, spontaneous
change of requirements
Systematic variant management of high importance:
unsystematic variant management often works initially,
but can not be scaled
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Image: Trumpf
Variant display of 2D-
laser cutting machines

33. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Further topics: Marketing (3/3)
Further Topics
Image: ESI / OPTIMA
Booth for
Fa. Optima Group at the fair
Interpack 2011:
Trade fair concepts may
include fixed time slots for
the presentations. The
serving and the collection of
3D-glasses has to be
organized. Another option is
the use of disposable
goggles. The audience can
additionally track the 3D-
scene using simple screens.
Due to the light-swallowing
effect of the 3D-filter a
darkening may be required.
33

34. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Further topics: Process support with Augmented Reality
Display of the next work step in the field of
view of observer
Camera image of the real object superimposed
by correctly positioned display
Capturing of actual situation (dismantling,
control,…)
Image: Volkswagen
AR-based repair assistant
„Marta“ on tablet
Further Topics
control,…)
Remote-service staff in addition is
possible
Hardware: tablet (industrial-suited),
data glasses (expected)
Image: Fraunhofer IPA
AR-supported
machine operation
34
Image: Nee
Cross-fade
online-process data
onto workpiece

35. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Further topics: Teleoperations/ Teleservices (1/2)
Tracking of machines in control center
Condition monitoring, recording working
parameters
Remote control: usage in cases where cameras
due to environmental conditions or signal
transit times are not possible
Image: Fraunhofer IPA
Remote configuration
of a Specht machining
center via touchscreen
Further Topics
transit times are not possible
Image: Fraunhofer IPA
Image: Financial Times
3D-Visualisation
machining center
Specht von Hüller-Hille
Projection in control center
of Rio Tinto:
Remote monitoring
mine cars
35

36. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Further topics: Teleoperations/ Teleservices (2/2)
Further Topics
Tele-Support with
Augmented Reality:
Operator receives view of
worker with problem
Worker receives instructions
from operator
36
Image: Re‘flekt

37. Design Mock-Ups Automation TechnologyEnvironment Process Simulation Training Further Topics
Summary
Special-purpose engineering is a very interesting field of application for
Virtual Reality and Augmented Reality
Type of software/ hardware depends on the application
Batch size 1 is not an argument against the usage of simulation technology:
testing needs are rising with the degree of novelty
Further TopicsTrainingAutomation TechnologyProcess SimulationMock-UpsEnvironment Design
testing needs are rising with the degree of novelty
More relevant:
o Product complexity and risk of costs resulting from errors
o Preconditions are created in the form of digital development process chains
that serve as data providers
The latter is one of the key success factors for the use of virtual techniques
37

38. Literature
Neugebauer, R. et. al.: Perspektiven von
Virtual-Reality-Technologien in der
Produktionstechnik- VRAX, 2004
Dierssen, S.: Die virtuelle Maschine:
Konfiguration, Simulation, Visualisierung.
In: SimVis, S. 145-156, SCS Publishing
House e.V., 2000
Sun, Shu-Huang; Tsai, Li-Zhan:
Development of virtual training platform of
injection molding machine based on VR
technology, Springer-Verlag London, 2012
Gausemeier, J.: Augmented Reality und
Virtual Reality in der Produktentwicklung.
In: VEC Innovation Days, 11.-12.07.2006,House e.V., 2000
Mujber, T.S.; et. al.: Virtual reality
applications in manufacturing process
simulation, In: Journal of Materials
Processing Technology, S. 155-156,
Elsevier, 2004
In: VEC Innovation Days, 11.-12.07.2006,
Stuttgart. Stuttgart: DaimlerChrysler AG,
2006
Runde, C.: Konzeption und Einführung von
virtueller Realität als Komponente der
Digitalen Fabrik in Industrieunternehmen.
Heimsheim: Jost-Jetter Verlag, 2007.

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© 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