“CAE Driven Design of Forging Presses”altairatc.com/europe/Presentations_2009/Session_08/FLUIDON at EHT… · EPLAN Fluid System Documentation Fluidtronic – CAE Driven Design

Slide 1FLUIDON at HTC 09

© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.

It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH

“CAE Driven Designof Forging Presses”

At Present and in Future

Dr. Heiko BaumFLUIDON GmbH

COMPETENCE IN FLUID POWER SYSTEMS SIMULATIONKOMPETENZ IN DER SIMULATION FLUIDTECHNISCHER SYSTEME

3rd European HyperWorks Technology Conference




Survey

Fluidtronic – A design environment for fluid technical mechatronical systems1

Forging Presses – A Brief Introduction2

CAE-Driven Forging Press Development at Present3

An Outlook onto Future CAE-Driven Forging Press Development4

Conclusion5




Fluidtronic - A design environment for fluid technical mechatronical systems

• Target of the combined research project "Fluidtronic" is the early identification of inherent system risks and the guarantee of a reliable commissioning and plant function over the entire product life time.

• This is only possible, when the cooperation of the technical disciplines/domains respectively of the involved enterprises synchronizes better and is integrated into efficient product development processes.

• For these reasons the development of a fluid technical mechatronical system needs a general enterprise-wide development platform which can be described as a development environment.

More information is available underwww.fluidtronic.de

• Central thoughts of the development environment:

• Required are reference processes, that definethe workflow of the collaborative development

• Required are interfaces between simulationand project planning tools

• All data from the simulation and projekt planning environments will be exchanged and managed via PLM-support




Survey





Conclusion5




The Fluidtronic reference forging press

Modern open-die forging plants consisting of the forging press and one or two rail-bound manipulators are highly dynamic production plants.

Apart from the pure production speed, the main focus today is on the achievement of minimum forging tolerances and a consistently high level of quality.

Furthermore, the logging of the production process and possible deviations from the specifications is demanded, in particular for products for energy engineering and for the aircraft and aerospace industries.

Push-down type forging press with two columns




Survey





Conclusion5




Limitations of a 1D system simulation of large production machines

QSLSumme1

1

23

QSL1

QSL2

WK5

Dekompression1a

Geschwindigkeitsregler1a

NS250 NS130RNS130L

QNS130L QNS130RQNS250

VZRVZL

RZRRZL

Hochtank

Hyd

Pneu

vPresse

S3b

VSB

M2

M1

RM1

2

RF

Solldruck

ZPRH1

Speicherblock1

WRCE32

SWRC160FG_WRC160

SWRC100FG_WRC100

VS3a

NS100_WRC100 NS100_WRC160

Vol1

Gaskolben

Hyd

Pneu

SL2

x-fach

VS3

S3a

SG_FOut

VA2SL1

x-fach

Q_Tankklappe

Tankklappe

Blende1

QSVA

Diffusor2Diffusor1

L1

x|fach

L3

x|fachL2

x|fach

L4

x|fach

L9

x|fachL10

x|fach

VA1

S5

PT1NG100

S4

PT1NG160

xWRCE100xWRCE160

S3

S2

H2S

p

Q

Huebe

Zaehler1

XPresse

S1

VS8

VS7VS6

VS4 VS5Q_WRCE100Q_WRCE160

WRCE100

K

WRCE160

K

VS2

RSP

VS0

Q_SP

Q_DBV_SP

DBV_SP

nPumpeSAntriebS SchmiedePumpen

VS1

Q_WRCE32

VR5VR4

VR2

VR1

RRP

VR0

Q_RP

Q_DBV_RP

DBV_RP

nPumpeRAntriebR RueckzugPumpen

ZPRS

Schmiedesteuerung1

SMSMEER Korrektur_OT

Korrektur_UT

RueckzugSchmieden

xUTUTK xOT

OTK

Schmiedezylinder5Flaechen1

To simulate a working sequence, large parts of the original control strategy have to be included in the model.

The elasticity of the frame is merely represented by a linear spring-damper.

The work piece behavior is described by characteristics or empirical equations.




First steps to a mechatronic system simulation

© Université du LuxembourgDipl.-Ing. C. Hostert,Prof. Dr.-Ing. S. Maas,Prof. Dr.-Ing. A. Zürbes,

Results

Co-Simulation of Mechatronic Systems

Co-Simulation Set-up

Multy-Body




Survey





Conclusion5




Fluidtronic

A vision for a CAE-driven development of production machines

flexibility of components

DSHplushydraulics

MotionSolveMulti-Body

RADIOSSFinite Element

co-simulationof mechatronic

systemsdata for stress analysis

CAE supported design level

OptiStructgeometry optimization

PLCcontrols

PLM supported design level

EPLANdocumentation

CADgeometries for models

project data exchange

Measurementsvalidation

HyperStdyparameter optimization

validation level




Step1: Initial System Design with EPLAN Fluid System Documentation

Iterative customization and improvement of the

configuration with the results of simulation

DSHplus

Pre-configuration of the press in thedesign template

Check of the configuration with a hydraulic simulation

DSHplus

Automated derivation of the simulation model

DSHplus

Development template = EPLAN design template and DSHplus simulation template




Step 2: Set-up of the DSHplus Hydraulic Model of the Forging Press

Implementationof DSHplus-OPCInterface

Implementationof DSHplus-STCInterface




Step 3: Preparation of the CoDeSys PLC-Controller and Visualization




Step 4: Set-up of the MotionView Mechanical Model




625

(ca.

170

0)

2000

M1

DSHplus-OPC

DSHplus-EPLAN

DSHplus-STC

M3M2

370

320

M4

• Monitor 1

DSHplus Hydraulic Model

• Monitor 2

CoDeSys PLC-Controller and Visualization

• Monitor 3

MotionView Mechanical Model

• Monitor 4

EPLAN Fluid System Documentation

Fluidtronic – CAE Driven Design Demonstrator

At a rack 4 monitors are fastened, on which programs involved into the CAE-Driven-Design can be seen.The interplay of the programs can be presented "live" or in the form of prefabricated videos.




Survey





Conclusion5




Conclusion

• An optimization of the developments as well as a general development accompanying use of project planning and simulation software has the potential to overcome the deficits of conventional developments.

• The structured interaction of all technical domains, involved in the development, and their supply with detailed system information and current data leads to an acceleration of the developments at a simultaneous optimization of the overall system.

• A CAE Design Demonstrator has been buildedin order to present the advantages of the new development environment for fluid-technical mechantronical systems.

• Have a closer look onto the CAE Driven Design Demonstrator at the FLUIDON booth (B12) in the exhibition area.

CAE Driven Design Demonstrator

Documents

“CAE Driven Design of Forging Presses”altairatc.com/europe/Presentations_2009/Session_08/FLUIDON at EHT… · EPLAN Fluid System Documentation Fluidtronic – CAE Driven Design