Digital Tools for Design and Manufacture' - Heriot-Watt University

‘Digital Tools for Design and Manufacture’

Jim Ritchie ([email protected])

Institute of Mechanical, Process and Energy Engineering

School of Engineering and Physical Sciences

IMRC Digital Tools Theme

mailto:[email protected]

Digital Tools Theme

Knowledge Capture & push

New Tools & methodologies

Applied Psychology ICT

People-centred 3D Digital Tools

– highly intuitive, person-centric tools that will help them easily record, locate, manipulate and exploit information & knowledge concerning the design and manufacture of 3D products.

[Seven year review report.]

Digital Tools: Rated internationally leading in both 3rd and 7th year IMRC reviews

Truly interdisciplinary Product Design and Manufacture, Virtual Reality, Signal Processing, Machine Learning, Biometrics, Psychology/Psychophysics, Knowledge Capture.

Impact Award winning KTPs & collaboration with a wide range of international companies & institutions from micro-SME design firms to multi-national concerns (e.g.Rolls-Royce, Selex, Ikea).

Digital Engineering

(Ritchie/Lim)

Digital Textures

(Chantler)

KIM GRAND CHALLENGE

COSTAR

HAPTIC VR

META C-TEX and

related projects.

ReTex

VirTex PerTex

Digital Tools Strategic Intent

Knowledge Capture & data push

New Design Tools

Making the implicit explicit

Science of Psychology

New input/output modalities


Design

Serious Games Haptic

Nanomanufacture VOICE META

Digital Engineering

(Ritchie/Lim)

Digital Textures

(Chantler)

KIM GRAND CHALLENGE

COSTAR

HAPTIC VR

C-TEX and related

projects.

ReTex

VirTex PerTex

Digital Engineering

Knowledge Capture & data push

New Design Tools

Making the implicit explicit

Science of Psychology

New input/output modalities


Design

META Serious Games Haptic

Nanomanufacture

META VOICE

IMRC Research

Firsts META Project

New Projects

Future Directions

Digital Engineering Outline

5

IMRC Research

Firsts

Digital Engineering Outline

Virtual Assembly

Tie Bar

Lower

Guide

Left

Frame

Right

Frame

Left Frame

Right Frame

Tie Bar

Lower Guide

Upper Guide Tie Bar Tie BarTie Bar

Upper Guide

Upper Guide

Lower Guide

Lower Guide

Manufacturing informatics

Virtual Aided Design

Developed 6 Novel VR tools

Point-To-Point

Continuous Path

WayPoint Routing

Bundle Router

Size Management

Rubberbanding

Cable Creation

Cable Creation

Follow Cable

Routing a bundle of wires

Scale Up/Down

Re-positioning cable layout

Cable Harness Design

Design in the digital world

0

5

10

15

20

25

TCTs(mins)

Expert 1: Pro/ENGINEERExpert 2: Pro/ENGINEER

Expert 3: Pro/ENGINEER

Expert 4: SolidDesigner

Expert 5: CATIAExpert 6: CHIVE

Virtual Aided Design Cable Harness Routing Productivity Gains


Virtual Aided Design Design Activity Distribution by Time and Task


Interactive Assembly Planning & Automatic Plan Generation

Component Assembly Time (s) Component Assembly Time (s) CAB01 7.592 CON22 22.36 CAB02 8.233 CON23 17.36 CON01 13.56 CON24 93.27

CON04 34.63 BH-2250 29.63 CON05 26.83 BH1750 17.70 CON10 100.3 BH2250 19.87 CON21 26.40 BH3250 7.844

Select Cable Select Connector Select Bulkhead

Virtual Aided Process Planning

Digital innovation for manufacturing/manufacturing informatics

Interactive Assembly Planning & Automatic Plan Generation Virtual Aided Process Planning

-------------------------------------------------------- CABLE HARNESS BUILDING SEQUENCE --------------------------------------------------------

Op Num W/Centre Assembly Instructions Tooling Assembly Time (s)

10 Cable Bench

Connect cable CAB02(Type: CONTROLCY Number of Cores: 7 Core Cross-Section: 1 Colour (RGB): 225,125,0) to inline connector CON23 (Type: plug Shell size: 2 Number of poles: 7)

Hand Assembly 8.2

20 Cable Bench and inline connector CON24 (Type: socket Shell size: 2 Number of poles: 7)

Hand Assembly 22.6

30 Cable Bench

Connect cable CAB01 (Type: SINGLECORE Number of Cores: 1 Core Cross-Section: 4.8 Colour (RGB): 255,0,0) to inline connector CON22 (Type: plug Shell size: 1 Number of poles: 2)

Hand Assembly 7.6

40 Cable Bench and inline connector CON21 (Type: socket Shell size: 1 Number of poles: 2)

Hand Assembly 20.7


Effective, interactive, intuitive design tool.

Immersion gives more intuitive, accurate and faster design process.

Capability of non-intrusively analyzing engineering tasks.

Analysis focused on cause-and-affect relationships and where improvements in

interface design should take place.

Generate time studied plans.

Design categorization can be applied elsewhere.

Potential for knowledge acquisition.

Virtual Aided Design and Manufacture

Managing lifecycles of products/Frontier informatics

Design/Plan Data Analysis

User Logging

Knowledge Capture/

Formalisation

Non-intrusive Engineering

Knowledge Acquisition

Knowledge Store

Virtual Aided Knowledge Capture

Managing design information

<?xml version="1.0" encoding="UTF-8" ?> <costar_events>

<cable_drag-drop> <pick_cable>1</pick_cable> <drag_cable>1</drag_cable>

<release_cable>1</release_cable> <cablepointname>

A01H01C01S01P02 </cablepointname>

<cable_move_reason> Physical Interference

</cable_move_reason> </cable_drag-drop>

</costar_events>

XML

(activity CableDragDrop) (subactivity PickCable CableDragDrop) (subactivity DragCable CableDragDrop) (subactivity ReleaseCable CableDragDrop) (cablepointname A01H01C01S01P02

currentcable) (occurrence_of physicalObstruction)

PSL

Select cable point A01H01C01S01P02 and

drag & drop. The reason for the moving the cable is due to

physical interference

English syntax

Cable drag and drop

Virtual Aided Knowledge Capture Knowledge Formats




Instantiations of capture and expert information push.

Select cable points A01H01C01S02P02 and A01H01C01S03P01 and drag & drop them. The reason for the moving the cable is physical obstruction.



Haptic technology: technology which interfaces the user via the sense of touch by applying forces,

vibrations and/or motions to the user via an interactive device/devices.

HAPTIC VR

• PC based workstation • Phantom haptic I/O device • Reachin display device • Software: VisualToolKit (VTK), Reachin libraries, Phantom libraries

ReachIn Desktop System and

Phantom Desktop haptic device.


Haptic Influence

Chamfer

21.02Hand Assembly

Assemble large CogPos(96.6175330,22.4246700,128.893980),Ori( -43.165500, -91.805110, -93.034100)

Assy Station

40

16.77Hand Assembly

Assemble BushingPos(57.3906780,142.885600,81.9569080),Ori( -42.694040, -91.084870, -93.079510)

Assy Station

50

10.97Hand Assembly

Assemble Small CogPos(77.9532930,81.1293100,175.265240),Ori( -5.0906140,88.9074180, -88.645660)

Assy Station

30

16.32Hand Assembly


Assy Station

20

Hand Assembly

Assemble HousingPos(14.3335300,39.0732500,86.8622900),Ori( -44.575480, -91.273460, -90.148500)

Assy Station

10

Assembly Time (s)

ToolingAssembly InstructionW/CenterOp Num

-------------------------HAMMS TRIAL ASSEMBLY PLAN-------------------------

Hand Assembly


Assy Station

40

Hand Assembly


Assy Station

50

Hand Assembly


Assy Station

30

Hand Assembly


Assy Station

20

6.95Hand Assembly


Assy Station

10

Assembly Time (s)



21.02Hand Assembly


Assy Station

40

16.77Hand Assembly


Assy Station

50

10.97Hand Assembly


Assy Station

30

16.32Hand Assembly


Assy Station

20

Hand Assembly


Assy Station

10

Assembly Time (s)



Hand Assembly


Assy Station

40

Hand Assembly


Assy Station

50

Hand Assembly


Assy Station

30

Hand Assembly


Assy Station

20

6.95Hand Assembly


Assy Station

10

Assembly Time (s)



3D Chronocyclegraphs

Positioning and assembling

Virtual Aided Assembly Planning

VR and simulation

• Human centric concurrent engineering, collaboration....

• Future engineering interfaces....

• Intuitive, ergonomic, cognitive support, simple to use….

• Natural interfaces for virtual engineering….

• Knowledge capture – new opportunities in CAD....

• Analyse user perception....

Opportunities

Collaborative design and managing design information

Digital Engineering Vision

PLM

Vision

Digital Engineering Vision

PLM

Vision

META Mechanical Engineering Task Analysis

META Project VR and simulation


Design in the digital world Manufacturing informatics

META Mechanical Engineering Task Analysis

• Incorporate large number of industrial partners. • Involve CAD vendor. • CAD trials with company engineers in similar

domains. • VR trials on their products. • Demonstrate generic nature of work and

formats. • Biometric data logging and post processing.

Industrial engagement

META Industrial Partners

META Project

Industrial engagement

http://www.rolls-royce.com/

http://www.renishaw.com/en/renishaw-touch-probes-rotary-encoders-linear-encoders-angle-encoders-laser-calibration-dental-cad-cam-raman-spectroscopy-and-surgical-robots--1030

http://www.selexgalileo.com/SelexGalileo/EN/index.sdo;jsessionid=F900074D87C242AACBD5DF521018ECA3.fnm_prd_srv2

http://www.bath.ac.uk/

META

Studentships – PhD Virtual machining

• Craig Fletcher – PhD Engineering gaming

• Zoe Kosmadoudi

Mechanical Engineering Task Analysis (META) Engineering knowledge acquisition through user human-centred engineering task analysis.

Dr Ray Sung, Ying Liu

META Project

Current and frontier challenges

META Vision

Physical Logging

PLM

To evaluate expert engineers doing real product engineering tasks with a view to: • Including physical user monitoring such as brain activity (electroencephalography - EEG), physical responses (electrocardiography – ECG), eye movement, interaction rates, fuzzy logic and document access.

• To provide robust industrial-equivalent experiments for knowledge capture and information push.

• Develop standards and methods for formalisation.

• Can interpreting the user experience help us identify key decision making points?

AIMS

31

2011 CAD User Trial - Hardware

EEG CAP NeXus-32

Ubiquitous Integration and Synchronisation Architecture

• Data Acquisition – NeXus-10:

• Skin Conductance (GSR)

– NeXus-32: • F3 and F4 on 10-20

system; EEG signals

– Questionnaire on each step

• Data Acquisition – NeXus-10:

• Skin Conductance (GSR)

– NeXus-32: • F3 and F4 on 10-20

system; EEG signals

– Questionnaire on each step

• Fuzzy Models – Physiological Signal ==> Arousal and

Valence Space • According to hypothesis • Five levels of inputs and outputs

– Arousal and Valence Space ==> Emotions • Modified Affect Grid (Russell et.al. 1989) • Frustration, Satisfaction, Engagement and

Challenge Depressed

Stress/

Anxiety Excited/

Joy

Relaxed

PPtoAV(mamdani)

PeakFreqAlpha

GSR

Arousal

Valence

• Physiological Signal ==> Arousal & Valence Space

Arousal and Valence Space ==> Emotions

AVtoEmotion(mamdani)

Arousal

Valence

Frustration

Satisfaction

Engagement

Challenge

Frus

tratio

n En

gage

men

t

Satis

fact

ion

Chal

leng

ing

Arousal and Valence Space ==> Emotions Map Affect grids to Surface Graphs

Arousal and Valence Space ==> Emotions Emotion outputs

Experimental set up

T

44

2011 CAD User Trial – CAD Software

Creo Elements Siemens NX

47

2011 CAD User Trial – Results 3

English Syntax

48


IDEF0 Diagram

49


DRed Graph for NX & Excel

• Preliminary results:

Knowledge Management with Psycho-Physiological Signals in

CAD

Further experimental work: • Portable system to take to companies

• Analysis of results.

• VR/CAD comparison trials.

META – Further work

Current and frontier challenges

New Projects

New Projects


Nano-manufacturing

Manufacturing informatics Current and frontier challenges


Digital tools for the planning and manufacture of micro and nano products

Jim Ritchie, Jining Sun, Xichun Luo

Institute of Mechanical, Process and Energy Engineering (IMPEE)

Design in the digital world and nano-manufacturing

Aims: • Develop haptics human machine interface and

stream file generation software as digital tools to assist planning and manufacture of 3D micro and nano products by FIB.

• Feasibility study on a hybrid machining

approach for mass production of nano products.

New Projects

Planning for Nanomanufacture

FIB facility at Heriot-Watt

• SEM resolution:

Imaging: 1 nm

Fabrication: 5 nm

• H-V, L-V and E-SEM mode

• E-beam blanker

• BSED, SED detectors

• FIB resolution:

Imaging: 7 nm

Fabrication : 14 nm

• Gas injection system (3):

Pt, H2O, SiOx FEI Quanta 3D FEG


Advantages • Accurate control of 3D pattern with direct writing (no mask) • Highly automated and high resolution (5 nm)

Disadvantages • Low throughput • Expensive

Redeposition effect/sputtering yield Monte Carlo simulation

Presenter

Presentation Notes

Fundamentally, a FIB system utilize a stream of high energy ionized atoms of relatively massive element, focusing them on the sample both for purpose of etching or milling the surface and a method of imaging. The ion’s greater mass allows them to easily expel the surface atoms from their positions and produce secondary electrons form the surface, allowing the ion beam to image the sample before, during and after the lithography process.

Hybrid manufacturing approach

Nanostructured diamond tools (www.contour-diamond.com)


Haptics: a bridge to the nano/micro world

• Straightforward input file (CAD file);

• Stream file conversion

• Optimized scanning strategy (through haptics)

• Divergence compensation

Digital tools >> Knowledge Capture....

Manufacturing informatics and nano-manufacturing

VADER Virtual Aided Design Engineering Reviews

New Projects

Objective: To automatically unobtrusively capture design review knowledge and make it accessible for reuse. The problem: Visited 3 partners so far to learn about their current design review methods. Findings:

– All thought it can be a time-consuming process. – All rely on manual or semi-automatic capture. – VR used by only one partner. – Some thought captured information was hard to search and locate. – Log books used by engineers but not all data is captured. – None of the systems used have a fully searchable knowledge store.

Links between product data and knowledge

J

VADER Application Development

• Ubiquitous logging framework: • Comments, audio, video, screen capture, snapshot, etc;

• Open source tools; • Cross platform; • Simple user interface; • Timeline view; • Visualisation and search tools;

J

VADER Virtual Aided Design Engineering Reviews

Skanska Design Review

VADER Application

• Early prototype. • Time-phased synchronisation enables chronological record of

review to be produced. • Unobtrusive knowledge capture and reuse is now possible. • Intuitive user friendly interface allows seamless capture and

formalisation of knowledge. • Interface to be extensively improved through further research. • Generic. • Links to PLM and other company databases possible. • Long desired goal of engineering companies. • VADER will be extended to CAD and non-digital team reviews and

individual engineer design activities BUT these will be integrated providing engineering knowledge provenance and reduced knowledge capture overhead.

J

New Frontiers

Design in the digital world Nano-manufacturing

Manufacturing informatics Current and frontier challenges


Future Directions

Gaps in Digital Engineering Tools

Gaps (WINVR2011 and JVRC2011):

No interactive design using VR.

VR to CAD data link problematic.

No exemplars/comparisons of industrial use of VR in manufacturing/assembly.

No intuitive real time analysis – prevents new product design paradigms being researched.

No generic knowledge capture tools embedded within CAD.

No material removal or other manufacturing process tools available.

Concurrent engineering nor supported adequately in CAD or VR.

Expensive technology solutions.

Need more feasibility studies to convince industry of benefits.

Future Directions

Current Challenges and Opportunities

Cable harness design/nano products

Design reviews/PLM links

Immersive/haptic assembly

Cable harness design/ nano products

D&M apps integrate?

Cable harness design/nano products

Haptic milling/drilling, FIB, soldering, assembly

Desktop applications/cheaper platforms

CAD/VR comparison

Virtual Concurrent Engineering

Vision

Virtual Concurrent Engineering throughout the Product Lifecycle

Customer Requirements

Conceptual Design

Process and Production Planning Planning

Embodiment/Detail Design

Manufacture Product Support Recycle

‘Digital Perception and Engagement for Collaborative Design’ Individual engineers, informal reviews, formal reviews. Multiple platforms.

Knowledge Store

Questions?

Other project partnerships: EPSRC, EU, TSB, KTP, Industrial, PhD, MPhil, undergraduate.

Documents

Digital Tools for Design and Manufacture' - Heriot-Watt University