Virtual Product Creation in Industry: The Difficult Transformation from IT Enabler Technology to Core Engineering Competence

676 Pages·2021·25.537 MB·English

by  Rainer Stark

Rainer Stark
Virtual Product
Creation in
Industry
The Difficult Transformation from IT
Enabler Technology to Core Engineering
Competence
Virtual Product Creation in Industry
Rainer Stark
Virtual Product Creation
in Industry
The Difficult Transformation from IT Enabler
Technology to Core Engineering Competence
RainerStark
IndustrialInformationTechnology
BerlinInstituteofTechnology
Berlin,Germany
ISBN978-3-662-64299-3 ISBN978-3-662-64301-3 (eBook)
https://doi.org/10.1007/978-3-662-64301-3
©Springer-VerlagGmbHGermany,partofSpringerNature2022
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Contents
1 MotivationandApproach ...................................... 1
2 Prologue—UnderstandingtheDifferenceinApproach ............ 5
2.1 PioneeringinSelf-madeModebyTechnicalExperts ......... 6
2.2 Scaling-UpbyGrowingDigitalDesignandAnalysis
GroupswithCustomizedSolutions ........................ 7
2.3 Desire to Restrict—The Dilemma of Limited
UnderstandingoftheRoleofVirtualProductCreation ........ 7
2.4 TheNewDigitalPresence—LivingaNewUnderstanding
ofInformationBasedValueCreation ....................... 9
3 TheBigPicture—InformationTechnologyinEnterprises ......... 13
3.1 IntroductionandBasics .................................. 13
3.2 HistoryofInformationTechnology(IT) .................... 14
3.2.1 Hardware:FromNumberingandMechanics
TowardsElectronics .............................. 14
3.2.2 Software:TheKeyRoleofOperatingSystems
ofModernComputers ............................ 24
3.3 TheSet-UpofITinIndustrialCompanies .................. 30
3.3.1 History of IT Technical and Organizational
Drivers in the Twentieth and Twenty-First
Century ........................................ 30
3.3.2 Today’sITFactorySet-UpandFutureBusiness
Concepts ....................................... 34
References .................................................... 41
4 VirtualProductCreation(VPC)Explained ...................... 43
4.1 TheNewEngineeringDisciplineVirtualProductCreation .... 43
4.2 VirtualProductCreationCapabilitiesandActivities .......... 48
References .................................................... 56
v
vi Contents
5 TheTechnologyHistoryofVirtualProductCreation ............. 57
5.1 TheHistoryofComputerAidedDesign(CAD)Systems
andGeometricModeling ................................. 57
5.2 DigitalProductValidationandVerification .................. 61
5.2.1 IntroductionintoValidationandVerification
(V&V) ......................................... 61
5.2.2 EvolutionofV&VTechnologiesandComputer
AidedEngineering(CAE) ........................ 62
5.3 ProductDataManagement(PDM) ......................... 67
References .................................................... 71
6 TheSet-UpofVirtualProductCreationinIndustry—Best
Practices,ErrorModesandInnovationSpeed ................... 75
6.1 BasicsAwarenessandSenseforChange .................... 75
6.2 UnderstandingOwnershipofSkillset—TheDifference
Between Traditional Engineering Skillset and New
DigitalSkillset .......................................... 80
6.3 UnderstandingtheNatureofVirtualProductCreation
CollaborationinDevelopmentProjectExecution ............ 82
6.4 The Traditional Set-Up of Virtual Product Creation
andItsFlaws ........................................... 96
6.5 TheNewRoleofVirtualProductCreation—Evolving
fromITTechnologyTowardsEngineeringandLifecycle
Competence ............................................ 107
6.6 BestPracticesofIntegratingVirtualProductCreation
intoMainstreamingEngineering ........................... 109
References .................................................... 111
7 MajorTechnology1:ComputerAidedDesign—CAD ............. 113
7.1 EngineeringUnderstandingofCAD ....................... 114
7.1.1 WhyDoesanEngineerUseCAD? ................. 114
7.1.2 WhatDoesCADDoforanEngineer? .............. 114
7.2 HowDoesCADWork? .................................. 116
7.2.1 SystemArchitectureofaCADSystem .............. 117
7.2.2 CADModelingTechnologies ...................... 118
7.2.3 GeometryProcessingandTopology ................ 119
7.2.4 VolumeModelTypes ............................. 121
7.2.5 MathematicalRepresentation ...................... 121
7.3 BasicTechnologies ...................................... 123
7.3.1 Feature-BasedModeling .......................... 123
7.3.2 ParametricModeling ............................. 128
7.4 AdvancedTechnologies .................................. 129
References .................................................... 137
Contents vii
8 Major Technology 2: Computer-Aided Industrial
Design—CAID ................................................ 139
8.1 EngineeringUnderstandingofCAID ....................... 140
8.1.1 Why Does an Engineer Use CAID Instead
ofCAD? ....................................... 140
8.1.2 WhereisCAIDBeingUsed? ...................... 140
8.2 HowDoesCAIDWork? ................................. 142
8.2.1 HowDoesaClassicalDesignProcessUseCAID? .... 142
8.2.2 InputDevices ................................... 144
8.2.3 Three-DimensionalImmersiveModeling ............ 144
8.3 AdvancedTechnologyofCAID ........................... 145
References .................................................... 153
9 MajorTechnology3:CAPP,CAMandNCTechnology ........... 155
9.1 Computer-AidedProcessPlanning—CAPP ................. 156
9.1.1 EngineeringUnderstandingofCAPP ............... 156
9.1.2 HowDoesCAPPWork? .......................... 158
9.1.3 CAPPMethodologyandTechnology ............... 159
9.1.4 RequirementsforCAPP .......................... 161
9.1.5 CAPPChallengesandProblems ................... 163
9.2 Computer-AidedManufacturing—CAM .................... 164
9.2.1 CAD/CAMIntegration ........................... 164
9.2.2 EngineeringUnderstandingofCAM ................ 167
9.2.3 WhyDoesanEngineerUseCAM? ................. 167
9.2.4 WhatAretheBenefitsofCAM? ................... 169
9.2.5 CAMTechnologyandProcess ..................... 170
9.3 NumericalControl—NC ................................. 172
9.3.1 EngineeringUnderstandingofNC ................. 172
9.3.2 HowDoesNCWork? ............................ 173
References .................................................... 182
10 MajorTechnology4:ComputerAidedEngineering—CAE ........ 185
10.1 BackgroundandEvolutionofCAE ........................ 186
10.2 EngineeringUnderstandingofCAE ........................ 187
10.2.1 WhyDoesanEngineerUseCAE? ................. 187
10.2.2 WhatisCAEDoingforanEngineer? ............... 189
10.3 HowDoesCAEWork? .................................. 193
10.4 CAEinProductDevelopment ............................. 196
10.4.1 FromCADtoCAE—CAEModelBuild ............ 199
10.4.2 Interfaces/FormatstoTransferCADModels
toCAE ......................................... 203
10.4.3 Pre-processingofaFEAModel .................... 205
10.4.4 Utilizing FEA Models Within Optimization
Problems ....................................... 211
viii Contents
10.5 AdvancedCAETechnologies ............................. 212
10.6 ExemplaryAutomotiveFEAProjectCases .................. 214
10.7 FinalRemarks .......................................... 219
References .................................................... 221
11 MajorTechnology5:ProductDataManagementandBill
ofMaterials—PDM/BOM ...................................... 223
11.1 IntroductionofPDMandBOM ........................... 224
11.2 EngineeringUnderstandingofPDMandBOM .............. 231
11.2.1 WhatisPDMDoingforanEngineer? .............. 233
11.2.2 WhatisBOMDoingforanEngineer? .............. 241
11.3 HowDoesPDMWork? .................................. 254
11.4 HowtoIntegratePDMinLargeScalePLMEnvironments? ... 256
11.5 How to Customize PDM/BOM to Company PLM
andVPCNeeds? ........................................ 261
11.6 Expected Changes in Future Industrial PDM/PLM
Operations ............................................. 266
References .................................................... 271
12 MajorTechnology6:DigitalMock-Up—DMU ................... 273
12.1 EngineeringUnderstandingofDMU ....................... 275
12.1.1 Why Does an Engineer Use DMU Instead
ofCAD? ....................................... 276
12.1.2 WhatDoesDMUDoforanEngineer? .............. 278
12.2 TheRoleofaDMUinProductDevelopment ................ 280
12.3 UsageofDifferentDMUTypes ........................... 282
12.3.1 StaticDigitalMock-Up ........................... 282
12.3.2 DynamicDigitalMock-Up ........................ 283
12.3.3 Functional Digital Mock-Up (“Functional
Mock-Up”) ..................................... 284
12.4 DMUSet-UpandModelBuilding ......................... 288
12.5 DMUBasedEngineeringAnalysisWork ................... 293
References .................................................... 304
13 MajorTechnology7:VirtualReality—VR ....................... 305
13.1 EngineeringUnderstandingofVirtualReality ............... 308
13.1.1 WhyDoesanEngineerUseVirtualReality? ......... 309
13.2 HowDoesVirtualRealityWork? .......................... 310
13.3 VirtualRealityTechnologies .............................. 312
13.3.1 Setup oftheOverall VirtualRealitySystem
Architecture .................................... 312
13.3.2 HeadMountedDisplays,3DGlasses,Projection
Displays ........................................ 313
13.3.3 Tracking ....................................... 314
Contents ix
13.4 HumanInteractionwithVR .............................. 317
13.4.1 DevelopmentandUseofVRApplications ........... 320
13.5 UseofVRforEngineeringWorkingTasks .................. 321
13.5.1 TechnologicalLimitations ........................ 321
13.5.2 VRApplications ................................. 322
13.5.3 SummaryoftheTechnology’sBenefitsandMain
Trends ......................................... 326
References .................................................... 326
14 MajorTechnology8:AugmentedReality—AR ................... 327
14.1 EngineeringUnderstandingofAR ......................... 329
14.2 WhyDoesanEngineerUseAR? .......................... 329
14.2.1 WhatisARDoingforanEngineer? ................ 331
14.3 HowDoesARWork? .................................... 339
14.4 ARTechnologies ........................................ 340
14.4.1 SetupofARHMDs/SystemArchitecture ............ 343
14.4.2 Tracking ....................................... 343
14.5 HumanInteraction ...................................... 345
14.6 DevelopmentforARApplications ......................... 346
14.6.1 SystemSelectionforIndustrialAR ................. 346
14.6.2 ImplementationDesign ........................... 347
14.7 TechnologicalLimitationstoOvercome .................... 349
14.8 SummaryoftheTechnology’sBenefitsandMainTrends ...... 349
References .................................................... 350
15 MajorTechnology9:DigitalFactory—DF ....................... 353
15.1 EngineeringUnderstandingoftheDigitalFactory ............ 354
15.1.1 WhyDoesanEngineerUseDigitalFactory? ......... 354
15.1.2 WhatisDigitalFactoryDoingforanEngineer? ...... 359
15.2 HowDoestheDigitalFactoryWork? ...................... 360
15.3 ProcessandSystemImplementationoftheDigitalFactory .... 362
15.3.1 Logistics-andProductionFlowSimulation .......... 362
15.3.2 AutomationTechnologies/Robotics ................. 365
15.3.3 SimulationofManualLabor/Ergonomics ........... 365
15.4 DigitalFactoryTechnologies .............................. 365
15.4.1 DigitalFactoryBasicModelingTechnologies ........ 365
15.4.2 LayoutPlanning ................................. 366
15.4.3 Factory-DigitalMock-Up(DMU) .................. 367
15.4.4 BehaviorModels ................................ 369
15.4.5 ElectronicsandControls .......................... 369
15.4.6 BasicSimulationTechnologies .................... 370
15.4.7 VirtualCommissioningandRoboticSimulation ...... 370
15.4.8 MaterialFlowSimulation ......................... 374
15.4.9 ErgonomicsValidation ........................... 375
x Contents
15.5 AdvancedTechnologies .................................. 376
15.5.1 ConsistentDataModelingandExchange ............ 377
15.5.2 VirtualRealityUsedintheContextofDigital
Factory ......................................... 377
15.5.3 Human–Robot-Collaboration ...................... 379
References .................................................... 380
16 MajorTechnology10:ArtificialIntelligence(AI)inVirtual
ProductCreation .............................................. 381
16.1 WhatisIntelligence?WhatisArtificialIntelligence? ......... 382
16.2 Knowledge-Based Systems and Their Application
inIndustry ............................................. 383
16.3 MachineLearning—TheMostWidelyUsedAISubfield
inIndustry ............................................. 385
16.3.1 DeepLearning .................................. 389
16.3.2 StandardProcessforMachineLearningProjects ..... 390
16.4 (Big)DatainProductLifecycleManagement ................ 392
16.5 InternetofThings ....................................... 394
16.6 ExampleofaVirtualProductCreationAIApplication ........ 396
16.6.1 TheMainFunctionDescription .................... 397
16.6.2 BestPractice .................................... 399
References .................................................... 400
17 TheHiddenDemandsoftheEngineeringCommunity ............ 403
17.1 Hidden Engineering Demand #1: Intra Company
CompetencetoDrivetheDigitalFuture .................... 405
17.2 HiddenEngineeringDemand#2:RobustandProfessional
ITApplicationIntegration ................................ 407
17.3 Hidden Engineering Demand #3: Digital Simplicity
andJoy ................................................ 410
17.4 HiddenEngineeringDemand#4:PersonalAssistance
toAvoidFailureIntrinsicWork ............................ 412
17.5 Hidden Engineering Demand #5: Self-modifiable
PersonalDigitalWorkingEnvironments .................... 415
17.6 HiddenEngineeringDemand#6:QuickandContinuous
Improvement ........................................... 418
17.7 HiddenEngineeringDemand#7:FlexibleDigitalTest
BedsinProductionITEnvironments ....................... 421
17.8 Hidden Engineering Demand #8: True Appreciation
forDigitalResponsibilities ............................... 425
17.9 HiddenEngineeringDemand#9:UpfrontSimulation
ofDigitalEngineeringCollaboration ....................... 427
17.10 Hidden Engineering Demand #10: New Advanced
HumanInterfaces ....................................... 430