Jürgen Gausemeier

Virtual and augmented reality support for discrete manufacturing system simulation

Nowadays companies operate in a difficult environment: the dynamics of innovations increase and product life cycles become shorter. Furthermore products and the corresponding manufacturing processes get more and more complex. Therefore, companies need new methods for the planning of manufacturing systems. One promising approach in this context is digital factory/virtual production-the modeling and analysis of computer models of the planned factory with the objective to reduce time and costs. For the modeling and analysis various simulation methods and programs have been developed. They are a highly valuable support for planning and visualizing the manufacturing system. But there is one major disadvantage: only experienced and long trained experts are able to operate with these programs. The graphical user interface is very complex and not intuitive to use. This results in an extensive and error-prone modeling of complex simulation models and a time-consuming interpretation of the simulation results. To overcome these weak points, intuitive and understandable man-machine interfaces like augmented and virtual reality can be used. This paper describes the architecture of a system which uses the technologies of augmented and virtual reality to support the planning process of complex manufacturing systems. The proposed system assists the user in modeling, the validation of the simulation model, and the subsequent optimization of the production system. A general application of the VR- and AR-technologies and of the simulation is realized by the development of appropriate linking and integration mechanisms. For the visualization of the arising 3D-data within the VR- and AR-environments, a dedicated 3D-rendering library is used.

A cooperative virtual prototyping system for mechatronic solution elements based assembly

In order to catch up with the steps of rapidly changing markets, the product development period of modern mechatronic products has to be as short as possible. However, mechatronic engineering is based on the interaction of mechanical engineering, electronic engineering, and computer science. Therefore, inefficient communication between the engineers who come from different domains becomes a manifest obstruction for accelerating the design of mechatronic products. Nevertheless, innovations in the field of virtual prototyping offer some potential solutions to this problem. In this paper, we present a cooperative virtual prototyping system, which utilizes the concept of solution elements and virtual reality techniques to facilitate assembling and analyzing virtual mechatronic prototypes in a multi-disciplinary workgroup.

AR-planning tool: designing flexible manufacturing systems with augmented reality

The technology of augmented reality (AR), as a new user interface, introduces a completely new perspective for the design of technical manufacturing systems. This technique supports a face to face collaboration where users need to be able to easily cooperate with each other. As with typical construction sets like LEGO or Fischertechnik, the planning engineers model the future manufacturing system in their real environment. The components are taken from virtual construction sets and are positioned interactively in the manufacturing hall. Planning rules are used to assist the user and to prevents possible errors. This article describes the conception of a virtual construction set and the realization of its prototype. The description of the development of this construction set is supplemented by an illustration of the used hardware and software components.

Design Methodology for Intelligent Technical Systems

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Produkte und Produktionssysteme integrativ konzipieren: Modellbildung und Analyse in der frühen Phase der Produktentstehung

Unternehmen mussen aufgrund der vorherrschenden Markt- und Wettbewerbssituation Produkte immer schneller und kostengunstiger entwickeln und produzieren. Fertigungstechnologien bestimmen in hohem Mase das Produktkonzept. Die Abhangigkeiten zwischen Produkt und Produktionssystem werden heute jedoch nur unzureichend berucksichtigt. Die Folge sind aufwandige Iterationsschleifen im Entwicklungsprozess. Produkt und Produktionssystem sind daher im Wechselspiel zu konzipieren. Dieses Buch beschreibt das BMBF-geforderte Verbundprojekt VireS, Virtuelle Synchronisation von Produktentwicklung und Produktionssystementwicklung. Es wird ein Instrumentarium zur integrativen Entwicklung von Produkt und Produktionssystem dargestellt. Bestandteile des Instrumentariums sind Vorgehensmodelle, Bewertungsmethoden und eine domanenubergreifende Spezifikationstechnik fur den integrativen Entwurf. Das Buch unterstutzt den Entwickler entlang des Entwicklungsprozesses bei der systematischen Konzipierung von Produkt und Produktionssystem.

An Engineer’s Workstation to Support Integrated Development of Flexible Production Control Systems

Today’s manufacturing industry demands flexible and decentralized production control systems to avoid hours of down time of the production line in case of a failure of a single central production control computer or program. Additionally, today’s market forces demand smaller lot sizes and a more flexible mixture of different products manufactured in parallel on one production line. These requirements increase the complexity of the control software. Consequently, sophisticated techniques for the development of such production systems are needed. In this paper we present an overview of our seamless methodology for integrated design, analysis, and validation for such production control systems. We illustrate our approach by an existing material flow system which is a major part of a real production system. We show how our modelling approach is used for simulation facilities, code generation for programmable logic controllers, and maintenance purposes.

BUSINESS MODEL PATTERNS FOR DISRUPTIVE TECHNOLOGIES

Companies nowadays face a myriad of business opportunities as a direct consequence of manifold disruptive technology developments. As a basic characteristic, disruptive technologies lead to a severe shift in value-creation networks giving rise to new market segments. One of the key challenges is to anticipate the business logics within these nascent and formerly unknown markets. Business model patterns promise to tackle this challenge. They can be interpreted as proven business model elements, which reveal valuable insights about pursued business logics. The approach in general helps increasing efficiency in business models design processes, but especially lacks methodological support so far. The paper at hand, therefore presents a methodology for pattern-based business model design simplifying development and analysis of business models for disruptive technologies. The methodology has been validated within several industrial projects.

Specifying the Principle Solution in Mechatronic Development Enterprises

The development of mechatronic systems starts with conceptual design, followed by design concretization and ends with system integration. The result of the conceptual design phase is the principle solution. It describes the main physical and logical operating characteristics of the system in a domain-spanning way. On the basis of this jointly developed principle solution, further design concretizations will take place in parallel within the domains involved. Finally, during the system integration phase, the outcomes from the individual domains are integrated to form an overall system. We developed a set of semiformal specification techniques to describe the principle solution of mechatronic systems. In collaboration with UNITY AG, we extended the usefulness of the specification technique for the management of development processes and development organization in enterprises.

Systems Engineering Management Based on a Discipline-Spanning System Model☆

Abstract In many current development projects targets concerning time, cost and quality are often not achieved. This is due to the complexity of the product and its engineering processes. The conceivable development of information and communication technology will enable advanced mechatronic systems. Their manifold system functions, the cross-linking of elements within the system and their hardly manageable interactions induce a much higher complexity in the development process and make it much more challenging than today. As approaches of Model Based Systems Engineering (MBSE) get more and more accepted within industry, they can be the foundation for a better management of the product development process. Due to this, we state that model based systems engineering forms the basis for systems engineering management to ensure, that project targets are achieved. In this contribution we point out, how a discipline-spanning system model can be used as the core of system engineering management: We introduce a modelling technique and its utilization for project planning as well as assessment and control. We present approaches for planning operational structures as well as technical reviews and further for measuring development progress and product maturity on different system hierarchy levels, using the information modeled within the system model.

Planning and optimisation of manufacturing process chains for functionally graded components—part 1: methodological foundations

Functional gradation denotes a continuous distribution of properties over at least one spatial dimension of a component made of a single material. This distribution is tailored with respect to the later intended application of the component (Biermann et al. in Proceedings of the 1st international conference on thermo-mechanically graded materials, collaborative research centre transregio 30, Verlag Wissenschaftliche Scripten, Auerbach, pp 195–200, 2012). The improved utilisation of the material enables light weight design and a reduced resource consumption, thus offering an alternative for modern composite materials. However, their production requires complex thermo-mechanically coupled manufacturing process chains that increase the effort for the holistic design. To realise the full potential of functional gradation, novel ways for the planning and analysis of the corresponding manufacturing process chains have to be developed. This contribution proposes methods for the description of functionally graded components, as well as the synthetisation and optimisation of their corresponding process chains. The process knowledge, models and methods required are consolidated in a comprehensive planning framework.