Przemysław Zawadzki

Application of Virtual Reality Techniques in Design of Ergonomic Manufacturing Workplaces

This paper presents possibilities of application of the immersive VR and the haptic technologies during the complex process of design and virtual prototyping of the manufacturing workplaces characterized with a high level of ergonomic quality. Two case studies are presented: a workplace for stud welding and a set of two workplaces, for hole drilling and manual assembly. In the first case study, haptic device with force feedback effect was used to improve ergonomics of main operator activities. In the second case study, immersive approach was used, namely Head-Mounted Device, tracking and gesture recognition systems, to test and improve ergonomics of the whole workplace. Application of VR techniques allows to present the virtual prototype of the workplace in its real operation environment, limiting the need for use of real mock-ups. Therefore, Virtual Reality allows to conduct a number of analyses related to designed prototypes, such as: dimensions of devices and possibilities of adjustment to height of the human operator, and arrangement of control and signaling devices according to the rules of ergonomic design. To conduct these analyses, full interaction between user and workplace must be programmed, including collision detection, kinematics of the devices and possibilities of activating their various functions in relation with other objects in the virtual scene.

Virtual 3D Atlas of a Human Body - Development of an Educational Medical Software Application

Abstract This paper presents a process of building a prototype of an educational application for teaching anatomy with elements of physiology, with use of a Virtual Reality environment. Preparation of mesh models of individual human organs is described, along with further visualization techniques, which were used to ensure a proper level of a visual representation. Stages of user interface preparation are also described – both visual and functional aspects covered – with a detailed review of a visual programming process, which was used to obtain a logical structure of connections inside the VR environment. Process of preparation of dynamic graphical data-namely animation of the pulmonary alveoli – and integration it with the virtual environment is also presented. The final application can be used in a number of ways, including large-screen stereoscopic projection with on- screen graphical user interface and single-user immersive stereoscopic projection using a head-mounted device with an optical tracking system. Results of assessment of the application advantages and disadvantages at the current stage of development allowed to formulate several directions of further advancement.

STRENGTH OF ABS PARTS PRODUCED BY FUSED DEPOSITION MODELLING TECHNOLOGY – A CRITICAL ORIENTATION PROBLEM

Numerous experimental studies, including experiments performed by the authors, have shown that the part orientation during layer deposition has a very strong influence on final strength of a product manufactured by additive Fused Deposition Technology. The paper presents the results of tensile, bending and impact strength tests performed on samples of various orientations, made out of ABS material using FDM technology. The results of these tests allowed discovering a unique phenomenon – with the changing orientation, not only the values of strength indexes change, but macroscopic material behavior under load as well. The transition between a “yield point” and “brittle” material usually happens in a certain range of orientation values, named a critical orientation by the authors. The paper indicates supposed ranges of critical orientation for various types of loads.

Application of additively manufactured polymer composite prototypes in foundry

The paper presents a method, developed by the authors, for manufacturing polymer composites with the matrix manufactured in a layered manner (via 3D printing – Fused Deposition Modeling) out of a thermoplastic material. As an example of practical application of this method, functional prototypes are presented, which were used as elements of foundry tooling – patterns for sand molding. In case of manufacturing prototype castings or short series of products, foundries usually cooperate with modeling studios, which produce patterns by conventional, subtractive manufacturing technologies. If patterns have complex shapes, this results in high manufacturing costs and significantly longer time of tooling preparation. The method proposed by the authors allows manufacturing functional prototypes in a short time thanks to utilizing capabilities of additive manufacturing (3D printing) technology. Thanks to using two types of materials simultaneously (ABS combined with chemically hardened resins), the produced prototypes are capable of carrying increased loads. Moreover, the method developed by the authors is characterized by manufacturing costs lower than in the basic technology of Fused Deposition Modeling. During the presented studies, the pattern was produced as a polymer composite and it was used to prepare a mold and a set of metal castings.

Preparation and Production Control in Smart Factory Model

Implementing the smart factory concept places demands not only for enterprises but also for scientific units. In order to be able to effectively develop solutions in compliance with the Industry 4.0 concept, it is necessary to improve qualifications of scientific personnel and students who are supposed to implement those assumptions in practice. The paper describes the structure of smart factory model, developed at Poznan University of Technology, which enables both learning about such solutions and doing research work in that scope. The model includes issues connected with the field of production management – starting from interpretation of client requirements, to automation of product design development, to preparing and controlling the production process.

Design and Implementation of a Complex Virtual Reality System for Product Design with Active Participation of End User

The paper presents studies on design and implementation of a complex Virtual Reality system for product design. Main objective of work presented in the paper was to obtain a tool suitable for on-line work with the clients on configuration of visual features of customized city buses. A complex product such as a city bus can have more than 100 visible features (options), which can be changed to obtain infinite configuration possibilities. The paper presents the overview and functions, as well as development process of the created system. Efficiency of the system in the visual configuration process was confirmed by representatives of the company. Capabilities of the system were tested using a sample of users from all the company departments involved in the bus design process. It confirmed high effectiveness of the system in terms of presenting variability of the product features in a clear visual way and improvement of the whole configuration process.

Fulfilling Individual Requirements of Customers in Smart Factory Model

The paper presents a concept of integration of modern processes of design of customizable products and production control, in scope of Industry 4.0 idea. Production processes must be constantly adapted, to meet changing customers’ requirements. This enforces flexibility on production companies. High quality products, delivered on time, sold with an acceptable price––this is already a standard. The main concepts described in the paper revolve around involving customers into design process by use of various systems based on knowledge. This can lead to competitive advantage and a number of other benefits shown in the paper. Products customization is still a big challenge for production companies, because it demands appropriate planning and production control, which is also presented.

Virtual Reality Production Training System in the Scope of Intelligent Factory

The paper presents a prototype Virtual Reality system for learning of operation in an intelligent factory, working according to the concept of Industry 4.0. The SmartFactory laboratory—example of part of intelligent factory—is described. The VR prototype system and process of its building is also presented, starting from digitalization of the real smart factory, through logic programming and connection of peripheral VR devices. Functions of the training system are presented, along with directions of future studies and development.

Efficiency of Automatic Design in the Production Preparation Process for an Intelligent Factory

This article presents the research on the efficiency of performance of automatic design of variant products system, including the process of product variant configuration, preparation of the 3D model in CAD system and the preparation of the assembly instructions for the manufacturing positions. The variants of the described product take the form of various combinations of individual assembly parts combined together and constitute an example of customized products, and the process of their manufacture (assembly) is the subject of the research carried out in the SmartFactory Laboratory at the Poznan University of Technology.

Virtual reality training of hard and soft skills in production

The paper1 presents development and test procedure of two Virtual Reality systems for training of skills necessary in a modern production company. The two systems allow teaching hard skills (example: forklift operation) and soft skills (example: quality management tools). Basic ideas, concepts of the virtual courses and their test procedure is presented, along with obtained results.