dr antony robotham - executive director ewg-dss ......dr a robotham ewg-dss liverpool 2012 virtual...
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Dr Antony Robotham - Executive Director
EWG-DSS Liverpool 2012 12 - 13 April 2012
Dr A Robotham
EWG-DSS Liverpool 2012
THE VALUE OF SIMULATION AND IMMERSIVE VIRTUAL
REALITY ENVIRONMENTS TO DESIGN DECISION MAKING
IN NEW PRODUCT DEVELOPMENT
DR A J ROBOTHAM & DR F SHAO
Dr A Robotham
EWG-DSS Liverpool 2012
Content
Virtual Engineering Centre
Virtual Engineering
Virtual Engineering Across the Product Lifecycle – Examples
Scenarios and Case Study with Bentley Motors
Conclusions
Dr A Robotham
EWG-DSS Liverpool 2012
VIRTUAL ENGINEERING CENTRE
Dr A Robotham
EWG-DSS Liverpool 2012
Virtual Engineering Centre
Located in North West region of UK
Largest manufacturing region in the UK by GVA
Manufacturing generates 20% of the region’s GVA
Employs 400,000 people in the region
Virtual Engineering Centre
Dr A Robotham
EWG-DSS Liverpool 2012
Virtual Engineering Centre
A Centre of Excellence in Virtual Engineering…
VE best practice demonstration
VE business development and research
VE education and skills development
… providing VE support to the aerospace supply chain
and other high valued added manufacturing sectors
Dr A Robotham
EWG-DSS Liverpool 2012
VEC Project Partners
Project Partners
University of Liverpool
STFC Daresbury Laboratory
NWAA
Morson Projects
BAE Systems
Airbus (Associate)
Funding
NWDA
ERDF
Dr A Robotham
EWG-DSS Liverpool 2012
VE Technology Specialists
Virtual Engineering Centre
Applied Computing & Engineering Ltd
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EWG-DSS Liverpool 2012
VEC Technical Facilities
LAN to HPC &
Internet
CAE Workgroup
VR Workgroup VESL
Workgroup
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EWG-DSS Liverpool 2012
Virtual Reality Workgroup
LAN 100 Mbps
CATIA V6 Server DELL PowerEdge
License Server DELL T7800 64-bit DS Virtools PTC Division
Optical Tracking System 12 x Vicon Bonita Infrared Cameras 100 Mbps Ethernet connection Vicon “Tracker” software VRPN communication protocol
“Virtual Touch” System Haption Virtuose Haptic Device 6 x Degrees of Freedom Force feedback VRPN communication protocol
Head Mounted Display NVIS nVisor SX111 HMD NVIDIA Quadro 4800 Graphics 2 x 1280 x 1024 eye displays 102o Horizontal Field of View Passive Stereo - 50o Binocular HFOV Magnetic/Infrared Tracking
Computer Network 3 x DELL T5500 64-bit 1 x DELL T3500 32-bit 100 Mbps Ethernet connection Various software applications
HP
C Lin
k
10 Gbps via Fibre Optic
Stereo Projection System NVIDIA Quadro 5800 Graphics 2 x WUXGA Active Stereo projectors 6.0m x 2.1m screen 3390 x 1200 resolution single image 3.6 million pixels in total
Dr A Robotham
EWG-DSS Liverpool 2012
Virtual Reality at the VEC
Dr A Robotham
EWG-DSS Liverpool 2012
CAE Workflow
Virtual Product Design CATIA V6 Solid /Surface Geometry Feature Modelling Parametric
Virtual Production - Assembly DELMIA / HAPTION RTI
Virtual Reality - Immersion 3DVIA Virtools PTC Division 3DXML
Virtual Engineering - CFD ANSYS Fluent
Prep Stage
Solve Stage
Post Stage
Virtual Engineering - FEA SIMULIA
Prep Stage
Solve Stage
Post Stage
IGES STEP
Geometry Prep SpaceClaim Direct Modelling Parametric
HPC
Virtual Documents 3DVIA Composer / Player
Optimisation ModelCenter
ENOVIA PLM
Optimisation iSight
OPTIS Physics based rendering
WITNESS Discrete Event Simulation
NASTRAN FEA Modelling ADAMS MBD Modelling
SolidWorks CAD
OPENFOAM Open Source CFD Pointwise Meshing tool
Dr A Robotham
EWG-DSS Liverpool 2012
VIRTUAL ENGINEERING
Dr A Robotham
EWG-DSS Liverpool 2012
Virtual Engineering
Integration of product and process
modelling using digital technologies
Dr A Robotham
EWG-DSS Liverpool 2012
Virtual Prototypes
A product model in a synthetic environment
VIRTUAL PROTOTYPE
TS = Technical System
Hu = Human System
En = Active Environment
Transformational Process
En Hu
TS
State 0 State 1
Theory of Technical Systems: V Hubka
Dr A Robotham
EWG-DSS Liverpool 2012
Virtual Prototypes
VIRTUAL PROTOTYPE
TS = Synthetic Helicopter
Hu = Pilot in Flight Deck
En = Synthetic Ship & Air Wake
Air to Ship Landing
En Hu
TS
Flying Landed
A product model in a synthetic environment
Dr A Robotham
EWG-DSS Liverpool 2012
VE across the Product Lifecycle
VE enables integration across the product life cycle …
… but requires 1000s of scenarios to be modelled using VPs
VIRTUAL
ENGINEERING
Dr A Robotham
EWG-DSS Liverpool 2012
VPs across the Product Lifecycle
High fidelity VPs support early decision making in NPD
VIRTUAL
PROTOTYPES
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EWG-DSS Liverpool 2012
VPs in support of NPD
VPs are an effective support to the
iterative activities of the Fuzzy
Front End of NPD …
… and the systematic development of
holistic, integrated solutions
Opportunity
Identification
De
ma
nd
Pu
ll
Overall Problem
Overall Solution
Sub Problem
Sub Solution
DE
CO
MP
OS
ITIO
N
SY
NT
HE
SIS
Dr A Robotham
EWG-DSS Liverpool 2012
VE EXAMPLES
Dr A Robotham
EWG-DSS Liverpool 2012
Requirements Capture: VOC
Dr A Robotham
EWG-DSS Liverpool 2012
Concept Definition: Flight Behaviour
Geometry Structural Model
Aerodynamic Model
cw
lt ct
et
ew
MAC
CoG
Sweep
Y
X
Y
X
wi
ywi
fi
xfi t1
b/2
X
b/10
bt/2
Dr A Robotham
EWG-DSS Liverpool 2012
Design: Functional Development
Dr A Robotham
EWG-DSS Liverpool 2012
Manufacture: Process Simulation
Dr A Robotham
EWG-DSS Liverpool 2012
Assembly: Ergonomic Assessment
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EWG-DSS Liverpool 2012
Development: Ride Qualities
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EWG-DSS Liverpool 2012
Development: Optimisation
Size of Design Space = 2 Size of Design Space = 3
Dr A Robotham
EWG-DSS Liverpool 2012
Test & Certification: UAV Mission
Hub
Platform
Environment CFCS
Product Model
Visualisation
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EWG-DSS Liverpool 2012
Operations: Flight Handling Qualities
En u
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EWG-DSS Liverpool 2012
Operations: Planning & Training
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EWG-DSS Liverpool 2012
Upgrades: Improved Performance
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EWG-DSS Liverpool 2012
Disposal: Nuclear Decommissioning
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EWG-DSS Liverpool 2012
SCENARIOS
Dr A Robotham
EWG-DSS Liverpool 2012
Product Quality
The totality of product quality is achieved only when
all life cycle phases have been considered
all stakeholders are delighted
Dr A Robotham
EWG-DSS Liverpool 2012
Scenarios
A concrete description of activity that the user
engages in when performing a specific task
A description sufficiently detailed so that design
implications can be inferred and reasoned about
Scenarios are not formal; they are not
scientific in any fancy sense
Carroll, JM (1995)
Dr A Robotham
EWG-DSS Liverpool 2012
Scenarios
Multiple scenarios allow us to
explore different visions of the future
“cover the field” as much as possible
a creative tool that facilitates
the leap from observation to invention
Verplank, W et al (1993)
Dr A Robotham
EWG-DSS Liverpool 2012
Scenarios in Virtual Engineering
Customers demand more sophisticated,
higher quality products
Engineering simulations can provide:
insight into the behaviour of virtual products
a comprehensive coverage of the solution space
data and information to make design decisions
Dr A Robotham
EWG-DSS Liverpool 2012
Scenarios in Virtual Engineering
However, engineering simulations only represent a
small set of product properties and are limited
bound by the fidelity of the underlying physics
Therefore, hundreds of different simulation models
may be required to represent all the scenarios
identified in the product life cycle
Additionally, each scenario requires accurate
representations of the product, the active
environment, and the human operator
Dr A Robotham
EWG-DSS Liverpool 2012
Scenarios in Immersive Virtual Reality
Immersive Virtual Reality enables:
interaction with the virtual product in real-time
exploration of many different aspects of a scenario
assessment of user stimuli on the functionality
However, to achieve real-time interaction often
requires engineering simulations to be simplified
and limited to tasks that can computed quickly
Dr A Robotham
EWG-DSS Liverpool 2012
Case Study with Bentley Motors
Dr A Robotham
EWG-DSS Liverpool 2012
Case Study with Bentley Motors
Dr A Robotham
EWG-DSS Liverpool 2012
Case Study with Bentley Motors
Dr A Robotham
EWG-DSS Liverpool 2012
Case Study with Bentley Motors
Dr A Robotham
EWG-DSS Liverpool 2012
Case Study with Bentley Motors
Dr A Robotham
EWG-DSS Liverpool 2012
Immersive Virtual Reality
Working with Bentley Motors is was apparent that
immersive virtual reality provides:
a collaborative environment for the design team;
an information resource shared by all;
a means of communication;
a means for visualising life cycle events;
awareness of stakeholder needs during design;
a stimulus for creativity and synthesis;
a means to monitor the progress of design work; and
a means to support quality assurance in design.
Dr A Robotham
EWG-DSS Liverpool 2012
CONCLUSIONS
Dr A Robotham
EWG-DSS Liverpool 2012
Concluding Remarks
Virtual Prototypes have an important role to play in NPD
Hi-fidelity physics-based models are required
of the product and the active environment
Exploration of the total design space will be expensive...
...so it requires efficient software & effective hardware
Virtual scenarios demand management
Dr A Robotham
EWG-DSS Liverpool 2012
Thank You