whitepaper virtual techniques in the aviation industry · 2018-09-25 · o knowledge management...

© Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC)

Dr.-Ing. Dipl.-Kfm. Christoph Runde Virtual Dimension Center (VDC) Fellbach Auberlenstr. 13 70736 Fellbach www.vdc-fellbach.de

Whitepaper

Virtual Techniques in the Aviation Industry

VP Aircraft VT in Marketing VP Manufacturing Training Production

Virtual Techniques in Aviation

2

Virtual Prototyping Aircraft Virtual Prototyping

Manufacturing

Training Marketing

Factory planning: target setting

Basic evaluation

o Inventory

Factory concept planning

o Architecture, media systems

o General construction planning

o Layout planning

o Material flow, logistics

Factory detailed planning

o Safety at work

o Automation technology

o DMU integration

o Manufacturing processes

o Materials handling

o Assembly planning

Implementation preparation

Implementation monitoring

o Monitoring, verification

Initial support

o Commissioning ramp-up

o Commissioning training

Project completion

o Knowledge management

Hedging design

o Form finding, design

o Haptics

Functional protection

o Virtual Mock-Up

o Functional product

• Structural mechanics, fatique,

crash

• Fluid mechanics

• …

• Flight simulation

• Ergonomics, usability,

MMI design

• Assistance systems

o Acceptance:

• Virtual certification

o Service:

• Documentation

• Repairability, maintainability

o Manufacturability

• Mountability

• Constructability

• Process ergonomics

Training production

Training operation

Training maintenance

and repair

Market research and environmental

analysis

o Competitive analysis

o Customer analysis

Target definition

o Support of different target

indicators through virtual

techniques

Strategy definition

o Virtual techniques in product

development

o Customer integration with virtual

techniques

Marketing-Mix

o Variant development

o Virtual techniques for print, web,

point-of-sales, digital signage in

communication

o Virtual sell-in, virtual training and

virtual store in distribution

Marketing control

o Virtual store/ test/ training to

verify target achievement

Production

Assistance systems

Quality assurance

and documentation


Image: Ethiopian Airlines

Design study

in 3D

Image: Uni Groningen

Design review in a

4-sided-CAVE

(projection room)

Design study

aircraft cabin

Virtual Prototyping Aircraft: Hedging design

Form finding, design

Term design: Design of all kinds of objects

according to criteria of functionality (e.g.

ergonomics) and aesthetics [according to

http://www.designlexikon.net]

Design classes [according to P. Gorb]:

o Product (e.g. industrial design, packaging

design, service design)

o Information (e.g. graphic design, branding,

media design, web design)

o Environment (e.g. retail design, exhibition

design, interior design)

Image: Airbus

3

VP Aircraft

http://www.designlexikon.net/


Image: Fraunhofer IPK

Image: Immersion

Flap simulator:

programming force-path

behaviour

Programmable knob

User interface

Virtual Prototyping Aircraft: Hedging design

Haptics

Quality impression through haptics

Requirement: "blind" operation (-> averted

gaze)

Central:

o Haptic feedback during actuation and

o Gaining usable data for ergonomics and the

design of operating haptics

Haptic free programmable interfaces available

Rotary knobs interchangeable via plug-in

system

Test the influence of button size, weight,

shape and material on the respective

operating behavior

4

Images: Immersion

VP Aircraft


Virtual mock-up model

for VR

Virtual Prototyping Aircraft: Functional protection

Virtual Mock-Up

Digital overall model of the aircraft

Consideration of all planning trades – MCA

(major component assembly), interior

construction, electrics, hydraulics, ...

Collision investigations

Double occupancy of assembly space

Interactive examination of flexible

components (cables, hoses) possible

Minimum distances

Basis for feasibility studies

(installation/ dismounting investigations)

Image: Embraer

Image: ESI

Image: ESI

Interactive examination

of flexible components

(cables, hoses) in front of

VR-Powerwall

Interactive control of

section panes for

investigation of assembly

space

5

VP Aircraft


Virtual bird strike

examination

Virtual Prototyping Aircraft: Functional hedging

Functional capability – structural mechanics

VR-applications: often postprocessing of data

from physical simulation, such as Computational

Fluid Dynamics (CFD) or Finite-Elemente-Analysis

(FEM) o Rigidity

o Impact loads

o Vibrations

o Crash

o Airbag

o …

Strong use of interaction metaphors

Support local or distributed cooperative work

with VR

Augmented Reality (AR) for comparisons

model - trial

Image: CEI

Image: Lauer & Weiss

Image: ITV Denkendorf

Stability simulation of

screw connections

Simulation of a biaxial

tensile load of a fabric for

the use of composites

6

VP Aircraft


Image: CEI

Simulation of suction of

dirt particles when

starting the engines

Functional capability – Fluid mechanics:

Post-processing of simulation data from fluid

mechanics:

o Outer flow, aerodynamics, uplift and drag

o Heat exchanger, simulation of the cooling

module

o Electromagnetic fields, hydraulics, emission

propagation

o Air conditioning and air flow aircraft interior:

HVAC (heating, ventilation and air

conditioning)

o Thermal design, thermal analysis, defrost

Aerodynamics-

examinations on virtual

prototype

HAVAC- and breathing

simulation with avatar

7

Image: xx

Image: CEI

Image: CEI

VP Aircraft



Image: Barco

Image: Lufthansa

Modern flight simulator

at Lufthansa

Functional capability – Flight simulation:

Flight behavior

Safe offline testing of new assistance systems

Testing novel human-machine interfaces

Behavioral research

Head-up display development

Design information interface

Design Reviews

Acoustics / NVH

…

Image: British Aerospace

VECTA Flight Simulator

(late 1980s)

8

Interior view flight

simulator

VP Aircraft



ESIs Virtual Seat Solution:

evaluation seat comfort,

evaluation of legroom

and freedom of

movement, absorption of

vibrations

Virtual hedging of display

visibility

Virtual hedging of

manual reachability of all

control elements

Image: ESI

Image: ESI

Image: Optis


Functionality capability – Ergonomics &

Usability

Early verification of accessibility and visibility

of control elements

Hedging visibility of safety-relevant control

and display elements, safety at work

Virtual examination of comfort

Consideration of ergonomic aspects for age

groups, percentiles, somatotypes (securing

product functionality for large part of the

population)

Consideration of human as a physical factor

9

VP Aircraft


Virtual hedging of

reachability and usability

with haptic interface Image: Optis

Functional capability – Ergonomics & Usability

10

VP Aircraft



Virtual pre-certification of

aircraft seats with Virtual

Seat Solution (EuroNCA,

JNCAP)

Image: CEI

Image: DLR

Virtual crash test with

3D dummy

11

Image: ESI

Virtual certification

Objective: acceptance of parts of the aircraft

without a physical prototype

Aviation:

o Virtual pre-certification of aircraft seats

(according to EuroNCA, JNCAP, ChinaNCAP)

o Numerical experiments and analysis have long

been part of approval processes

o For impact simulations (of the aircraft or bird

strike)

o Simulation of realistic environmental

conditions, which are difficult to simulate in

the laboratory (vibration, temperature,

altitude, flow velocity, real loading condition

wing)

Image: DLR

Ditching of a commercial

aircraft

VP Aircraft



Image: ESI

Image: Virtalis

Virtual examination

maintainability in direct

interaction

Installation/ disassembly

examination with haptics

(position setting and

force-feedback via

mechanical articulated

arm system)

Image: ESI

Virtual examination

maintainability with

avatar


Service – Maintainability, repairability:

Service Engineering: Checking accessibility

visually and manually

Inspection of the accessibility of assembly

groups, fasteners, lubrication points, etc.

o Visually

o Manually

o with respective tool

All variants testable

All perspectives and positions can be

considered

12

VP Aircraft


Image: Fraunhofer IPA

Simulation of industrial

component cleansing

Image: Visenso

Simulation of a

casting process

Image: Visenso

Comparative

representation of

differently configured

milling processes


Manufacturability:

Design of manufacturing processes: often a

complex spacial task

VR-application: postprocessing of CFD or

FEM data

Simulative design of manufacturing

processes

Analysis of alternative manufacturing process

configurations

13

VP Aircraft


Assembly investigation

with ambidextrous

interaction VR


Manufacturability – Constructability and

mountability:

Virtual environments with collision detection

and slipping simulation are used in the

investigation of assembly and disassembly

For this purpose, the position and orientation

of a component which has to be installed/

disassembled is specified with a spatial input

system

Examination of assembly aids

Also use of geometry prototype (e.g. 3D print)

mounted on 1 or 2 haptic terminals (force

feedback)

Collision output acoustic, graphic or haptic

Image: Optis

Image: ESI

Image: xxx

Subjective assessment of

buildability through

interactive navigation

through the model

Virtual examination of

the use of lifting gear

14

Image: ESI

VP Aircraft


Image: Bharathiar University

Image: Optis

Image: ESI


Manufacturability – Process ergonomics

(product immanent):

Comfort and accessibility analyses

Visibility analyses

Collision checks

Realistic motion simulation

Human models from anthropometry database

for statistical body shape sizing

Powerwall with flysticks

[but: accommodative conflict]

Use of Head Mounted Displays

Ergonomics examination

through direct

interaction in VR

15

Ergonomics examination

with 3D human model

Investigation of assembly

ergonomics with avatar,

which is controlled by a

real user by means of

motion capturing

VP Aircraft


16

Phase 4 – Detail planning

o Industrial safety

o Automation technology

o DMU integration

o Manufacturing processes

o Conveyor technology

o Assembly planning

Phase 5 – Preparation implementation

Phase 6 – Monitoring implementation

Phase 7 – Ramp-up support

o Commissioning: Ramp-up

o Commissioning: Training

Phase 8 – Project completion

o Knowledge management

Virtual Prototyping Manufacturing: Overview

Factory planning:

Types of projects:

o Factory replanning

o Extension

o Reorganisation of an existing factory

Phase 1 – Target definition

Phase 2 – Basics determination

o Inventory

Phase 3 – Concept planning

o Architecture/ media systems

o General construction

o Layout planning

o Material flow/ logistics

VP Manufacturing


17

Image: Visenso

Extrusion:

Simulation

Virtual Prototyping Manufacturing: Basics determination

Information acquisition and evaluation as

basis for the following plannings

Creation of the quantity structure for

following process simulation

In the case of replanning (Brown Field

projects): documentation and validation of

current level of implementation (CAD plans,

3D-documentation, etc.) and target/ actual-

comparison for validation

Simulative feasibility studies for suitable

manufacturing processes (see VDC

Whitepaper “Virtual Reality in manufacturing

processes”)

Image: Scantec 3D

Laser scan of a

complete plant

Image: Scantec 3D

Mixed data processing:

laser scan (grey) and CAD

(colored) for prevention of

double occupancy of

assembly space

VP Manufacturing


Image: xxx

Decision aspects of an

aircraft manufacturer:

dock vs. flow production,

transport system, working

platforms

18

Image: Fh-IPA

Virtual Prototyping Manufacturing: Concept planning

General construction: 3D- variant visualization

of general construction and factory building

Planning building infrastructure

Layout planning: dimensioning and structuring

of areas and warehouses (rough layout) in 2D/

3D with interactive planning desk: 2D-layout

on desk surface, 3D on wall; interactive cube

for positioning of objects (machines, etc.) on

desk

Hedging through material flow and logistics

simulation

Virtual walk through factory

Image: xxxxxxx Image: Fh-PA

Visualization general

construction

Daimler Rastatt

Image: VDC

Meeting for layout

planning at factory

planning desk

VP Manufacturing


Determination of target

times by processing a "VR

scene" (assembly engine);

Entries appear

automatically in the left

table

Simulation extrusion

Virtual Prototyping Manufacturing: Detail planning

Planning of conveyor, assembly and automation

technology with regard to efficiency, safety and

ergonomics

Virtual commissioning of geometric-logical

models

Process security through production simulation

Manual assembly tasks can be simulated through o 3D human models or

o VR (tracking, motion capturing)

Industrial safety: Hedging with an interactive 3D

model

Integration in factory DMUs o Geometric integration

o Functional integration

o Procedural integration

Image: xxx

Image: Altran

19

Image: Visenso

Virtual workplace

planning with visTABLE® Image: xxx Image: PlaVis

VP Manufacturing


20

Virtual Prototyping Manufacturing: Monitoring implementation

Image: RE'FLEKT

Image: TU

München

Image: Scantec 3D

Extracted 3D-model

from laser scan of a

transformer station

AR-planning in existing

plant:

conveyor technology

AR-based

planning

of new

objects in

existing

system

Coordination, control and

documentation of implementation

VR for target/ actual-comparison of

implemented status by means of mixed

data processing (laser scans vs. 3D-

construction)

Augmented Reality (fade-in target-

planning on current status)

Targets:

o Quality control

o Project control

(e.g. billing of performed work)

VP Manufacturing


21

Virtual Prototyping Manufacturing: Ramp-up support

Commissioning: Virtual Ramp-Up

Virtual design of sensors, actuators

Avoidance of collisions, deadlocks

Hardware-in-the-loop simulations

Transmission of control code (offline

programming) to physical plants

Shortening the ramp-up time by simulation-

based preliminary tests with simultaneously

improved level of planning maturity of

robotics and automation systems

Commissioning: Training

[see slide „Training production“]

Image: Fh-IPA

Image: RIF

3D-model of a

automated assembly line

Hardware-in-the-loop:

physical control vs.

virtual model

Image: ESI

Operating safety and

handling can be

inspected early due to

digital model

VP Manufacturing


22

VP Manufacturing

Virtual Prototyping Manufacturing: Project completion

Evaluation of the past project and securing the

gained knowledge

Backing up 3D geometry data from phase 2 (basic

determination) and phase 6 (implementation

monitoring)

Backing up factory DMU model and all simulation

models from phase 4 (detail planning)

Backing up 3D knowledge management system

from phase 7 (ramp-up support)

4 types of knowledge in virtual environments:

position, structure, behavior, procedural

knowledge

4 opportunities for learning in virtual

environments:

spatial, conceptual, motoric, procedural learning Image: Fh-IPA

Image: VRMMP

Image: VRMMP

Position and meaning of

a display

Functionality of a process

Integral, total 3D-model

consisting of layout,

conveyor technology and

robotics


Representation of a

night scene in a flight

simulator

Training – Operation

Flight simulators:

safe training for future pilots

o Understanding of all displays

o Operation, handling

o Special aircraft behaviour

o Big vehicles, high seating positions

o Unclear aircraft areas

Safe simulation and training of critical

situations

Obstructions (also night vision)

Communication with others (e.g. traffic

control) Image: xxx

23

Image: Halldale

Use of a flight

simulator Image: Barco

Image: Barco

Spheric projection

for a flight simulator

Training


View in the simulator of

an airport tower

Training – Operation

Simulators for airport towers and

control centers

o Understanding of all displays

o Operation, handling

o Working procedures

o Monitoring and recording the situation at

the airport (simulated windows)

o Dealing with obstructions

o Communication (mainly with pilots)

Image: xxx

24

Image: Barco


an airport tower Image: Barco

Image: Barco


an airport tower

Training


Virtual repair training

with Head Mounted

Display and haptic

interface

25

Image: NASA

Tactile supported training Image: Haption

Instructions in

interactive environment

Training – Maintenance/ Repair

Processes, process knowledge, dangers of

damage

Learning concepts: demonstrate - accompany –

examine

Resource/ tool applications

All variations

All perspectives

[Animated] AR projection (hidden installations

on real vehicle)

Image: xxx Image: Altran

Training


Image: Haption

Assembly training in a

CAVE of PSA Peugeot

Citroën

Coating trainer

SimSpray

Training – Manufacturing

In case of non-availability of factory/ plant/

device

Also in advance

Safe (for man and machine)

Possibly cheaper

3D-based Operator Training Simulators

(OTS)

26

Image: SimSpray

Image: Optis

Assembly training with

avatar, which is

controlled by a real user

by means of motion

capturing

Training


Image: Altran/CenterlineDesign

Scheme of LASER

projection


Photograph of the

view on a projection

area

Production: Assistance systems

LASER projection

For quality assurance

Display of mounting positions for brackets,

wiring harness and other systems

Guide function for drilling and cutting

27

Production


Image: Testia

Assembly of a bracket at

the projected position

Image: Testia

Overall projection and

display of the next

working steps

3D capturing and

projection unit


Augmented Reality projection

SART-Augmented Reality projection

system for

o Inspection

o Quality assurance (target/ actual

comparison)

o Installation instructions

o Guides via video projection (also film

with instructions)

3D capture unit (depth imaging camera)

is used for referencing the projection

relative to the 3D object

Image: Testia

28

Production


Image: Testia

DMU Browser with

guiding function

Image: Boeing

AR-based harness

assembly with data

glasses (1992)

Tracking the

A350 wing mounting

Tablet PC based Augmented Reality

DMU viewer

In-place display of meta information by means

of AR via DMU

Correct display of product and process

information by means of AR via DMU

Smart glasses based Augmented Reality

Wishful thinking for a long time

Hardware (smart glasses) currently not yet

practically usable for Augmented Reality

Image: Testia

29

Production



Image: xxx

Detect changes

Comparison 3D scan

with CAD

MCAx –measuring arm

Production: Quality assurance and documentation

Scanning and Reverse Engineering

MCAx: 3D capture of small to medium sized

parts

MCAx-coordinate measuring arm:

o Precise,

o Reliable,

o Easy to use

(manual),

o Transportable

7-axis measuring system

30

3D scan to CAD

Imageer: Altran/CenterlineDesign

Production


Structure tests and

measurements

Structure scanning

Optical scanner


K-series: capture medium sized to large

components

Portable system K-series, optical coordinate

measuring system

No mechanical restrictions: set up freely and

capture desired points or surfaces

o Structure tests and measurements

o Damage control

o Door tension

o Structure scanning

31

Images:

Altran/CenterlineDesign

Production



Optical measuring

system in use

Deviations of panels in

2 axis

Optical

3D object detection


LASER radar: spacious measuring

technology

No confusion between adjacent interior

lining

Automatic part measurement

Automatic tool measurement

Thickness calculation

Verification of the profile of the outer shell

Scripts possible

for automatic

measurement

of many

components

32

Images:


2D section through

3D scan of the wing

Production



Assembly of MCAs

Images:


Measurement of the overall assembly

Laser scan unit


iGPS– large-scale measurement technology

MCA (major component assembly)-

preparation and assembly

MCA assembly

Verification of aerodynamics and

symmetry

33

Production



Scanned 3D model of a

helicopter

Images:


Scanned 3D model of a

part of an aircraft

Surphaser


Surphaser: large-scale measurement

technology

The surphaser scans both short and medium

distances: 1m to 130m

Thus suitable for reverse engineering

Submillimeter accuracy

Scan rate of up to 1 million points per

second

34

Production



Marker positions

Images:


Graphical overlay of real

perspective and 3D

computer graphics

Marker

Mobile CAD usage and Augmented Reality

Graphical overlay of real objects with virtual 3D

data for quality assurance

For documentation: screenshots

Paperless assembly

35

Production



Image: Testia

Graphical overlay

target specifications

on current status


Detailled view on

serving trolley

Fixed tablet PC with

AR scene

Use of Augmented Reality

Use of tablet PCs: camera records real image;

display of the composite image on the tablet

Possibly mounting for fixing the tablet

Target-actual comparisons

Display of missing components

Digitizing new knowledge about mobile devices

(camera recording, sensor data acquisition,

etc.); filing for documentation and sharing with

others (such as knowledge management

systems and social media)

[Knowledge types in virtual environments:

position, structural, behavioral and procedural

knowledge]


36

Production



37

Marketing: Virtual techniques in marketing process: 5 steps

1. Market and environmental analysis

Competitive analysis: Benchmarks

Customer analysis

Virtual Store

Tests & Presentations

Customer dialogue

2. Target definition

Order hedging and

mass customization

Creativity support

Customer integration with VR

Overcoming digital gap

High-tech image

3. Strategy definition

Virtual engineering in product development

Customer integration with VR

4. Marketing-Mix

Variant development

3D and VR for print, web,

point-of-sales, digital signage

in communication

Virtual sell-in, virtual training and

virtual store in distribution

5. Marketing mapping

Virtual store/ test/ training for verifying

target achievement

VT in Marketing


Image: SensoMotoric Instruments

Examination of

competitor products by

means of Reverse

Engineering

Interactive comparison of

interior design variants by

means of a 3D

configurator


38

Image: NIAR

Marketing: Market and environmental analysis

Variant comparisons prior to the creation of

physical, haptic prototypes (thinning variants)

Virtual benchmarks: comparison of own (still

virtual) designs with competitive products

Product tests and acceptance tests on the basis

of virtual prototypes: gaze analyses, dialogue,

recording critique and suggestions

Secret tests of new products, hidden from

competitors, failed approaches remain

confidential

Virtual customer dialogue via 3D web

platforms or virtual worlds

Statistical evaluation of preferences using 3D

configurators

Gaze analyses:

stereo-3D-glasses with

integrated eye tracking

VT in Marketing


Increase customer

orientation and customer

satisfaction: Virtual

comfort examinations for

the passengers: does the

product meet the

requirements of the

market? Image: NIAR

Image: Gravity

Innovative capability:

creative working

environment in the form

of a augmented reality

based sketching (with

GravitySketch)

Image: ESI

39

Marketing: Target definition

The achievement of goals in marketing is

measured on the basis of so-called target

indicators

o Indicator customer satisfaction

o Indicator innovation capability

o Indicator customer orientation

o Indicator engagement/ satisfaction employees

o Indicator image

Question: contribution of virtual techniques to

target indicators? Increase of employee

satisfaction: integration

of employees in

development process

VT in Marketing


Image: Ethiopian Airlines

For good customer

relations:

design visualization

interior to ensure a

common understanding

Estimation of the

efficiency of the use of

AR

Image: Rapex

Image: xxx

40

Image: Testia

Marketing: Strategy definition

Strategy „superior, attractive products“

Offer impeccable products designed for their complete

life cycle: massive frontloading

Desired products of the customer

Minimization of product recalls

Strategy „superior, efficient processes“

VR/ AR based fast and secure product development that

takes all relevant aspects into account

Strategy “superior, customer relations”

Preparation of the offer jointly with the customer

Inclusion of all wishes

Immediate statements on feasibility, price,

delivery time, ...

Integrated solutions: initial configuration at

home, detailing on site

Product recalls of

respective product group

in the European Union

VT in Marketing


Design representation

aircraft construction Image: ESI

Image: bitmanagement

Product configuration

in 3D

Image: ESI

Virtual development at

Boeing

41

VT in Marketing

Marketing: Marketing-Mix

Product policy:

Pursuit objectives of virtual engineering

Further pursuit of promising product variants

in development

Communication:

Supply of print, web, PoS, digital signage,

trade fair presence with 3D data for:

(interactive, animated, custom, multimodal)

presentation

Reduction of time-to-campaign

Reduction of costs for cross media content

Distribution:

Sales support with virtual techniques (e.g.

configuration, immersion)

© Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC)

Thank you very much for your interest!

You are interested in this topic and you are looking for contact persons/

implementation partners? Please contact us.

Virtual Dimension Center (VDC) Fellbach Auberlenstraße 13 70736 Fellbach www.vdc-fellbach.de

whitepaper virtual techniques in the aviation industry · 2018-09-25 · o knowledge management...

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