2017 vdc-whitepaper virtual acceptance in the field of ...€¦ · factory acceptance: acceptance...

Whitepaper

Virtual Acceptance in the field of MechanicalEngineering

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

Dr.-Ing. Dipl.-Kfm. Christoph RundeVirtual Dimension Center (VDC) FellbachAuberlenstr. 1370736 Fellbachwww.vdc-fellbach.de

Engineering

Virtual techniques for acceptance in mechanical engineeringBasics of acceptance Insight in other industries

The Acceptance (1/2)

Motivation:

� Virtual techniques (VR, AR, MR) known for tasks in development, training, marketing, assistance. Also conceivable for the acceptance?

� Acceptance of (at least partial) aspects of a product without physical realization could save time and money

The legal term of acceptance:

Basics of Acceptance

The legal term of acceptance:� Declaration that a thing or a condition meets certain criteria, in particular that a work´s

capability is confirmed� The terms "acceptance“ is also used in the sense of actual takeover

Special-order contract

� § 640 BGB regulates the acceptance� Declaration of the customer´s acceptance of the work is of considerable

importance for the execution of a special-order contract� Entrepreneur is entitled to the acceptance, if the work - apart from unessential defects -

is made according to the contract


The Acceptance (2/2)

� Factory acceptance: acceptance of a product at the manufacturer

� Usually the factory acceptance is followed by the Site Acceptance Test (SAT) at the customer

� Conducted jointly by client and contractor

� The basis of the test is the functional specification document and if necessary


document and if necessary

� further changes agreed upon conclusion of contract Changes (change request)

� (reduced) functional test (Factory acceptance test (FAT)) [e.g. transport and final assembly damages]

� All steps of the factory acceptance are recorded in a written acceptance protocol, which is then signed jointly by the client and the contractor

��

(Virtual) tool changer regarding

collision and sliding conditions


DIN EN 10204:2005 "Metallic products – Types of test certificates" (Acceptance test certificates)


� Determines the different types of test certificates that can be made available to the customer for the supply of metallic products in accordance with the terms of the order

Source: Wikipedia: EN 10204

Werksbescheinigung 2.1

Source: Haver & Boecker

Abnahmeprüfzeugnis 3.1

Source: Haver & Boecker


BG RCI 223: Appendix 3: General checklist forthe initial comissioning of machinesFormal requirements for thecomissioning

� Declaration of conformity

� CE-marking

� Characteristics attached

Requirements for the operatingmanual

� German operating manual

� Special symbols for safety instructions

� Table of contents, index

� Information on noise emissions

Operating instructions

� Structure and overview

� Maintenance, set-up and repair work and fault clearance

� Description of hazards

� Protection for set-up work

� No sinking of heavy machine parts in case of pressure loss

� Effectiveness of protective devices

� Sufficient protection

� Protective devices only removable with tools

� Pictograms for residual dangers


� German operating manual

� Intended Use

� Characteristics energy supply

� Residual risks

� Personal protective equipment

� Transport instructions

� Operating states and modes

� Information about commissioning

� Safety devices

� Actuators and their effects

� Instructions for error detection and fault location

� Maintenance of safety-related components

� Description of hazards

� Performing of tests

� Behavior in the case of defects

Safety check

� Safety devices available

� Protective devices for all dangerous movements

� No incentives to the surroundings of protective devices

� Safety devices according to Appendix I No. 1.4.1 of the machine guideline

� Secured hot and very cold surfaces

� Pictograms for residual dangers

� Main switch for each type of energy

� Touch protection on the electrical control cabinet

� Labeling of electrical equipment

� Endangerment after return of electricity

� Emergency stop device

� Operating area safely accessible

� Electric security

� Bypass of protective devices

� Protective devices installed as intended


Trade Association Raw Materials and Chemical Industry BG RCI T-Series / Safe Technology

� Leaflet T 002: Hose lines - Safe use: Appendix 1b: Acceptance test certificate 3.1

� Leaflet T 008: Machines: Safety concepts andprotective devices

� Leaflet T 008-1: Checklists Machines: Check


� Leaflet T 008-1: Checklists Machines: Check before initial comissioning

� Leaflet T 008-3: Checklists Machines: Electricalequipment

� Leaflet T 008-4: Checklists Machines: Hydraulicequipment

� Leaflet T 008-5: Checklists Machines: Pneumaticequipment


DIN ISO 22514-1 and -2: Statistical Procedures in Process Management -Capability and Performance - Part 2: Process Performance and Process Capability Parameters of time-dependent Process Models

� Describes methods for determining parameters for estimating the quality capability and performance of product and process features

� Process results are divided in eight (statistical)


� Process results are divided in eight (statistical) distribution types

� Calculation formulas for the statistical measures for each of these distributions

� Statistical methods only refer to continuous quality features

� Applicable to processes in all industrial and economic sectors


The 7 most common mistakes in the frame of the acceptance

1. The acceptance modalities are not clearly defined and sufficiently specified. The acceptance at the manufacturer is not sufficiently prepared. Examples for an insufficient preparation are missing raw materials, a not undisturbed run of the machine or a not yet carried out cold and warm start.

2. The machine is adjusted before the actual "Run Off" only according to the gut feeling.


3. No proof of suitability for the used measuring systems was made.

4. Often the calculation method for the capability characteristics is not sufficiently specified.

5. Multidimensional features such as position tolerances are treated as one-dimensional features.

6. Many non-validated Excel form sheets with macros which determine the results are defective.

7. The documentation is incomplete. In particular, the environmental conditions are not sufficiently recorded. Source: Q-DAS GmbH, Weinheim.

http://www.q-das.de/de/anwendungen/qs-stat/haeufige-fehler-

maschinenabnahme/


Styling & Design in the frame of the acceptance

� Photo-realistic illustrations, styling evaluation: geometry, colors, materials

� Realistic presentation through real dimensions

� Variant analysis, preselection prior to rapid prototyping

� Display in the respective environment (e.g.

Image: ESI

Design-Review of the

Trumpf TruLaser

Cell 3000

Virtual techniques for acceptance in mechanical engineering

� Display in the respective environment (e.g. factory environment)

� Comparison possibility: real system - virtualprototype

� Acceptance tests

� Operating tests

Image: Trumpf

Design Review

in the Cave of the VRCP

3D-Visualisation of the

Trulaser 3030

Image: TU Chemnitz


Virtual Mock-Ups in the frame of the acceptance (1/3)

Collision / Optimisation of the assembly space

� Merging of the different disciplines (mechanics, hydraulics, electrics, ...)

� Optimisation of the assembly space

� Avoidance of a double occupancy of the

Image: ESI

Analysis for OPTIMA


� Avoidance of a double occupancy of the installation space

� Collision check in motion

� Consideration of inventory by means of laser scanning: mixed data processing

Image: Scantec 3D

Image: Visenso

Processing of mixed data:

Laser scan (grey) and CAD

(colored) to avoid a

double occupancy of the

assembly space

Virtual Mock-Up:

Deep-drawing press with

process simulation



Usability / Ergonomics

� Usability, visibility

� Accessibility (hands, tools)

� Strains

User in VR environment or virtual human

Image: OPTIMA

Gripping area analysis

with a Mixed Mock-Up


� User in VR environment or virtual human model

� Advantage of real users: subjective estimation, (implicit) expert knowledge

� Advantage human model: objective, statements for large part of the population achievable

Image: Siemens PLM

Approachability analysis

with a virtual human

model



Serviceability

� Checking accessibility visually and manually

� Checking accessibility assembly units, connecting elements, grease nipples, etc. visually with hands and tools

� All variants, perspectives and positions

Image: ESI Courtesy of Extricom

Virtual disassembly:

Accessibility


Image: Industriehansa

Image: Fraunhofer IPA

� All variants, perspectives and positions

� Testing assembly/ disassembly, assembly sequences

� Test and evaluation of assembly aids (spines, bevelled corners, etc.) for manual assembly

� Memorandum, determination of the incentive time

Documentation of the

work steps:

Generation of the

incentive time

Accessibility analysis in a

machining centre


Process simulation in the frame of the acceptance (1/3)

Material flow

� Virtual commissioning ofgeometric-logical modelsof conveyor systems

� Dimensioning of buffer, bearing, control


Conveyor system

Deutsche Post


Dimensioning of buffer, bearing, control concept/ sensor technology

� As appropriate linkage with material flowsimulator (e.g. plant simulation)



Shell assembly

Daimler

Commissioning warehouse

Rhode Schuhe


Design of manufacturing processes

� Simulation objective: desired component properties (geometry, tolerances, thickness, strength, prevention of cavities) in a optimized process (process reliability, process speed)

� VR applications show the process itself and the

Image: Visenso

Chipping production



� VR applications show the process itself and the result

� Cut free specific areas

� Take samples

� Put particle sources

� Temperature profile/ development

� Material strain/ stress

Image: Visenso

Image: Visenso

Extrusion simulation

Cooling off cast part


Cleanroom applications

� Flow behaviour in plant

� Objective: Guarantee of a uniform laminar flow

� Minimisation of turbulences

Image: Optima

Flow simulation in a

cleanroom

packaging plant



� Minimisation of turbulences

� Minimisation of shading

Image: Optima

Flow simulation in a

cleanroom

packaging plant


Simulation automation engineering in the frame of the acceptance

Prototyping automation concept

� Offline programming

� Virtual tests and optimization

� Design of sensors, actuators

Avoid collisions, deadlocks

Image: RIF

Simulation model of

automatized working

stations


� Avoid collisions, deadlocks

� Usage/ generation of the real (soft) PLC / robot control codes if necessary

Image: RIF


Simulation model

of two machining stations

with

equipping robots

Simulation model

shell assembly


Simulation industrial safety in the frame of the acceptance

� Safety technology, accident prevention

� Checking gripping areas

� Testing separation systems, barriers, sensors, processing (security concept) Image: Fraunhofer IPA

„IPA-Security Cell“:

virtual validation of the

security concept


Image: Fraunhofer IAO

Image: VRMMP

Crane simulator:

danger zone in red

in the case of

unloading

Signage in plant

manufacturing


Consideration of stochastic in virtual environments

� Statistical variance in material flow models

o default probabilities (e.g. mean time to failure)

o fluctuating incoming orders

� Tolerance analysis within the scope of the DMU / VMU

Image: IPO.Plan

Evaluation of tugger

train planning


DMU / VMU

� Consideration of robustness in automatizationsimulations (failure of components such as sensors)

Image: Siemens

Aesthetica tolerance -

analysis & -visualisation

Scheme compressor-

automatization system

with redundancy

Image: OPTIS


� Objective: Acceptance of parts of the vehicle without a physical prototype

� Car realized at least:o Outer edge according to ECE-R26 (Economic

Commission for Europe): Checking exterior area of radii and edges.

Automotive Engineering: Virtual certification („virtual TÜV (Technical Control Board)“)

Image: Daimler

Test object for virtual

certification

Daimler

Insight in other industries

area of radii and edges.o Wheel covers according to EG 78/549:

Checking the coverage of the margins.o Label according to 70/222 EWG: Checking

the slope and the distance between license plate and lane.

o Use of auxiliary geometries, e.g. 100mm sphere, 30 °-cone

Image: Daimler

Certification at Daimler

using a Powerwall


Aircraft manufacturing: Virtual certification

Image: CEI

Virtual crash test with

3D-Dummy

� Objective: Acceptance of parts of the aircraft without a physical prototype

� Aviation: o Virtual pre-certification of plane seats

(according to EuroNCA, JNCAP, ChinaNCAP)o Numerical experiments and analysis are part

Insight in other industries

Virtual pre-certification of

plane seats with Virtual

Seat Solution

(see also EuroNCA,

JNCAP)

Image: DLRImage: ESI

o Numerical experiments and analysis are part of approval processes for a longer period of time

o For collision simulations (of the aircraft or birdstrike)

o Imitation of realistic environmental conditions, which are difficult to simulate in the laboratory (vibration, temperature, altitude, flow velocity, real load case wing)

Image: DLR

Ditching of a commercial

aircraft

Thank you very much for your interest!

You are interested in this topic and you are looking for contact persons? Feel free to contact us.

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

Dr.-Ing. Dipl.-Kfm. Christoph RundeVirtual Dimension Center (VDC) FellbachAuberlenstr. 1370736 Fellbachwww.vdc-fellbach.de

2017 vdc-whitepaper virtual acceptance in the field of ...€¦ · factory acceptance: acceptance...

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