Laboratory for Machine Tools and Production Engineering€¦ · CAD (Computer Aided Design, see annotation figure 7, page 11) CAM (Computer Aided Manufacturing) ... Planing and Simulation

Production Management B – Spring Semester 2009

Product Lifecycle Management I L08 P. 0

Lecture 08

Production Management B

Lecture 08Product Lifecycle Management I

Organisation:Dipl.-Ing. Michael JungSteinbachstr. 53BRaum 528Tel.: [email protected]

Laboratory for Machine Tools and Production Engineering

Chair of Production EngineeringProf. Dr.-Ing. Dipl.-Wirt. Ing. G. Schuh

Chair of Production ManagementProf. Dr.-Ing. A. Kampker



Lecture 08

Index:

Index Page 1

Schedule Page 2

Glossary Page 3

Target of this lecture Page 4

LectureProduct Lifecycle Management (PLM) Page 6

Important of information flows within CAx-applications Page 9

Differentiation between CAD, PDM and PLM Page 10

Computer-internal display formats of CAD-modelling Page 13

Objectives of CAD-interface applications Page 19

Integration of CAD and FEA Page 25

Final statement Page 28

Bibliography Page 29



Lecture 08

Schedule:

No. Date Responsible

L1 27.04.2009 Mr. Rittstieg 0241 80 20396

L2 04.05.2009 Mr. Bartoscheck 0241 80 28203

L3 18.05.2009 Mr. Fuchs 0241 80 26265

L4 25.05.2009Mr. Reil

0241 80 27964

L5 08.06.2009 Mr. Potente 0241 80 27387

L6 15.06.2009 Mr. Bauhoff (fir) 0241 47705-439

L7 22.06.2009 Mr. Hoeschen 0241 80 27382

L8 29.06.2009 Mr. Jung 0241 80 27392

L9 06.07.2009 Mr. Rauhut 0241 80 28206

L11 13.07.2009Mr. Koch

0241 80 25321

L12 20.07.2009 Mr. Cuber (fir) 0241 47705-420

Customer Relations Management

Enterprise Ressource Planning I

Enterprise Ressource Planning II

Topic

IT in Production Management

Enterprise Ressource Planning III

Product Lifecycle Management II

Digitale Plant Planning and Simulation

Business Engineering - Method of selecting IT-Systems (Trovarit)

Supply Chain Management I

Supply Chain Management II

Product Lifecycle Management I



Lecture 08

Glossary:

CAD (Computer Aided Design, see annotation figure 7, page 11)

CAM (Computer Aided Manufacturing) refers to computer applications for controlling manufacturing. This includes the direct controlling of machine tools, machining centers or assembly lines as well as logistic problems, e.g. controlling of material flow or registration of operating data.

CAE (Computer Aided Engineering) refers to all activities within CAD, CAP*, CAM and CAQ**, i.e. all computer applications in technical divisions of companies.

CAP (Computer Aided Planning) is the computer adoption in process- and production planning, e.g. generation of NC-information, working plans or parts lists.

CAQ (Computer Aided Quality Assurance) is the computer adoption in quality assurance e.g. generation of check programs, plans or statistical analysis of check values.

Product Data Management (PDM) is a technical information management system for manufacturing companies and engineering service providers. It provides an information platform for product development with core competences like system integration, data management, process management, project management and authorization management.

Engineering Data Management (EDM) is another expression (synonym) for PDM.



Lecture 08

Target of this lecture:

The lecture introduces to the topic of Product Lifecycle management and presents current IT tools in the development process. The lecture explains different computer-internal display formats of CAD-Modeling. The lecture shows the importance of information flows within CAx-applications and the objectives and problems of CAD-interface applications.



Lecture 08

Seite 5© WZL/Fraunhofer IPT

Product Lifecycle Management (PLM)

… includes management and controlling of product data - during the complete product life cycle along the enhanced logistics supply chain -beginning from design engineering and production beyond sales (distribution) and ending with maintenance.

Integrated PLM offers access to all product and process data of the complete life cycle of a product.

The functionality exceeds the system.Prof. Dr. Stucky, aifb, Karlsruhe

PLM

CSC PLOENZKE AG

ProductLifecycle

Management

Productdevelopment

Manufacturing & assembly

Market

Service &maintenance

Distribution &shipping

Productionpreparation

Product planningDisassembly

& recycling

The Term Product Lifecycle Management is used differently by the literature and by system providers. Generally three different approaches are distinguished:

PLM as a synonym for Product-Data-Management:PLM is a no new systemclass and no new form of PDM-System, but the

consequent transformation to on WEB-technology based location- and companie overlapping application of the PDM-core-competences datamanagement, process management and system integration in all areas and phases of the industrial added value.

PLM as integral integrational platform of different IT-systems:PLM is a engineering-driven PDM system. PDM is supporting every employee

during the whole product life cycle by administration of all related data and processes.

PLM as integral organisational concept of mangament for dataadministration an information availibilty:



Lecture 08


Development of PLM with function integration of CAx and ERP

Figure 2

PLM – horizontal Integration

IntersectionConfigurationParts management Parts lists management

MRP: Material Requirement PlanningMRP I: Material Resource Planning IMRP II: Management Resource Planning IIERP: Enterprise Resource Planning

timetime

2D-CAD1960

MRP1950

Notes:CAD (Computer Aided Design, see annotation figure 7, page 11)

CAM (Computer Aided Manufacturing) refers to computer applications for controlling manufacturing. This includes the direct controlling of machine tools, machining centres or assembly lines as well as logistic problems, e.g. controlling of material flow or registration of operating data.

CAE (Computer Aided Engineering) refers to all activities within CAD, CAP*, CAM and CAQ**, i.e. all computer applications in technical divisions of companies.

*CAP (Computer Aided Planning) is the computer adoption in process- and production planning, e.g. generation of NC-information, working plans or parts lists.

**CAQ (Computer Aided Quality Assurance) is the computer adoption in quality assurance e.g. generation of check programmes, plans or statistical analysis of check values.

Product Data Management (PDM) is a technical information management system for manufacturing companies and engineering service providers. It provides an information platform for product development with core competences like system integration, data management, process management, project management and authorisation management.

Engineering Data Management (EDM) is another expression (synonym) for PDM.



Lecture 08


Product Lifecycle Management is integrating processes, technologies and humans

Attending process

Product appearance

Productfabrication

Productdevelopment

Marketing Acquisition Salereal

product

Real Produktlife

Produkt-nutzung

Produkt-entsorgung

PLM-System Integrational platformIntegrational platform

Information generatingTools

Modeling Tools(CAD/CAM/CAP)

Calculation- andSimulation Tools (CAE)

Visualising Tools(DMU, VR, AR)

Information andCollaborationmanagement

Product Data Management

Supply Chain Mangement

Customer RelationshipMangement

Anmerkungen zur Folie:Product development process from product life cycle viewThe product life cycle consists of the main phases

Product appearance (planning, development)Product development (process planning, operative production) and the real Product life (Use and disposal)

The main process phases are supplemented by attending processes

Term plurality in context with PLMReasons for the term plurality:

Chronological further development of the systems (e.g. Enhancement of functions)Different Marketing strategies of the software-producersAs well used nowadays terms are EDM and PDM

Classification „PLM – PDM“:Traditional PDM-Approach: PDM is acting as interface between technical and commercialinformation processing, that means between CAx-systems on the one hand and acquisitionand production on the other hand. Therefore these systems were limited to the development.PLM-Approach: PLM is expanding the PDM-functionalities and has the ability to provideprocess integrating data and information. In addition it is separating the detachement of intern and extern users along the supply chain. PLM supports cooperative forms of collaborationbeyond company boundaries.



Lecture 08


Beispiel für einen digitalen Produktentstehungsprozess

ConstructionStyling Coverage & Clearing Check Production-

planning

Generating Ideas and creation ogLösungsvarianten für das Autodesign3D-Visualisierung z.B. durch VR-Sketchingoder Virtual Clay ModellingComparison and choiceof a design

3D-Creation of singlecomponents like e.g. a crankshaft with CAD-ToolsJoining singlecomponents to assembliesCreation of parts lists

CAE-Analyse: Calculation and interpretation of components, e.g. verification, if a crank isfatigue endurableCollision-analyses of componentsFitting- and demountingtestingBuildability testing

Compilation of streamdynamic simulationsstreamsimulation witha DMU (Digital Mock-Up)FEM (Finite Element Method) for static loadtestCrash-TestsErgonomic analyses

Planing and Simulation of production processChoice of the machineOrder of productionstepsParallelisation of production stepsProcess optimisation

Anmerkungen zur Folie:



Lecture 08


Supporting IT-systems for PLM

CAD

CAM

CAD: Computer Aided DesignCAE: Computer Aided EngineeringCAM: Computer Aided Manufacturing

CAP: Computer Aided PlanningCAQ: Computer Aided QualityCRM: Custom Relationship Management

ERP: Enterprise Ressource PlanningPDM: Product Data ManagementPLM: Product Lifecycle Management

SCM: Supply Chain Management

ERP

nach EDM-Report Nr.1, 2003

PLM reference process

CRM

CAQ

PDM

CAQ

SCMCAP

CAE

CAQ

CRM

Market DevelopmentOperations

scheduling &process planning

Productionplanning

Manufacturing & assembly Sales Service &

maintenanceDisassembly & recycling

Notes:It is not that the PLM-IT-systems lead to the idea of PLM but the other way round: PLM-IT-systems represent the functionalities and processes behind the idea of PLM.

The use of a combined basis of PLM-data for development, order processing, configuration etc. implies a new application process routine among the entire product lifecycle.

By realising the simultaneous data access of all persons involved in the product and the process, PLM supports resp. operationalises the idea of Simultaneous Engineering resp. Concurrent Engineering.

PLM reduces redundancies of data within the product life cycle.



Lecture 08


Important of information flows within CAx-applications

CAD: Computer Aided DesignCAP: Computer Aided PlanningNC: Numerical ControlERP: Enterprise Resource

PlanningPPS: Production Planning

SystemCAM: Computer Aided

ManufacturingCAQ: Computer Aided

Quality Assurance

EDM/PDM

CAP CAQ

ERP(PPS)

CAD

NC-Programm-ing system

Working plan &Operation plan

Quotationprocessing

Finaldispatch

NC-Programme

Feedback Operations

CAMcontrol centre

Production

customerOrder

Quotation

Dra

win

g

Parts list &drawing

Workingplan

Parts list

Order

Shop-order

Audit-operation

control variable

Measuringdata

Notes:For handling orders respectively manufacturing products an information exchange between different divisions of a company is necessary.

Among other things it deals with drawings, parts lists, working plans etc.. Thus huge amounts of data and complex information contents like geometry data are transferred.



Lecture 08


Differentiation between CAD, PDM and PLMIntegration depth

Product structure

Documents

Change and configuration management

Collaboration

Project planningand calculation

CAD

PDM

Projection BasicEngineering

Maintenance& service

Processplanning

Production &assembly

PLMProject management

CollaborativeEngineering Change

management

As-built

Knowledgemanagement

DetailEngineering

Configurationmanagement

Visualization

Constructionchange

Structures

Documentmanagement

Variant configuration

Legende:PLM=Product Lifecycle ManagementPDM=Produkt DatenmanagementCAD=Computer Aided Design

Integration breadth

Anmerkungen zur Folie:The lifecycle of a product from product emergence in the development to acquisition and production up to service is significantly characterized by a stronginternal dissection and a heterogeneous system landscape.

The Product Lifecycle Management(PLM), with the idea of integration, depth of integration as well as integration threshold, points out that the focus on areas of the individual system do not represent the standard anymore and only is a integral view on the whole Life Cycle of the different processes.

Reckoning the PLM as an Management Concept it includes the administrationand controlling of all product data along the whole Life Cycle of the advancedlogistic chain, from Construction and Production up to the Sale and Maintenance.

The integrated PLM offers acces to all product and process data of the Lice Cyleof a Product. (Prof. Dr. Stucky, Karlsruhe)

Hence the drawings and documents, compiled with CAD, are part of the Product-Management which coevally is responsible to supply the PLM-System with dataduring the whole Lice Cycle.



Lecture 08


History of development of workplaces for design engineering

l1 w1 l2 w2

d3

d4d1

d5

l1

b

d2

d5d5

d5

Abi

lity

for f

urth

erpr

oces

sing

of d

ata

2D-CADsystem

3D-CADsystem Virtual Reality

InteractionImmersion

Intuitional presentation

Digitalprototype

Electronicdrawing boardDrawing board

till 50‘s 60‘s 80‘s 21. century time

Notes:CAD stands for „Computer Aided Design“. The term appeared in 1957 when a NC*- (Numerical Control) system was developed by Douglas T. Roos in the United States.

CAD is a collective term for all activities where EDP (Electronic Data Processing) is directly or indirectly applied within the scope of construction and design. This can refer to common technical calculations with or without graphical output, the adoption of technical information systems and the two dimensional (2D) drawing display as well as to the three dimensional (3D) designing.

*NC (Numerical Control) is the numerical control of machine tools. The distance- and operate-information is binary-coded and inserted into machine tools by storage media like floppy disks or CD-ROMs or directly by a control computer (DNC: Direct Numerical Control) respectively by an integrated freely programmable computer (CNC: Computer Numerical Control).

VR (Virtual Reality) is a method for visualising and manipulating product models in a 3D-environment. With a VR-application one is integrated into a 3D-environment that is close to reality in order to display product models (digital prototypes) including all demanded functions during its life cycle.



Lecture 08


Examples of CAD-application

examples

CAD-

applications

CAD: Computer Aided Design

l1 w1 l2 w2

d3

d4d1

d5

l1

b

d2

d5d5

d5

Quotation processing

Machinedesign

DetailingElectronicdesign

Manufacturing resources

design



Lecture 08


Computer-internal display formats of CAD-modelling

-+ =

Translation vectordrillingnotdescribable

2D - line model:point, line

2 ½ D - profile line model:point, line, vector

3D - wire-frame model:point, line

3D - surface model:point, line, surface

3D- CSG-volume model(Constructive Solids Geometry): volume

3D-B-Rep model(Boundary Representation):point, line, surface, volume

Hybrid model:(3D-CSG volume model + 3D-B-Rep model)

Notes:The most important differentiating factors of CAD-systems are the internal data structures for geometry-processing. They are also called computer internal displays.

In the following, computer internal displays (representations) that are important in practice are explained.



Lecture 08


Application-suitability of computer-internal representations3D

B-Rep2D 21

2 D3D

Wireframe

3DArea

3DCSG

3DHybrid

appropriate

partially appropriate

not appropriate

CSG: Constructive Solid Geometry

B-Rep: Boundary Representation

Drawings, blueprints, electricalengineering, circuit boards

Preparation of drawings

Rotationally symmetricalcomponents

Profile -shaped components

Components with regulargeometry (hydraulic block)

Direct NC -programming

Kinematics, animated simulation

Finite elements analysis (FEA)

Photorealistic illustration

Components with sculptured geometry (medical equipments,mould and die making)

high calculating performance(higher investment volume)

low calculating performance(lower investment volume)



Lecture 08


2D-CAD systemsSystem-specific advantages

Low complexity

Low investment volume (hardware, software)

Good drawing functions

Point- and line functions (e.g. circle on two tangents and one point)

Dimensioning and hatching functions

Line types and thickness, colours

Typical functions

Making drawings with different views and cuttings

Electronic construction and circuit board layout

Design drafts and layouts

Factory planning and plant construction

Application areas

Gear drawing

Fact

ory

layo

ut

Notes:For 2D-CAD-systems the investment volume is low and the working technique is similar to making drawings.

2D-CAD-systems though require a certain amount of abilities of abstraction regarding to the implementation from 3D-conception to 2D representation.

Important demand in many companies is the compilation of drawings conforming to standards. That is why most CAD-systems have modules that assist the preparation of drawings.



Lecture 08


System-specific advantagesRelative small data volume

Specific orientation to surface design

Easy link up with NC-programming

Curvatures, surface intersections

Stretching slant and sloping surface

Specific functions for surface description(e.g. guidelines processing)

Typical functions

Description of sculptured surfaces

Mould and die making

Design

Application areas

3D-CAD systems based on surface models

Sculptured surface

Mold and die design

Notes:For the description of sculptured surfaces that cannot be characterised analytically, special 3D-CAD-systems based on surface models have been developed. A typical example of application is the description of forging blanks.



Lecture 08


3D-CAD systems based on CSG-modelsSystem-specific advantages

Volume information available

Quick generation of simple geometries

History of development available

Intersection of volume bodies

Volume calculation

Translation- and rotation functions

Typical functions

Animated simulation

Plant engineering and construction

Regular geometries

Application areas

FactoryA

nim

ated

sim

ulat

ion

Valve

Cams

Valvehead

Lever

Notes:For generating of analytically describable geometries, CAD-systems based on CSG-models (Constructive Solids Geometry) are suitable.

Thereby work pieces are described by volume bodies that are combined by Boolean Operations (addition, subtraction and deviation).

Sculptured surfaces cannot be created by this means. The connection to NC-programmes is difficult because of missing surface information.



Lecture 08


3D-CAD systems based on B-Rep-modelsSystem-specific advantages

Complete geometry model(Points, lines, surfaces, volume)

Suitable for any design and construction

Usable for direct NC-machining

Surface- and volume functions

Almost all advantages of surfaces- and CSG-models

Typical functions

Any design and construction

Complex products and geometries

Application areas

Gear

Generator

Notes:CAD-models that are based on B-Rep-models (Boundary Representation) manage all geometrical basic elements, beginning with a point and ending with the volume in a consistent data structure.

Thus all advantages of other computer internal displays are available. But these CAD-systems (hybrid-model also) require high-end hardware and that causes a high investment volume.



Lecture 08


Objectives of CAD-interface applications

Objects of CAD-interface applications

Transfer of CAD-data

Avoidance of multiple inputs

Reduction of cycle times

Prevention of data inconsistencies and redundancies

CADCAD

Rapid prototyping Numerical controlled machine tools

Finite Element Analysis

Virtual Reality

Digital Mock-Up

Engineering data management

Notes:The cost-intensive adoption of CAD-systems is only effective and economical if the produced data can be used by different divisions within the company and by customers respectively distributors.

Interfaces for exchanging data are necessary because normally different CAD-configurations are used by sender and receiver.

In connection with simultaneous engineering and design cooperation the importance of high-end data and information interfaces is very high.



Lecture 08


Data exchange with standard interfaces in the field of CAxCAD

Computer AidedDesign

CADComputer Aided

Design

CAPComputer Aided

Planning

CAMComputer AidedManufacturing

ERPEnterprise

Resource Planning

IGES, EDIFVDAFS, VDAPS

STEPSTEP SQL

IGES, VDAFS, STEP

CLDATA,IRDATA, STEP

CAQComputer Aided

Quality Assurance

ApplikationsspezifischesKopplungsprogramm

IGES: Initial Graphics Exchange Specification

EDIF: Electronic Design Interchange FormatVDAFS: Verband der Automobilindustrie –

Flächenschnittstelle(Association of automotive industry

– surface interface)VDAPS: Verband der Automobilindustrie –

Programmschnittstelle(Association of automotive industry – program interface)

STEP: Standard for the Exchange of Product Data

CLDATA: Cutter Location Data IRDATA: Industrial Robot DataSQL: Structured Query Language

Ope

ratin

g da

ta

Geometry data

Operating data

Operating data

Notes:For the exchange of data between different divisions of the company some standard interfaces are available whose complexity is not sufficient to transfer all necessary information.

Because of using different pre- and post-processors information loss is a result of inexact interface definitions. An example is the exchange of drawing data between two different CAD-systems with the standard interface IGES. (Loss of information because of downsizing the 3D-Volume-Model to a 3D-Surface-Model, especially problematic at model-edges)



Lecture 08


Development of standards for product data exchange

1996 1997 1998 1999

Stückliste

STEP AP 214

Welle

STEP: Standard for the Exchange of Product DataAP: Application ProtocolVDAFS: Verband der Automobilindustrie – FlächenschnittstelleIGES: Initial Graphics Exchange Specification

VDAFS IGES

ProSTEP AG

0,02

Product data model

Technology data

Calculation data

Volume model

Surface model

Wire-frame model

Technical drawing

Organisation data/Parts list

Increasingindustrialutilisation

Notes:STEP (Standard for the Exchange of Product Data) is an international standard for describing physical and functional characteristics of product data.

The standard (standardisation) is formally known as ISO 10303 „Industrial automation systems and integration product data representation and exchange“. Many countries were involved in developing, e.g. Germany, England, France, Italy, Japan and USA.

STEP is based on the specification of standard information models for product defining data. This model covers all data during the product’s entire life cycle that refers to the product and its production.

STEP allows the computer-interpretable representation and the exchange of product model data of the entire product life cycle and it supports the integration of production chains, web-based teamwork, the management of product life cycles and the re-use of concept, planning and production data.

For consistent and explicit description of the product model the formal description language EXPRESS has been defined. EXPRESS is not a programming but a specification language that unites different concepts.

The significant advantage of STEP over IGES is in the additional transfer of organisation data, calculation data, etc., like for example assembly-strucures. STEP is steadily developed further and is also nowadays one of the most prominent standards.



Lecture 08


Product data exchange with STEP

ProSTEP AG

Usage within application areas with STEP

Computer Aided Design (CAD)

Computer Aided Manufacturing (CAM)

Engineering analysis (e.g. FEA)

Process planning

Product Data Management (PDM)

…

Product data

04 Material spezifizieren DGK

05 ggf. Langläuferteile spezifizieren DGK

06 Baustruktur, Verantwortlichkeiten festlegen DGK CDM

M1 Internes Design Review durchführen DGK Abstimmungsgespräch

07 Einzelteile festlegen DGK

08 Make-or-Buy Entscheidung treffen DGK, MET

09 ggf. Laufdynamik berechnen LD

10 ggf. statisches/dynamisches Verhalten berechnen STA

M2 QFD-Methode anwenden DGK „House of Quality“

M3 Konstruktions-FMEA durchführen DGK FMEA-Formblatt

M4 Ergebnisse der Morphologie überprüfen DGK Morphologischer Kasten

11 Einzelteile grob gestalten DGK CATIA Exact Solids, Sheet Metal Designer

12 Anbindung an Drehgestell grob gestalten DGK CATIA Exact Solids, Sheet Metal Designer

M5 Informationsweitergabe und –rückführung oder Abstimmung mit Statik, Laufdynamik

DGK, STA, LD

Datenaustausch oder Abstimmungsgespräch

M6 Digital Mock Up (DMU) aufbauen DGK 4D-Navigator

M7 Internes Design Freeze durchführen DGK, STA, LD

CATIA Exact Solids, 4D-Navigator

M8 Bauteilbeanspruchung überschlägig prüfen DGK Generative Part Stress

spe zi fiz i e re n

*

*

Design Geometry Parts lists Production plans Kinematicssimulation

Quality control plans,measuring data

Manufacturing resources &method plansProduction dataNC-ProgrammingProduct-

documentationFinite Element

Analysis



Lecture 08


Possibilities of realising interfaces within the field of CAx

Man

ufac

ture

r-sp

ecifi

cA

pplic

atio

n-sp

ecifi

cN

eutra

lLinking based on a standard data format

CADPre-

processorStandard

data format(e.g. IGES)

Post-processor NC

CAD Linking-programme NC

CAD/CAM(CAD-module)

Computer-internal model

CAD/CAM(NC-module)

Linking based on an application-specific linking-programme

Linking based on a shared computer-internal model representation CAD: Computer Aided Design

CAM: Computer Aided Manufacturing

IGES: Initial GraphicsExchange Specification

NC: Numerical Control

Notes:The example of linking CAD and NC shows how data exchange between two systems with different data formats is handled:

Exchange with standard data format and implementation into the system-specific format

Exchange with an application-specific linking programme

Exchange of data by using a standard computer-internal model. That is why no formatimplementation is necessary.



Lecture 08


Problems with CAD-data exchange in IGES-formatDispatching system

Utilisation of non IGES-compliant elements and attributes (e.g. colouring)

Pre-processorIncomplete implementation of IGES-elementsFailure within IGES-format (e.g. manufacturer-designed syntax)

Post-processorIncomplete analyses of allIGES-elements

Target systemHigher mathematical accuracy than within the dispatching systemNo adequate system element for some IGES-elements

CAD System

CAxSystem

Data exchange inIGES-format

Notes:In spite of standard interface formats a data exchange is normally not exact. As shown in the picture, every other interface has similar difficulties. Within the STEP-development these error causes should be avoided.



Lecture 08


Integration of CAD and FEACAD Model: Initial solution

Min. weight

Min. parts tension

Min. deformation

Optimised calculation geometryCAD Model: optimised alternative

Reverse transformationof optimised geometry

Automatic model transformation and

integration

FEM Model

Targets of optimisation: Parameter:

Wall thickness

Form

Topology

Notes:Besides actual CAD-systems additional supplementing EDP-modules contribute to a rationalisation in design.

Special calculating-modules based on FEA (Finite Element Analysis) assist a strain-related optimisation of parts geometries.

FEA is a calculation method that divides the physical structure of an object into finite mechanical/ mathematical defined elements. These elements are linked by discreet cross points. The state of an object under load is calculated by numerical approximation procedures in stepwise transmission of state variables at cross points.



Lecture 08


Digital Mock-Up – Production technical integrationDigital Mock-Up for usage simulation:

Dynamic on-/off-construction analysis withcollision testing

Review of available construction and assembly space

Involvement of humans into model world

Example: Changing lamp

Lamp

Human

Notes:Besides simulating and evaluating product characteristics Digital Mock-ups (DMU)* can verify process flows and production systems. By involving humans into the model world ergonomic aspects can be analysed, too.

*Digital Mock-Up (DMU) is an early calibration, simulating, verifying and rating of development results based on digital prototypes respectively virtual products.



Lecture 08


Potential of Digital Mock-Up

Development time and costs can be reduced with the help of DMU!Examples: Automotive industry up to 30% *

Aircraft industry up to 40% **

time

Trial

PMU Process

DMU process100 %

construction

DMU Check HW Check

Source:* Koytek ** US Air ForceSource: von Praun

Legend:DMU: Digital Mock-UpPMU: Physical Mock-UpHW: Hardware

time

Changing-costs

Product-quality

Costsper failure

DesignDevelopment

Process planningManufacturing Customer

Final inspection

Source: PfeiferBenchmark deficit



Lecture 08


Quantification for increase of productivity

CAD/CAM capable time share tf

Reduced time share tr = tf / R

Additional capacity tz = tf – tr

Working time reduced by CAD/CAM tmr = tm – tz

Factor of increase of productivity Cp = tm / tmr

Additional capacity tz

Reduction factor RTotal time tm

CAD/CAM capable time share tf Not influence-able by CAD/CAM

Design

Calcula

tion

Drawing

Chang

ing

Contro

lling

Seco

ndar

y

proc

essin

g

timesPr

ovidi

ng

infor

mation

Repea

ted

parts

sear

ch

Parts

list

creati

on

Notes:The calculation of the economic efficiency of CAD-systems is difficult. By considering all individual activities the total benefit based on time and costs is quantified in design.



Lecture 08

Final statement:PLM comprises the management and control of the complete product data of the whole lifecycle along the enhanced logistics supply chain.

CAD is a generic term for all activities that use EDP directly or indirectly within construction and development activities.

The use of 3D CAD models allows an easy linking to NC-programming and FEM-analysis.

Digital Mock-Up (DMU) supports early simulation and check of development results based on digital prototypes resp. Virtual products.

The calculation of efficiency of CAD-systems is difficult. The overall benefit regarding time and costs in construction is quantified through the mediation of single activities.



Lecture 08

Bibliography:

M. Grieves, Product Lifecycle Management: Driving the Next Generation of Lean Thinking, New York: McGraw-Hill, 2006

G. Susman, Product Life Cycle Management, Hamilton, Ont.: Society of Management Accountants of Canada, 1994

G. Hartmann, mySAP Product Lifecycle Mangement: Strategien –Technologie - Implementierung, Bonn, Galileo Press, 2004

J. Stark, Product Lifecycle Management: 21st Century Paradigm forProduct Realisation, London, Springer, 2006