Embed Size (px)
Citation preview
Simulering av hängning och
elektrodopp
Årsmöte SYF, 6 mars 2020Fredrik Edelvik, Martin Ottosson
Cutting product development time
Improving production systems efficiency
Enabling data driven services
by
Modeling, Simulation, Optimization and Data Analytics
We offer a process for industrial
innovation
The department develops simulation technology
for automatic path-planning and line-balancing, sealing,
virtual paint, flexible materials, metrology, and
intelligently moving manikins.
The department offers competence in dynamical
systems modeling, pharmacometrics, systems
biology and electrophysiology, machine
learning, AI, and big data analytics.
.
The department develops innovative and user-friendly
methods, algorithms and software for virtual
product and process development that offer
unique possibilities for simulation and optimization
of industrial multiphysics applications.
Computational Engineering and Design
Application areas
▪ Complex flows
▪ Structural mechanics
▪ Electromagnetics
▪ Particle simulations
▪ Multiphysics simulations
– Fluid-EM coupling
– Fluid-heat transfer coupling
– Fluid-structure interaction
Multiphysics simulation and optimization of products and processes emphasizing
mathematical modeling, numerical methods, algorithmic design and innovative software
Software tools
▪ IPS IBOFlow®
▪ IPS Flexible Structures
▪ IPS Virtual Paint
▪ IPS Edge Wicking
▪ IPS Paper Forming
▪ IPS Jetting
▪ DemifyTM
Virtual PaintCable Simulation
Path Planner IMMA
Inspection Path Planner
Robot Path Planner
IPS is a math based software tool for automatic verification ofassembly feasibility, design of flexible components, motionplanning and optimization of multi-robot stations, and simulationof key surface treatment processes. IPS successfullyimplements the potential of the virtual world.
Examples of IPS Applications
Software Spin-offs Framework
FCC
Fraunhofer/ITWM
Chalmers
Research Technology developmentSoftware development
MarketingSalesSupport and servicesSoftware development
IPS Sweden AB
flexStructures GmbH
MarketingSalesSupport and services
Reseller networkSCSK Corporation (Japan)PLG IT (Korea)Empias Inc. (Korea)Kite Beijing (China)Pan Information (China)GLB (China)
▪ Albany International
▪ AstraZeneca
▪ AUTO-KABEL
▪ AB VOLVO
▪ AUDI
▪ BERTRANDT
▪ BOSCH
▪ BMW
▪ CEVT
▪ CHANGAN
▪ CST GMBH
▪ COROPLAST
▪ DAIMLER
▪ DAIMLER FORSCHUNG
▪ DELPHI
▪ DOOSAN INFRACORE
▪ GEBAUER & GRILLER
▪ GEELY
▪ FORD
▪ FUJI HEAVY INDUSTRIES
(SUBARU)
▪ FUJIKURA
▪ GAC Engineering Institute
▪ GKN Aerospace Sweden
▪ HENSOLDT
▪ HEXAGON
▪ HITACHI METAL
▪ HITACHI Construction Machinery
▪ HONDA
▪ HYUNDAI
▪ JAC MOTORS
▪ JIANGXI XINDIAN
▪ JOHN DEERE
▪ KAWASAKI
▪ KYUNGSHIN
▪ LIEBHERR
▪ LEONI
▪ MAGNA STEYR CTS
▪ MAZDA
▪ Mycronic
▪ NIPPON SHARYO
▪ NEVS
▪ NIO CO. (NEXT EV)
▪ OPEL
▪ PLASTIC OMNIUM
▪ SAAB
▪ SCANIA
▪ SBN Suzhou Bordnetze Electrical Systems
▪ SEAT
▪ SL CORPORATION
▪ SONY Global Manufacturing
▪ SPECMA
▪ STIHL
▪ Stora Enso
▪ STÄUBLI
▪ SUMITOMO RIKO
▪ SUMITOMO Construction
Machinery
▪ SUZUKI MOTOR
▪ TETRA PAK Processing Systems
▪ TOTO
▪ TOYOTA
▪ VOLKSWAGEN
▪ VOLVO CARS
▪ YAMAHA
▪ YAZAKI PORTO
▪ ZF
Examples of IPS Software Customers
Virtual Paint Shop Novel methods, algorithms and software tools to optimize paint and surface treatment processes to
be more environmentally friendly, more energy and cost efficient, and give a better product quality
Spray painting▪ Unique algorithms for coupled simulation of air flows, electrostatics and
charged paint particles
▪ Full car spray painting simulations overnight on a standard computer
Hanging optimization▪ Optimization of collision free hanging pattern
Sealing▪ Fast and accurate process simulation of the material laydown. Extension to
adhesives.
▪ Automatic generation and programming of efficient robot motions
Oven Curing (IPS 3.9)▪ Robust and accurate CFD-based approach including conjugated heat
transfer of air and solid temperatures
Electrocoating▪ Ongoing research activities
IPS Virtual Paint – Fender example
Simulering av hängning
Digi-loadTestbädd för automatiserad upphängning och nedplock av gods
Oktober 2017 – Oktober 2020
Tool for optimal hanging of parts
▪ Input for automation and offline programming of robots requires a tool
where positioning of parts on hooks and hangers can be done in an
virtual environment
▪ Finding the most optimal hanging configuration is of great economic
relevance for the powder coater as she wants to use the conveyer line
as efficiently as possible
Tool for optimal hanging of parts
▪ Several criteria exist for hanging parts on hangers and conveyers
– Primary criteria's:
• Parts shall not collide with hanger
• Parts shall not collide with eachother
– Secondary criteria’s:
• Parts shall hang symmetrically on the hanger to avoid the hanger from tilting
• Parts shall be contained within a given volume. Else, there is risk of collision with
the surroundings
Tool for optimal hanging of parts
Lua script input
3D CAD
Holes and hangers that
fulfil all secondary criteria’s
List:
1.
2.
3.
….
Holes and hangers that
fulfil some criteria’s
CAD input
• User input:
• Define holes
Generate new surfaces
• Generate new surfacesbetter suitedfor calculatingmass centre
Calculate mass centre
• Necessary for defining how the part will hang from hole
Hang parts on hanger
• Primary criteria’s fulfilled
• Collision with hanger
• Collision with other parts
Fulfilling secondary criteria’s
• Symmetry
• Confined volume
CAD library
hangers
Definition
of holes
Definition of
hooks
Tool for optimal hanging of parts
▪ View of the user interface, IPS
Tool for optimal hanging of parts
Courtesy of Bogelack
Tool for optimal hanging of parts
▪ The tool can be used for:
– Give input to offline programing of robot
– Work as input for quotation and cost estimates
– Production planning in a virtual environment
▪ The tool could give the powder coater following advantages:
– Quote more quickly and more precise
– Increase the efficiency and throughput of the plant/line
– Get a better coating result
Tool for optimal hanging of parts
▪ Further development of the tool
– Include optimal packing of hangers on conveyer, check for collision
between hangers and surrounding, at critical areas (inclinations and bends)
– Give as input for digital twin to optimise offline robot programming
Simulering av elektrodopp och
galvanisering
▪ State-of-the-art solver for complex flow applications
– Unique immersed boundary techniques
– Greatly simplified pre-processing – no “bodyfitted” meshing
– Dynamic and adaptive octree grid
– GPU acceleration
▪ Add-on modules– Multiphase flows (Volume of Fluids)
– Complex rheology
– Conjugated heat transfer
– Particle and sprays
– Electrostatics
▪ Interfaces to other tools– LaStFEMTM for fluid-structure interaction
– DEMIFYTM for DEM-CFD applications
– CST MICROWAVE STUDIO for electronics cooling
Immersed Boundary Octree Flow Solver
Electrocoating – Drainage Simulation of Test Box
▪ Utveckla metoder, algoritmer och mjukvara för simulering av
elektrodopp och galvaniseringsprocesser
– Vätskeåtkomst och dränering vid godtycklig dopprörelse
– Från delar till hel bil eller hytt
– GPU acceleration för ökad prestanda
– Databas med badparametrar
– Lageruppbyggnad
▪ Budget och tidsplan
– Vinnova FFI ~5 MSEK
– In-kind ~5 MSEK
– Ansökan juni 2020, start hösten 2020
▪ Partners
– VCC, AB Volvo, Scania, CEVT, SPF & SYF företag
▪ Ta kontakt om ni är intresserade av att delta!
Projektidé – simulering av elektrodopp
Project Proposal
Project Reason/Benefit/Need
Past Vinnova projects on the Virtual PaintShop have resulted in methods, algorithms and
software tools for simulation of spray painting, sealing and oven curing. The software IPS
Virtual Paint is internationally recognized to be state-of-the-art and is today used by e.g. Volvo
Cars, AB Volvo, Scania, CEVT, Geely, Kia, Hyundai, Chang ‘an, and Plastic Omnium.
In this project the focus is on methods, algorithms, software and measurement techniques for
electrocoating and other electro-deposition processes, where a corrosion protective layer is
generated by dipping the object into electrolyte baths.
Software Features
• Fluid access and drainage simulation during arbitrary dipping motion
• Complexity ranging from parts to complete car or cab
• GPU acceleration to boost computational performance
• Database with bath properties
• E-coat layer build-up
• Tools for creation of additional drainage holes
• Streamlined GUI on IPS Virtual PaintShop platform
Validation using test objects and smaller parts will be performed at the laboratory at RISE IVF.
In addition, industrial test cases will be defined by the participating companies
Expected Results
• Reduce commissioning time for new products by 20 %
– Identify and solve fluid access and drainage problems
– Predict coating thickness to improve product quality
• Reduce environmental impact by less physical testing and optimized energy consumption by
process simulation.
• Reduced level of phosphate contamination and thereby improved quality of E-coat finish
• The math-based simulation approach is a key to increase the flexibility to meet the challenge
of increased complexity due to an increased number of product and material variants.
Project Deliverables
The results will be integrated in FCC’s software IPS Virtual Paint which is used by several of
the potential partners. Prototypes will be available during project.
Suggested partners
Companies: AB Volvo, Scania, Volvo Cars, CEVT, IPS AB, SYF and/or SPF
member companies
Research partners:
Fraunhofer-Chalmers Centre (Algorithms and software development)
RISE IVF (Validation procedure, measurements on test objects)
Proposer’s name / Company / Issue date
Fredrik Edelvik / FCC / 2020-02-19
E-mail / Telephone
[email protected]/ 0730 794220
Timing Date
Project start October 2020
Project end December 2022
Project:
Virtual PaintShop – Simulation of Electrocoating
Project target level:
Lit study
Pre study
Concept ready x
Ready for implementation x
Other
Estimated Budget Year 1 Year 2 Year 3
[MSEK] VINNOVA 1.7 1.7 1.6
Total budget [MSEK] 10.0
