The primary goal of any machine building project is to achieve perfectly running production of high-quality products. By leveraging accurate virtual prototypes, seamless production can be ensured earlier in the development process to help assess and improve product profitability.
The increasing complexity of machines requires active management of technical risks in product line development and customer implementation projects. This can be achieved through multiphysics simulation and model-based development to gain a deeper understanding of the phenomena and root-causes of unwanted behavior. Altair’s integrated product and process simulation tools allow a holistic view of the system from different roles to ensure perfectly running production earlier.
A targeted simulation can reveal corrective measures to reduce the noise level in the production facility. Structural optimization can be used to identify cost-effective design alternatives and precise multi-body simulation enables acoustic optimization. With targeted mass savings and mass damping, manufacturers can reduce vibration and determine constructive measures for reducing sound emission.
Consistent lightweight design throughout the machine helps reduce production, processing, and maintenance costs while also cutting production and idle times. Additionally, commissioning lightweight components benefits from reduced loading times on the way to the customer as well as faster set-up time at the customer's site. Lightweight design results from Altair® Inspire™ and Altair® OptiStruct® consider a variety of manufacturing processes including welded construction, plastic injection molding, sheet metal forming, casting, milling, 3D printing, and more.
The presentation outlines a solution strategy for how a digital twin of a milling machine is solving mechatronic challenges. To improve cycle times, accuracy, and addressing vibration problems a holistic system simulation serves as the basis for optimization. The efficient modeling of the real system behavior with flexibilities, contacts, gaps, friction, nonlinearities in the drives (incl. saturation effects of motors), power electronics in combination with the control system is the basis for efficient controller design and optimization of the control parameters. The dynamic interaction of multiple system components combining 3D finite elements analysis multi-body dynamics and control system helps avoiding Tracking-, drag-, positioning errors rebound, and accumulation effects.
To support the use of simulation tools in this endeavor, ABB in Spain enlisted the help of Altair ProductDesign's regional team, thanks to the company's experience in utilizing simulation tools to solve engineering challenges in the robotics industry. The project centered on improving the fatigue performance of a Twin Robot Xbar (TRX), one of ABB’s robotic part transfer systems that moves components between manufacturing stations.
The need to design more complex industrial machinery on shorter timelines means that companies ask engineers to do more with far less.
Chad Jackson, CEO of Lifecycle Insights, describes the digital approach to industrial machinery design and explains strategies leveraging Simulation, Data Science and High-Performance Computing. He shows how companies creating equipment that increases cycle speed and improves yields in this technical report.
The E-Book covers the following topics: