The use of simulation software with VR and AR systems during the planning process has already proven its worth in many companies. However, iPhysics simulation software is also available to the mechatronics team when the actual production of a machine or system begins.
Using digital twins in engineering and production
Every single step during the manufacturing process can be validated with the help of our simulation software. Even if this has already been done during the planning stage, it is an enormous safety gain for the entire team to put the machine into virtual operation again immediately before production. This prevents any negative surprises. It doesn’t matter whether this virtual commissioning takes place on a screen or a power wall, or whether VR + AR glasses are used. With AR glasses, the machine currently under construction can be brought to life on site and projected as a hologram based on real data. This means that the subsequent work processes can also be superimposed onto the virtual machine. The mechatronic team can therefore be sure that the respective work steps will work throughout the entire production process. This is particularly useful when additions are made to existing machines. The downtime of the system should be kept to a minimum, risks minimized as far as possible and the expansion implemented as quickly and easily as possible. This saves a lot of time and money. The new machines can also be tested virtually in advance during operation. It is also possible to see in advance what the machine will look like (also as a CAD model) in an existing production environment.
Visualize assembly
If the machines are available as a simulation model, the process can even be visualized in conjunction with the new system and made to run virtually. Process transitions and output quantities can thus be checked in detail. With the help of AR glasses, employees can familiarize themselves with the new machine in advance so that commissioning runs smoothly after assembly. When a new element is added to an existing system, the issue of collision calculation should not be underestimated. Even during the planning phase, it is possible to calculate precisely – based on the real data of both the planned and the existing machine – whether collisions may occur. Every machine or system has a large number of cables and hoses that transmit energy or are responsible for the hydraulics. The virtual representation of these freely moving elements of the machine is a major challenge that machineering has successfully met. Moving interfering edges must be taken into account at all times, because robot arms need freedom of movement for their processes. Until now, manufacturers have drawn hoses and cables as rigid elements in zero position, contrary to reality. It takes an enormous amount of numerical effort to draw a moving hose and calculate the real movements – and in real time. To prevent problems in the form of collisions, machineering has also found a solution for this: A ghost robot that mirrors the near future runs parallel to the virtual machine. With the help of AR glasses, machineering is able to delve even deeper and more precisely into the collision calculation. In one case, a potential collision was detected that could not be represented accurately enough using simulation alone.
Visualizing work instructions
Another major advantage is the topic of work instructions. Slots are stored in the software, meaning that a control cabinet can be wired correctly and quickly according to the instructions in the field of vision. The employee receives the instructions on where exactly which cable has to go in his field of vision and can implement this directly. Workplace design is also a major issue that can be optimized using a simulation. There is another blog article on this topic In three steps to an ergonomic workplace
Machineering recognized this trend early on and, in addition to the HoloLens, developed an iPhysics app that is connected to iPhysics as standard and enables the mobile viewing of complex mechatronic systems with augmented reality. In this way, we are at your side as a reliable technology partner along the entire value chain.
