CAD-VR integration as a tool for industrial assembly

CAD-VR integration as a tool for industrial assembly processes validation: a practical application Authors: Claudio Pascarelli, Mariangela Lazoi, Gabriele Papadia, Valerio Galli, Luigi Piarulli

Research context Virtual MANufacturing Project Product and process optimization, in the Oil & Gas industry, through the use of digital and innovative production technologies.

CAx – VR Integration Assembly simulations, model navigations and animations

Navigation and query of CFD and FEM Machining simulations results Machining processes simulations CAD-VR integration as a tool for industrial assembly processes validation: a practical application

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Research field Assembly process planning: Defining required process steps, equipment and tools. • Computer-aided process planning (CAPP) tried to automate this process with poor success. • In many companies, process planning is still a manual task.

• When assembly processes are complex, traditional methods are no more efficient and effective. • VR technology plays a vital role allowing operators to simulate even complex processes in an immersive and interactive environment. CAD-VR integration as a tool for industrial assembly processes validation: a practical application

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Research field Virtual Assembly The use of computer tools to make or “assist with” assembly-related engineering decisions through analysis, predictive models, visualization, and presentation of data without physical realization of the product or supporting processes. Jayaram et al. (1997)

About 40 studies analyzed

Case studies Real attempts to prove the ability of immersive VA in supporting real industrial practices.

These studies are more than ten years old: the technology in that period was “not able to repeat, in a real industrial environment, what had been done so far in laboratory environments”. CAD-VR integration as a tool for industrial assembly processes validation: a practical application

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Research scope and method Investigate the potential of CAD-VR integrated applications for the assembly processes planning and evaluation of Oil & Gas products of BHGE Nuovo Pignone, assessing the feasibility of an assembly plan by mean of VR. • Single case study describing the specific activities and results of VA research in an industrial company. • It is based on applicative evidence emerging from qualitative data. • Evidences and data were collected through the observation of the research and development practice in the VMAN project and from semi-structured interviews. CAD-VR integration as a tool for industrial assembly processes validation: a practical application

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Case study

CAD-VR integration as a tool for industrial assembly processes validation: a practical application

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Case study Vertical assembly method, of the diffuser and diaphragm assembly, for the first two stages of the pump, which consists of a total of 10 stages.

1. Lifting and tilting 1. Lifting and tilting at 90° phase of the suction offlange the suction housing flange

2. Tilting phase andshaft 2. Positioning of the vertical positioning onofthe flange the suction shaft


3. Mounting phase 3. Positioning of the second of the first two stage stagesdiaphragm 5/11

Case study Vertical assembly method, of the diffuser and diaphragm assembly, for the first two stages of the pump, which consists of a total of 10 stages.

SPECIFIC REQUESTS • Verify the feasibility of the assembly procedure; • Verify that during lifting and tilting of components, the selected anchorage points ensured workers to operate safely, avoiding unwanted overturning.


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Virtual Assembly simulations – HW/SW Infrastructure

STEP CAD-VR integration as a tool for industrial assembly processes validation: a practical application

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Virtual Assembly simulations – Methodology 1. Information gathering and analysis of the assembly process. 2. Virtual environment preparation. 3. Simulation of the assembly process. 4. Analysis of the assembly simulations results.


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Virtual Assembly simulations – Results The conducted simulation activities allowed the industrial company to validate, and partially correct, the assumed assembly procedure. More in detail the company was able to: 1. validate the position of the anchorage points of the lifting eyebolts chosen during the preliminary design phase; 2. verify the applicability and correctness of the assembly procedure and in particular of the components lifting and tilting procedure; 3. develop an assembly procedure (Visual Instructions) with detailed sequence of steps to be performed; 4. modify the design of an equipment in order to improve the ergonomics of the working position. CAD-VR integration as a tool for industrial assembly processes validation: a practical application

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Virtual Assembly simulations – Relevant results

Threaded Rod

Poor visibility

Uncomfortable posture


Nut

Washer

Poor accessibility 9/11

Virtual Assembly simulations – Relevant results

Before CAD-VR integration as a tool for industrial assembly processes validation: a practical application

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Conclusions The simulation of the assembly process, performed in a virtual environment, led to real and tangible benefits for the industrial partner: • it has been able to optimize the initial assumed assembly sequence and the design of some equipment, without the need for physical prototypes; • it could check for any hazards that could hardly be identified in a static/bidimensional environment (e.g. effects linked to the choice of incorrect anchorage points on the components). Deductible from relevant available literature but not yet sufficiently demonstrated in real industrial contexts. Limitations and possible future improvements regard: • the absence of left hand tracking in the virtual environment; • the lack of an haptic feedback system for the operator. CAD-VR integration as a tool for industrial assembly processes validation: a practical application

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