© Fraunhofer IFAM
Automation and Production Technology, Stade, Germany
Tim Haß
Fraunhofer IFAM
Fraunhofer IFAM
Automation and Production Technology
Head of Department: Dr. Dirk Niermann
Forschungszentrum CFK NORD
Ottenbecker Damm 12 | 21684 Stade
www.ifam.fraunhofer.de
© Fraunhofer IFAM
Klebtechnik und Oberflächen
AGENDA
Digitalization
3DExperience at Fraunhofer IFAM
Current Applications
Offline Programming and Simulation
Virtual Commissioning
Planned Applications and Future Goals
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Digitalization
Drivers of Digitalization
Source: BCG, Roland Berger
© Fraunhofer IFAM
Klebtechnik und Oberflächen
3DExperience at Fraunhofer IFAM
Integrated Platform for Robotic Applications
Integrated process development
Cross disciplinary engineering
Immersive environment for robot programming, robot simulation and validation of robot tasks
Workcell layout calibration
Support for advanced logic
3DExperience
Behavior Model
Kinematic Model
© Fraunhofer IFAM
Klebtechnik und Oberflächen
3DExperience at Fraunhofer IFAM
Construction of a Virtual Working Cell Robots from library
Customjigs, tools,machinery
Productgeometry
Factory environ-ment
CAD models including kinematics:
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Offline Programming and Simulation
Approach and Objectives
12
34
Geometry preperation& curve selection
Tag generation
Robot path generation
Robot programcreation
Simulation &Upload to robot
CAD data
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Offline Programming and Simulation
Project NFM-Glare
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Offline Programming and Simulation
Realistic Robot Simulation (RRS)
Increasing simulation accuracy
Optimized robot trajectories
Accurate motion planning
Accurate cycle-time simulation
Motion control software implemented from real robot controller (RCS module)
High accuracy processes
Limited space in working area
Multi-Robot simulation and manipulators with various DOF
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Virtual Machine Model
Kinematic simulation: geometry, position, robot axes and joints, inverse kinematic model, collision analysis
Behavior simulation: sequencing, IOs, bus configurations, motion behavior
Plant Controller
Original real controller/PLC
Virtual model of controller/PLC Simulated or emulated PLC
Interfaces between Machine Model and Plant Controller
Use of industrial communication interfaces
Compliance with communication protocol and cycle time synchronization
Virtual Commissioning
Implementation
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Virtual Commissioning
HiL and Full-System Simulation
+ Simulation of models with high complexity
+ No predefined time limits for communication
Limited availability of controller models
Not suitable for real time use
Test of real behavior not assured
Hardware-in-the-Loop Simulation
Full-System Simulation
+ Realistic test of controller systems
+ Real time communication
+ Variable cycle time synchronization depending on level of simulation (process, machine, facility)
Simulation of models with high complexity requires high computing power
Source: Georg Wünsch
Source: Georg Wünsch
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Virtual Commissioning
Communication Protocol
Virtual Machine Model in 3DExperience
Kinematic Model
Original PLC
Behavior ModelHMI
PLC Interface
Control Panels
OPC UA
Interface for data transfer from real plant controller to virtual environment in 3DExperience
Communication via OPC UA
Data gathering between virtual model in 3DExperience and real PLC
Source: Georg Wünsch
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Virtual Commissioning
Signal Exchange with PLC
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Virtual Commissioning
Benefits of Virtual Commissioning
Increasing software quality - debugging PLC code in a virtual environment before downloading it to the real equipment
Reducing the actual commissioning time
Optimization of processes
EngineeringManufacturing
and Assembly
Engineering
Modelling
Manufacturing and Assembly
Commissioning
CommissioningFacility Control
Virtual Commissioning
Time
Without virtual commissioning
Virtual commissioning
approach Time
reduction(Effort)
Earlier realization of rework and changes
Source: Georg Wünsch
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Planned Applications and Future Goals
Adaption of Systems Engineering methods
Development with the RFLP approach
Application of Model-Based Systems Engineering (MBSE)
Creation of a interconnected, cross-disciplinary system model
Enhancement of the virtual environment
More realistic simulation / Additional tools
Enrichment with additional data
Implementation of different use cases
Topics
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Planned Applications and Future Goals
Virtual product development based on Systems Engineering and RFLP
RequirementsEngineering
FunctionalDesign
LogicalDesign
PhysicalDesign
ComponentTesting
Integration
Verification
Validation
Source: :em
R
F
L
PMechanics
Electronics Software
Requirements
Engineering
Data
Simulation
Results
System Analysis
Requirements
Functional Architecture
Logical Architecture
Component Specification
System Integration
Simulation
Test
System Development
M-CAD
E-CAD
CAE
Behaviour Models
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Planned Applications and Future Goals
Model-Based Systems Engineering
RFLP
Software
SystemArchitecture
PLM
Processes
Documentation
BOM
MultiphysicsSimulation
CAD
Digital Mockup
Ergonomics
Kinematics
STEPAP233
CAESystem
Model
ComputationalFluid Dynamics
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Planned Applications and Future Goals
Increase realism of the simulation withadditional tools and workbenches
Simulation of physical behaviour
Use case:
Simulation of stringer deformation withSimulia/Dymolia and the physics engine
Fluid flow simulation and application ofadhesives, sealants, coating etc.
Optimized robot paths based on thesimulation results
Usage of different Simulation Tools in the3DExperience Platform
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Planned Applications and Future Goals
Possibility of path or geometryadjustments in 3DX based on sensorinformation
Use case:
Determination of the current position andgeometry of parts and toolsExamples:calibration of the end-effector TCP,position and measurements of parts
Real time path adjustment based on externally computed path (calculatedfrom camera information)
Implementation of Sensor Data in the 3DExperience Environment
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Planned Applications and Future Goals
Implementation of different kinematicmodels of various industrial robots
Custom kinematics include: Kuka iiwa, Fanuc hexapods, six axis portal roboticsystem, mobile robots,...
Implementation of User Defined Kinematics
Use case:
Generation of complex paths for theadhesive application on aircraftcomponents with a six axis portal roboticsystem
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Planned Applications and Future Goals
Automated Cabin and Cargo Assembly
Robot assisted assembly with automated guided vehicles
Digitilization of manual and cooperative processes
Simulation of human – robot collaboration
Use case:
Assembly of hat racks, side panelsand other components inthe fuselage
Cooperative mobile robotsand human workers in aconfined space
© Fraunhofer IFAM
Klebtechnik und Oberflächen
1 …
2 …
3 …
4 …
Planned Applications and Future Goals
Simulation of Cooperative Robot Processes and Human Ergonomics
Evaluation of productivity and ergonomics
Verification and process optimization
Risk evaluation
Source: IFA
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Planned Applications and Future Goals
Assembly Planning with VR/AR
Assembly planning andvisualization usingmixed reality
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Thank you for your attention
© Fraunhofer IFAM
Klebtechnik und Oberflächen
Dieses Dokument und alle darin enthaltenen Informationen sind das alleinige Eigentum des Fraunhofer IFAM. Die Zustellung dieses Dokumentes
oder die Offenlegung seines Inhalts begründen keine Rechte am geistigen Eigentum. Dieses Dokument darf ohne die ausdrückliche schriftliche
Genehmigung des Fraunhofer IFAM nicht vervielfältigt oder einem Dritten gegenüber enthüllt werden. Dieses Dokument und sein Inhalt dürfen nur
zu bestimmungsgemäßen Zwecken verwendet werden.
Die in diesem Dokument gemachten Aussagen stellen kein Angebot dar. Sie wurden auf der Grundlage der aufgeführten Annahmen und in gutem
Glauben gemacht. Wenn die zugehörigen Begründungen für diese Aussagen nicht angegeben sind, ist das Fraunhofer IFAM gern bereit, deren
Grundlage zu erläutern.
This document and all information contained herein is the sole property of Fraunhofer IFAM. No intellectual property rights are granted by the
delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express
written consent of Fraunhofer IFAM. This document and its content shall not be used for any purpose other than that for which it is supplied.
The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the
supporting grounds for these statements are not shown, Fraunhofer IFAM will be pleased to explain the basis thereof.
© by F raunhofe r I FAMAl l R ight s re se rved .Conf ident ia l and p ropr ie ta r y document .