Virtual Reality man made reality sense world What is Virtual Reality? Dipl.-Ing. Indra Kusumah Process Technology Fraunhofer IPT Steinbachstrasse 17 D-52074 Aachen Indra.kusumah@ipt.fraunhofer.de www.ipt.fraunhofer.de Definition: Virtual Reality is a high-end user interface that involves realtime simulations and interactions through multiple sensorial channels. These sensorial modalities are visual, auditory, tactile, smell, taste, [...] Burdea,1993 Seite 1
Table of Contents Virtual Reality Triangle I 3 Virtual Reality in Product Development Virtual Reality Technology Virtual Reality Applications Source: Fraunhofer IAO www.vr.iao.fhg.de Benefit of Virtual Reality Seite 2
Virtual Reality Triangle computer graphics simulation create a realistic looking world Interactivitiy being part of the action on the screen Immersion Source: Adam Opel AG synthesized world is not static respond to user inputs device input, gesture, verbalcommands, etc. I 3 human imagination creation of a virtual world problem solving application Interaction Imagination Burdea,1993 Seite 3
Table of Contents Virtual Reality Triangle I 3 Virtual Reality in Product Development Virtual Reality Technology Virtual Reality Applications Source: Fraunhofer IAO www.vr.iao.fhg.de Benefit of Virtual Reality Seite 4
Virtual Reality in Product Development CAD-Model CAD Conversion from parametric to triangle data, Reduction of triangles, Generation of Level of Details Definition of Groups, Definition of Constraints, Adding of Simulation CAVE, HMD, Desktop Stereo Projector Tracking Voice Control Force Feedback Tracking Realtime Interaction Optimization Digital Mockup FEM Adding Textures, Adding Sounds Computer Graphic Real 3D FEM-Model Rendering Imaging, Distances between Objects Seite 5
Digital Mockup of a Tool machine Digital Mockup of a wafer grinding machine Seite 6
Table of Contents Virtual Reality Triangle I 3 Virtual Reality in Product Development Virtual Reality Technology Virtual Reality Applications Source: Fraunhofer IAO www.vr.iao.fhg.de Benefit of Virtual Reality Seite 7
Virtual Reality Technology What do you need for an immersive Virtual Environment? High End Graphic Computer Stereo-Projection-System Software and Interfaces Interaction Devices 2 sided CAVE Source: Fraunhofer IPT Software Virtual Design 2 Source: vrcom Force Feedback Glove CyberGrasp Source: Virtual Technologies, Inc. Seite 8
High End Graphic Computer Option: SGI ONYX PC-Cluster SGI ONYX 3200 Source: Silicon Graphics Inc. PC Cluster Seite 9
Stereo-Projection-System What makes you see 3D? 2D Object Screen Projector Virtual 3D Object Stereo Viewing enables to see real 3D, meaning distances between between objects Two images with an average distance of 6.5 cm, which is the average eye distance, are necessary to enable real 3D viewing The brain superimposes both images to a 3D image Different filter technologies to separate images for left and right eye - passive stereo: using glasses with color or polarisation filter - active stereo: using shutter glasses, LCD-displays Viewer Shutter Glasses Source: Stereographics Seite 10
Stereo-Projection-System What kind of Stereo-Projection-Systems are available? Head Mounted Display Source: Virtual Research Systems, Inc. Screen projection systems - CAVE (Computer Aided Virtual Environment), - Holobench Head Mounted Displays Desktop graphic workstations CAVE ReaCTor-Lite Source: Trimension Systems Desktop VR Source: Stereographics Holobench Source: TAN Projektionstechnologie Seite 11
Interaction Devices Power supply sensor stylus Force Feedback Roboter Source: SensAble Stylus and electromagnetic Emitter Source: Polhemus Electromagnetic Emitter Source: Polhemus Select button emitter What kind of interaction is possible? Tracking System: - electromagnetic, inertia, ultrasonic tracking - measure eye position to render images concerning to point of view, e.g. look under a table or behind something - measure position of input devices to e.g. select objects Stylus, Spacemouse Voice control Force Feedback for friction, collision, gravity Devices: PHANToM, Sensing Gloves Accustic sensor Cable for tracking information Force Feedback Glove CyberGrasp Stylus Source: Virtual Technologies, Inc. Source: Polhemus Seite 12
Table of Contents Virtual Reality Triangle I 3 Virtual Reality in Product Development Virtual Reality Technology Virtual Reality Applications Source: Fraunhofer IAO www.vr.iao.fhg.de Benefit of Virtual Reality Seite 13
Virtual Reality Applications Virtual Reality Lab at Fraunhofer IPT L-Shaped two sided walk-in stereo projection system electromagnetic tracking Silicon Graphics Onyx 3200 with two graphic pipes several VR software packages Presently used applications Combination of Design Review and Digital Mockup Assembly simulation of rigid parts In development Virtual Process Engineering Combination of VR and video conference Assembly simulation of elastic tubes page 10 Seite 14
Combination of Design Review & Digital Mockup Development & Design Design Review / DMU Scenario virtual menu: rotate machine display FEM results on virtual monitor hide / show machine parts animated machine components: doors tool carriage in x, y and z collision checks: between tool carriage and plate between tool carriage and doors collision page 12 Seite 15
Combination of Design Review & Digital Mockup (Video)... page 13 Seite 16
Assembly Simulation Development & Design Assembly Simulation with Virtual Design 2 mounting of the grinding tool into support tolerances: 5mm 1mm recording of the assembly path two options of collision detection glide able: gliding of part possible ghost: moving of ghost part after collision 155.000 polygons at 7 fps on two pipes with an ONYX 3200 page 14 Seite 17
Assembly Simulation (Video) page 15 Seite 18
Assembly of elastic tubes (Video) generation of tube fixing of tube cutting of tube total length delete tube Seite 19
Simulation and visualization of manufacturing processes Manufacturing Process Finite Element Method Material Parameter Virtual Reality Seite 20
Steps of a Cutting Simulation Pre Processor Solver Post Processor material data flow curve: s = f(t,e,de/dt) friction: µ = f(t,s,v) density: r = f(t) spec. heat capacity.: cp = f(t) Taylor-Quinney: k = f(e,de/dt) E-Module: E = f(t) therm. expansion: dl = f(t)... process parameter feed [mm/ U] depth of cut [mm]...? Numerical Influence number of remeshing steps element type simulation results cutting force temperature chip geometry distribution of stress strain strainrate Seite 21
Procedure for Virtual Reality Post Processing Deform Output: Bohren.dat * * STEP NUMBER = 10 * * RZ 1 5663 1-0.725715E+01 0.263451E+02-0.187072E+01 2-0.143405E+02 0.231648E+02-0.186192E+01 3-0.860995E+01 0.242886E+02-0.186776E+01... URZ 1 5663 1 0.753087E+01 0.982587E+01-0.414815E+02 2 0.491817E+01 0.110875E+02-0.415255E+02 3 0.683126E+01 0.100244E+02-0.411097E+02... NDTMP 1 5663 1 0.200000E+02 2 0.200000E+02 3 0.200000E+02... ELMCON 1 24126 1 5569 5613 5567 5610 2 5567 5569 5610 5568 3 5569 5613 5610 5612... STRAIN 1 24126 1 0.144655E-01 2 0.659788E-02 3 0.405799E-01 Converter: Mesh.covise Strain.covise... Mesh.covise Strain.covise Covise: Virtual Reality VR Desktop Seite 22
Use of Virtual Reality Post Processing Mesh.covise Strain.covise mesh data mesh of domain surface data of domain surface Seite 23
Moduls of Virtual Reality Post Processing visualization of domain surface animation of time steps cutting of domain surface cutting planes modules of Virtual Reality Post Processing Volume Rendering color transfer of data visualization of iso surfaces interactive probe Seite 24
Comparative Visualization in Virtual Reality Post Processing Parameter Studies in Simulation: cutting parameter material parameter numerical parameter Comparative Visualization: synchron over several timesteps with same color maps superimposed Seite 25
Example of Virtual Reality Post Processing 3D-Simulation Bohren: Visualization of stress distribution Used Modules: Colors Domain Surface Cut Geometry Cutting Surface Animation Probe Scale World Move World Seite 26
Virtual Process Eingineering AdvantEdge power, temperature Manufacturing time, Comparisson of temperature, Comparisson of power, 3D Visualisation CATIA NC Manufacturing New Interfaces Integrated visualisation of micro and macro process in Virtual Reality System tool path, NC Programm Seite 27
Table of Contents Virtual Reality Triangle I 3 Virtual Reality in Product Development Virtual Reality Technology Virtual Reality Applications Source: Fraunhofer IAO www.vr.iao.fhg.de Benefit of Virtual Reality Seite 28
Benefit of Virtual Reality Source: Fraunhofer IPT What benefit do you have? 20% reduction of physical prototypes reduction of constructional fault shorter product development time higher product quality improvement of communication in interdisciplinary teams faster and cheaper check of different versions e.g. DaimlerChrysler has 8 different versions of a new car which are evaluated with VR, only 3 versions are build as physical prototypes perception of depth due to stereo visualization better visualization due to large projection screens intuitive human machine interface due to tracking Source: Fraunhofer IPT Seite 29
Contact at Fraunhofer IPT Dipl.-Ing. Indra Kusumah Prozesstechnologie Fraunhofer-Institut für Produktionstechnologie IPT Steinbachstrasse 17 D-52056 Aachen 0241 8904 243 0241 8904 6243 indra.kusumah@ipt.fraunhofer.de Seite 30