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Slide 1FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
“CAE Driven Designof Forging Presses”
At Present and in Future
Dr. Heiko BaumFLUIDON GmbH
COMPETENCE IN FLUID POWER SYSTEMS SIMULATIONKOMPETENZ IN DER SIMULATION FLUIDTECHNISCHER SYSTEME
3rd European HyperWorks Technology Conference
Slide 2FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Survey
Fluidtronic – A design environment for fluid technical mechatronical systems1
Forging Presses – A Brief Introduction2
CAE-Driven Forging Press Development at Present3
An Outlook onto Future CAE-Driven Forging Press Development4
Conclusion5
Slide 3FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Fluidtronic - A design environment for fluid technical mechatronical systems
• Target of the combined research project "Fluidtronic" is the early identification of inherent system risks and the guarantee of a reliable commissioning and plant function over the entire product life time.
• This is only possible, when the cooperation of the technical disciplines/domains respectively of the involved enterprises synchronizes better and is integrated into efficient product development processes.
• For these reasons the development of a fluid technical mechatronical system needs a general enterprise-wide development platform which can be described as a development environment.
More information is available underwww.fluidtronic.de
• Central thoughts of the development environment:
• Required are reference processes, that definethe workflow of the collaborative development
• Required are interfaces between simulationand project planning tools
• All data from the simulation and projekt planning environments will be exchanged and managed via PLM-support
Slide 4FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Survey
Fluidtronic – A design environment for fluid technical mechatronical systems1
Forging Presses – A Brief Introduction2
CAE-Driven Forging Press Development at Present3
An Outlook onto Future CAE-Driven Forging Press Development4
Conclusion5
Slide 5FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
The Fluidtronic reference forging press
Modern open-die forging plants consisting of the forging press and one or two rail-bound manipulators are highly dynamic production plants.
Apart from the pure production speed, the main focus today is on the achievement of minimum forging tolerances and a consistently high level of quality.
Furthermore, the logging of the production process and possible deviations from the specifications is demanded, in particular for products for energy engineering and for the aircraft and aerospace industries.
Push-down type forging press with two columns
Slide 6FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Survey
Fluidtronic – A design environment for fluid technical mechatronical systems1
Forging Presses – A Brief Introduction2
CAE-Driven Forging Press Development at Present3
An Outlook onto Future CAE-Driven Forging Press Development4
Conclusion5
Slide 7FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Limitations of a 1D system simulation of large production machines
QSLSumme1
1
23
QSL1
QSL2
WK5
Dekompression1a
Geschwindigkeitsregler1a
NS250 NS130RNS130L
QNS130L QNS130RQNS250
VZRVZL
RZRRZL
Hochtank
Hyd
Pneu
vPresse
S3b
VSB
M2
M1
RM1
2
RF
Solldruck
ZPRH1
Speicherblock1
WRCE32
SWRC160FG_WRC160
SWRC100FG_WRC100
VS3a
NS100_WRC100 NS100_WRC160
Vol1
Gaskolben
Hyd
Pneu
SL2
x-fach
VS3
S3a
SG_FOut
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x-fach
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Tankklappe
Blende1
QSVA
Diffusor2Diffusor1
L1
x|fach
L3
x|fachL2
x|fach
L4
x|fach
L9
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VA1
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PT1NG160
xWRCE100xWRCE160
S3
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p
Q
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Zaehler1
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VS8
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K
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nPumpeRAntriebR RueckzugPumpen
ZPRS
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SMSMEER Korrektur_OT
Korrektur_UT
RueckzugSchmieden
xUTUTK xOT
OTK
Schmiedezylinder5Flaechen1
To simulate a working sequence, large parts of the original control strategy have to be included in the model.
The elasticity of the frame is merely represented by a linear spring-damper.
The work piece behavior is described by characteristics or empirical equations.
Slide 8FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
First steps to a mechatronic system simulation
© Université du LuxembourgDipl.-Ing. C. Hostert,Prof. Dr.-Ing. S. Maas,Prof. Dr.-Ing. A. Zürbes,
Results
Co-Simulation of Mechatronic Systems
Co-Simulation Set-up
Multy-Body
Slide 9FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Survey
Fluidtronic – A design environment for fluid technical mechatronical systems1
Forging Presses – A Brief Introduction2
CAE-Driven Forging Press Development at Present3
An Outlook onto Future CAE-Driven Forging Press Development4
Conclusion5
Slide 10FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Fluidtronic
A vision for a CAE-driven development of production machines
flexibility of components
DSHplushydraulics
MotionSolveMulti-Body
RADIOSSFinite Element
co-simulationof mechatronic
systemsdata for stress analysis
CAE supported design level
OptiStructgeometry optimization
PLCcontrols
PLM supported design level
EPLANdocumentation
CADgeometries for models
project data exchange
Measurementsvalidation
HyperStdyparameter optimization
validation level
Slide 11FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Step1: Initial System Design with EPLAN Fluid System Documentation
Iterative customization and improvement of the
configuration with the results of simulation
DSHplus
Pre-configuration of the press in thedesign template
Check of the configuration with a hydraulic simulation
DSHplus
Automated derivation of the simulation model
DSHplus
Development template = EPLAN design template and DSHplus simulation template
Slide 12FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Step 2: Set-up of the DSHplus Hydraulic Model of the Forging Press
Implementationof DSHplus-OPCInterface
Implementationof DSHplus-STCInterface
Slide 13FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Step 3: Preparation of the CoDeSys PLC-Controller and Visualization
Slide 14FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Step 4: Set-up of the MotionView Mechanical Model
Slide 15FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
625
(ca.
170
0)
2000
M1
DSHplus-OPC
DSHplus-EPLAN
DSHplus-STC
M3M2
370
320
M4
• Monitor 1
DSHplus Hydraulic Model
• Monitor 2
CoDeSys PLC-Controller and Visualization
• Monitor 3
MotionView Mechanical Model
• Monitor 4
EPLAN Fluid System Documentation
Fluidtronic – CAE Driven Design Demonstrator
At a rack 4 monitors are fastened, on which programs involved into the CAE-Driven-Design can be seen.The interplay of the programs can be presented "live" or in the form of prefabricated videos.
Slide 16FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Survey
Fluidtronic – A design environment for fluid technical mechatronical systems1
Forging Presses – A Brief Introduction2
CAE-Driven Forging Press Development at Present3
An Outlook onto Future CAE-Driven Forging Press Development4
Conclusion5
Slide 17FLUIDON at HTC 09
© 2009 FLUIDONThis copyrighted document is the property of FLUIDON GmbH and is disclosed in confidence.
It may not be copied, disclosed to others, or used for manufacturing, without the prior written consent of FLUIDON GmbH
Conclusion
• An optimization of the developments as well as a general development accompanying use of project planning and simulation software has the potential to overcome the deficits of conventional developments.
• The structured interaction of all technical domains, involved in the development, and their supply with detailed system information and current data leads to an acceleration of the developments at a simultaneous optimization of the overall system.
• A CAE Design Demonstrator has been buildedin order to present the advantages of the new development environment for fluid-technical mechantronical systems.
• Have a closer look onto the CAE Driven Design Demonstrator at the FLUIDON booth (B12) in the exhibition area.
CAE Driven Design Demonstrator