Virtual prototyping and manufacturing planning by using tri-dexel models and haptic force feedback

This paper presents a new method of using the tri-dexel volumetric models and a haptics force feedback for virtual prototyping and manufacturing planning. In the proposed method, the initial polyhedral surface model is converted to a tri-dexel volumetric model by using a depth-peeling dexelization algorithm. In the virtual prototyping process, the tri-dexel volumetric model is updated by the swept volume of a moving cutter via a haptic force feedback interface device. A collision detection algorithm is proposed for the virtual sculpting and the pencil-cut planning with real-time haptic force feedback to the users. Tool paths are generated for machining the virtual sculpted parts via the simulation and verification on a virtual CNC machine tool before they are actually machined. Computer implementation and practical examples are also presented in this paper. The proposed method enables the haptic-aided virtual prototyping and manufacturing planning of complex surface parts.     

Haptic modeling for a virtual coordinate measuring machine

Introducing a haptic device into coordinate measuring machine (CMM) inspection path planning leads to the proposal of a novel CMM off-line inspection path planning environment, a haptic virtual coordinate measuring machine (HVCMM), which makes use of the haptic modeling technique for CMM off-line programming. The HVCMM is an accurate model of a real CMM, which simulates a CMM's operation and its measurement process in a virtual environment with haptic perception. In this paper, a simple and effective mechanics model is implemented for the proposed HVCMM. The HVCMM enables CMM off-line programming to take place exactly as if an operator were in front of a real CMM and moving a real CMM probe. Even more, operators can feel the collision between the CMM and a part. Since there is a force feedback when the probe reaches the surface of the part, besides showing the contact in the HVCMM environment, it is much easier to generate a collision-free probe path than using other off-line inspection planning methods. The HVCMM not only facilitates inspection path planning, but also speeds it up because the operator does not need to slow the probe down when it is approaching an object. Combined visual and force feedback is the best indicator for selecting measurement points.     

Snapping algorithm and heterogeneous bio-tissues modeling for medical surgical simulation and product prototyping

This paper presents a novel technique for modeling soft biological tissues as well as the development of an innovative interface for bio-manufacturing and medical applications. Heterogeneous deformable models may be used to represent the actual internal structures of deformable biological objects, which possess multiple components and non-uniform material properties. Both heterogeneous deformable object modeling and accurate haptic rendering can greatly enhance the realism and fidelity of virtual reality environments. In this paper, a tri-ray node snapping algorithm is proposed to generate a volumetric heterogeneous deformable model from a set of object interface surfaces between different materials. A constrained local static integration method is presented for simulating deformation and accurate force-feedback based on the material properties of a heterogeneous structure. Biological soft tissue modeling is used as an example to demonstrate the proposed techniques. By integrating the heterogeneous deformable model into a virtual environment, users can both observe different materials inside a deformable object as well as interact with it by touching the deformable object using a haptic device. The presented techniques can be used for surgical simulation, bio-product design, bio-manufacturing, and medical applications.     

Snapping algorithm and heterogeneous bio-tissues modeling for medical surgical simulation and product prototyping

This paper presents a novel technique for modeling soft biological tissues as well as the development of an innovative interface for bio-manufacturing and medical applications. Heterogeneous deformable models may be used to represent the actual internal structures of deformable biological objects, which possess multiple components and non-uniform material properties. Both heterogeneous deformable object modeling and accurate haptic rendering can greatly enhance the realism and fidelity of virtual reality environments. In this paper, a tri-ray node snapping algorithm is proposed to generate a volumetric heterogeneous deformable model from a set of object interface surfaces between different materials. A constrained local static integration method is presented for simulating deformation and accurate force-feedback based on the material properties of a heterogeneous structure. Biological soft tissue modeling is used as an example to demonstrate the proposed techniques. By integrating the heterogeneous deformable model into a virtual environment, users can both observe different materials inside a deformable object as well as interact with it by touching the deformable object using a haptic device. The presented techniques can be used for surgical simulation, bio-product design, bio-manufacturing, and medical applications.     

Six-Degree-of-Freedom Haptic Rendering in Virtual Teleoperation

Six-degree-of-freedom (6-DoF) haptic rendering of the telerobotic operation method using virtual joint coupling (VJC) is proposed. This algorithm couples six joints of a virtual robot with those of a 6-DoF haptic device based on a spring-damper model to render force and torque feedback to a user and drive the virtual robot in the teleoperation simulation. Our rigid body dynamics is decoupled from the haptic rendering loop with an open dynamic simulation library Open Dynamics Engine, which runs at a lower update rate, thereby alleviating computation demand and improving the stability of the system. To illustrate the role of haptics and physically based simulation in teleoperation, a path-following experiment with virtual constraints is carried out. An experiment of virtual assembly, in which a user performs assembly tasks by means of manipulation of a gripper mounted at the end of a virtual robot, is also implemented to verify the VJC algorithm.      

A Novel Twist Deformation Model of Soft Tissue in Surgery Simulation

Real-time performance and accuracy are two most challenging requirements in virtual surgery training. These difficulties limit the promotion of advanced models in virtual surgery, including many geometric and physical models. This paper proposes a physical model of virtual soft tissue, which is a twist model based on the Kriging interpolation and membrane analogy. The proposed model can quickly locate spatial position through Kriging interpolation method and accurately compute the force change on the soft tissue through membrane analogy method. The virtual surgery simulation system is built with a PHANTOM OMNI haptic interaction device to simulate the torsion of virtual stomach and arm, and further verifies the real-time performance and simulation accuracy of the proposed model. The experimental results show that the proposed soft tissue model has high speed and accuracy, realistic deformation, and reliable haptic feedback.     

Augmented reality user interface for an atomic force microscope-based nanorobotic system

A real-time augmented reality (AR) user interface for nanoscale interaction and manipulation applications using an atomic force microscope (AFM) is presented. Nanoscale three-dimensional (3-D) topography and force information sensed by an AFM probe are fed back to a user through a simulated AR system. The sample surface is modeled with a B-spline-based geometry model, upon which a collision detection algorithm determines whether and how the spherical AFM tip penetrates the surface. Based on these results, the induced surface deformations are simulated using continuum micro/nanoforce and Maugis-Dugdale elastic contact mechanics models, and 3-D decoupled force feedback information is obtained in real time. The simulated information is then blended in real time with the force measurements of the AFM in an AR human machine interface, comprising a computer graphics environment and a haptic interface. Accuracy, usability, and reliability of the proposed AR user interface is tested by experiments for three tasks: positioning the AFM probe tip close to a surface, just in contact with a surface, or below a surface by elastically indenting. Results of these tests showed the performance of the proposed user interface. This user interface would be critical for many nanorobotic applications in biotechnology, nanodevice prototyping, and nanotechnology education.     

A genetic scheduling methodology for virtual cellular manufacturing systems: an industrial application

Effective solutions to the cell formation and the production scheduling problems are vital in the design of virtual cellular manufacturing systems (VCMSs). This paper presents a new mathematical model and a scheduling algorithm based on the techniques of genetic algorithms for solving such problems. The objectives are: (1) to minimize the total materials and components travelling distance incurred in manufacturing the products, and (2) to minimize the sum of the tardiness of all products. The proposed algorithm differs from the canonical genetic algorithms in that the populations of candidate solutions consist of individuals of different age groups, and that each individual's birth and survival rates are governed by predefined aging patterns. The condition governing the birth and survival rates is developed to ensure a stable search process. In addition, Markov Chain analysis is used to investigate the convergence properties of the genetic search process theoretically. The results obtained indicate that if the individual representing the best candidate solution obtained is maintained throughout the search process, the genetic search process converges to the global optimal solution exponentially.

The proposed methodology is applied to design the manufacturing system of a company in China producing component parts for internal combustion engines. The performance of the proposed age-based genetic algorithm is compared with that of the conventional genetic algorithm based on this industrial case. The results show that the methodology proposed in this paper provides a simple, effective and efficient method for solving the manufacturing cell formation and production scheduling problems for VCMSs.     

Freeform modelling using sweep differential equation with haptic interface

This paper presents the development of a virtual sculpting system and addresses the issues of interactive freeform solid modelling with haptic interface. A virtual reality (VR) approach is taken to make the developed system more intuitive and interactive. The virtual sculpting method is based on the metaphor of carving a primitive or imported solid model into a 3D freeform object. The geometric modelling is based on the sweep differential equation method to compute the boundary of the tool swept volume. The ray-casting method is used to perform Boolean operations to simulate the sculpting process. A new method of surface reconstruction from dexel data is presented. The PHANToM™ manipulator is used to provide the position and orientation data of the sculpting tool and also to provide haptic sensation to the user hand during the sculpting. An accuracy analysis is performed to determine the limitations on the sculpted geometric details.     

Freeform modelling using sweep differential equation with haptic interface

This paper presents the development of a virtual sculpting system and addresses the issues of interactive freeform solid modelling with haptic interface. A virtual reality (VR) approach is taken to make the developed system more intuitive and interactive. The virtual sculpting method is based on the metaphor of carving a primitive or imported solid model into a 3D freeform object. The geometric modelling is based on the sweep differential equation method to compute the boundary of the tool swept volume. The ray-casting method is used to perform Boolean operations to simulate the sculpting process. A new method of surface reconstruction from dexel data is presented. The PHANToM? manipulator is used to provide the position and orientation data of the sculpting tool and also to provide haptic sensation to the user hand during the sculpting. An accuracy analysis is performed to determine the limitations on the sculpted geometric details.     

Virtual simulation of five-axis machine tool with consideration of CNC interpolation,servo dynamics,friction, and geometric errors

Abstract

A virtual machine tool (VMT) simulation system which considers tool center point (TCP) interpolation, geometric errors, servo dynamics, and friction effects for a five-axis machine tool is developed in this paper. A novel five-axis interpolation method is proposed to ensure that maximum velocity constraints for each axis can be satisfied. The geometric error model, including lead screw, straightness, angular and squareness errors is built to analyze the volumetric errors within the working space. The model which includes rigid body motion, friction model and servo control loops is utilized to evaluate servo dynamics and non-linear effects. The errors caused by the locations, servo dynamics, and friction effects are integrated into the VMT simulation program. Simulation results of TCP trajectory are represented by small line segments to generate NC codes. Then the NC codes are fed into VERICUT software to perform virtual cutting. To evaluate the interpolation design, cutting experiments are carried out on the five-axis engraving machine with a PC-based controller. The performances using the proposed interpolation method are comparable with the commercial CNC controller from Heidenhain. The effects of different error sources on the surface are demonstrated by cutting the sculpture of a human face. Path overcut caused by servo dynamics is found at sharp corners, and volumetric errors cause obvious tool marks and poor surface roughness. The proposed methodology can serve as a useful tool in evaluating the behaviors of error sources during the design stage.     

Teleoperated 3-D Force Feedback From the Nanoscale With an Atomic Force Microscope

In this study, 3-D experimental teleoperated force feedback during contact with nanoscale surfaces is demonstrated using an atomic force microscope (AFM) on the slave side and a haptic device on the master side. To achieve 3-D force feedback, coupling between one of the horizontal forces and the vertical force is a crucial bottleneck. To solve this coupling issue, a novel force decoupling algorithm is proposed. This algorithm uses local surface slopes, an empirical friction force model, and the haptic device motion angle projected onto the surface to estimate the friction value during experiments. With this estimation, it is possible to decouple the three orthogonal forces acting on the tip of the AFM cantilever. Moreover, using an adaptive observer, parameters of the friction model can be changed online, removing the necessity to calibrate the friction model initially. Finally, a modified passivity-based bilateral control is used to reflect the scaled nanoscale forces to the master side and the operator. The performance of the system is demonstrated on experimental results for flat and non-flat, and hard and soft surfaces.      

A training system for virtual surgical incisions with haptic playback

The haptic playback system is important to the training of sensorimotor skills. With the intent for training medical students in surgery, a real-time incision training system with haptic playback is developed in this paper. This system has three modes. Mode I sets the standard cutting trajectory of the incision operation carried out by an expert. Mode II allows students to track the trajectory by haptic guidance to feel the expert's motion. Mode III lets students experience the force feeling of the expert by following the trajectory via the visual cue. To accomplish these tasks, an adjustment proportional-derivative (PD) controller and a cutting model with real-time haptic feedback are devised. The cutting model adopts the mesh adaption method for real-time simulations of progressive cutting operations. These devised methods have been configured with a haptic device PHANToM Desktop to validate the capability of the proposed training system.     

Multi-objective cell formation and production planning in dynamic virtual cellular manufacturing systems

This article presents a fuzzy goal programming-based approach for solving a multi-objective mathematical model of cell formation problem and production planning in a dynamic virtual cellular manufacturing system. In a dynamic environment, the product mix and part demand change over a planning horizon decomposed into several time periods. Thus, the cell formation done for one period may be no longer efficient for subsequent periods and hence reconfiguration of cells is required. Due to the variation of demand and necessity of reconfiguration of cells, the virtual cellular manufacturing (VCM) concept has been proposed by researchers to utilise the benefits of cellular manufacturing without reconfiguration charges. In a VCM system, machines, parts and workers are temporarily grouped for one period during which machines and workers of a group dedicatedly serve the parts of that group. The only difference of VCM with a real CM is that machines of the same group are not necessarily brought to a physical proximity in VCM. The virtual cells are created periodically depending on changes in demand volumes and mix, as new parts accumulate during a planning horizon. The major advantage of the proposed model is the consideration of demand and part mix variation over a multi-period planning horizon with worker flexibility. The aim is to minimise holding cost, backorder cost and exceptional elements in a cubic space of machine–part–worker incidence matrix. To illustrate the applicability of the proposed model, an example has been solved and computational results are presented.     

Virtual reality prototyping of bio-molecules

Modelling, sharing and transmission of three-dimensional (3D) graphics data of biomolecules are essential in many bio visualization tasks from collaborative research and education to molecular simulation and drug discovery. In the current paper, modelling and representing of bio-molecular structure for virtual and physical rapid prototyping is presented. Our aim is to devise a uniform solution for visualizing, browsing, interacting and prototyping of bio-molecules in various environments including internet, immersive virtual reality (VR), and rapid manufacturing. To do so, we use non uniform rational B-spline surfaces (NURBS) to represent protein secondary structure and surface structure. NURBS protein structures are then tessellated to form bio-molecular graphics models. Their triangular mesh representation is next extracted from their scene graph. A geometric optimization process is followed to make data compatible for their formatting in compact and consistent VR standard to support protein internet browsing, protein VR visualization, protein 3D rapid prototyping and crystal sub-surface laser engraving.     

Virtual reality prototyping of bio-molecules

Modelling, sharing and transmission of three-dimensional (3D) graphics data of biomolecules are essential in many bio visualization tasks from collaborative research and education to molecular simulation and drug discovery. In the current paper, modelling and representing of bio-molecular structure for virtual and physical rapid prototyping is presented. Our aim is to devise a uniform solution for visualizing, browsing, interacting and prototyping of bio-molecules in various environments including internet, immersive virtual reality (VR), and rapid manufacturing. To do so, we use non uniform rational B-spline surfaces (NURBS) to represent protein secondary structure and surface structure. NURBS protein structures are then tessellated to form bio-molecular graphics models. Their triangular mesh representation is next extracted from their scene graph. A geometric optimization process is followed to make data compatible for their formatting in compact and consistent VR standard to support protein internet browsing, protein VR visualization, protein 3D rapid prototyping and crystal sub-surface laser engraving.     

虚拟制造及其体系结构

本文分析了虚拟制造产生的背景，提出了一种虚拟制造的体系结构，并进一步分析了虚拟制造中建模和仿真过程，最后例举了一个以独立制造岛为基础的虚拟企业结构。     

On-line, auto-tuning control of Electronic Expansion Valves

In this paper, the results of a research project aimed at deriving simple, high-performance, auto-tuning, robust control algorithms for evaporators controlled by means of EEVs (Electronic Expansion Valves) are reported. Control design is performed by resorting to a detailed virtual prototyping environment described in Beghi and Cecchinato (2009). The proposed control scheme consists of two nested loops. In the inner loop, the plant is connected in feedback to a PID controller. It is assumed that the structure of the process model is given but its parameters are unknown. The outer loop is composed of a parameter estimator and an adaptation algorithm that updates the parameters of the PID controller on the basis of the result of a system identification procedure. Performance of the proposed controller is evaluated in the virtual prototyping environment by means of simulations.     

Integrated Virtual Assembly Environment and its application in ship piping layout

Complex pipe layout plays an important role in ship building. Pipes prefabricating and assembling often depends on testing and rebuilding in outfitting. This leads to more workload, high cost and longer manufacturing cycles. In this paper, a new virtual assembly system called Integrated Virtual Assembly Environment (IVAE) is introduced, in which the ship outfitting can be simulated and process planning can be completed. With the help of assembly constraints management, collision detection and response, assembly sequence and paths planning, users can assemble the parts interactively in a virtual outfitting environment, just as in an actual cabin. As well as for virtual ship outfitting, IVAE can also be used in general product development. As a typical case, the pipe layout in the engine room of a 5000?M³ hydraulic dredge from Hudong-Zhonghua Shipbuilding (Group) Co., Ltd is given to test virtual ship outfitting in IVAE.     

Motion generation and virtual simulation in a digital environment

The growing complexity in product design and manufacturing processes has made virtual prototyping an important new approach that enhances products and process development. Considering the ergonomic issues evident in product lifecycles, digital human modelling (DHM) is adopted for virtual simulation and proactive evaluation. A motion generation from semantics (MGS) system is proposed in this research. The MGS system features include virtual prototyping, natural language instruction, a method time measurement (MTM) translator and motion generator. The system was implemented using product lifecycle management (PLM) software and validated in an automotive manufacturing company. The practice of intuitively generating manual operations and conducting virtual simulations enables the system planners to quickly respond to manufacturing process changes and recursively improve the tooling and process design flexibility and efficiency.