Virtual Product Creation in Industry: The Difficult Transformation from IT Enabler Technology to Core Engineering Competence

Description

Today, digital technologies represent an absolute must when it comes to creating new products and factories. However, day-to-day product development and manufacturing engineering operations have still only unlocked roughly fifty percent of the "digital potential". The question is why? This book provides compelling answers and remedies to that question. Its goal is to identify the main strengths and weaknesses of today’s set-up for digital engineering working solutions, and to outline important trends and developments for the future.   The book concentrates on explaining the critical basics of the individual technologies, before going into deeper analysis of the virtual solution interdependencies and guidelines on how to best align them for productive deployment in industrial and collaborative networks. Moreover, it addresses the changes needed in both, technical and management skills, in order to avoid fundamental breakdowns in running information technologies for virtual product creation in the future. Contents Abbreviations List of Figures List of Tables 1 Motivation and Approach 2 Prologue—Understanding the Difference in Approach 2.1 Pioneering in Self-made Mode by Technical Experts 2.2 Scaling-Up by Growing Digital Design and Analysis Groups with Customized Solutions 2.3 Desire to Restrict—The Dilemma of Limited Understanding of the Role of Virtual Product Creation 2.4 The New Digital Presence—Living a New Understanding of Information Based Value Creation 3 The Big Picture—Information Technology in Enterprises 3.1 Introduction and Basics 3.2 History of Information Technology (IT) 3.2.1 Hardware: From Numbering and Mechanics Towards Electronics 3.2.2 Software: The Key Role of Operating Systems of Modern Computers 3.3 The Set-Up of IT in Industrial Companies 3.3.1 History of IT Technical and Organizational Drivers in the Twentieth and Twenty-First Century 3.3.2 Today’s IT Factory Set-Up and Future Business Concepts References 4 Virtual Product Creation (VPC) Explained 4.1 The New Engineering Discipline Virtual Product Creation 4.2 Virtual Product Creation Capabilities and Activities References 5 The Technology History of Virtual Product Creation 5.1 The History of Computer Aided Design (CAD) Systems and Geometric Modeling 5.2 Digital Product Validation and Verification 5.2.1 Introduction into Validation and Verification (V&V) 5.2.2 Evolution of V&V Technologies and Computer Aided Engineering (CAE) 5.3 Product Data Management (PDM) References 6 The Set-Up of Virtual Product Creation in Industry—Best Practices, Error Modes and Innovation Speed 6.1 Basics Awareness and Sense for Change 6.2 Understanding Ownership of Skillset—The Difference Between Traditional Engineering Skillset and New Digital Skillset 6.3 Understanding the Nature of Virtual Product Creation Collaboration in Development Project Execution 6.4 The Traditional Set-Up of Virtual Product Creation and Its Flaws 6.5 The New Role of Virtual Product Creation—Evolving from IT Technology Towards Engineering and Lifecycle Competence 6.6 Best Practices of Integrating Virtual Product Creation into Mainstreaming Engineering References 7 Major Technology 1: Computer Aided Design—CAD 7.1 Engineering Understanding of CAD 7.1.1 Why Does an Engineer Use CAD? 7.1.2 What Does CAD Do for an Engineer? 7.2 How Does CAD Work? 7.2.1 System Architecture of a CAD System 7.2.2 CAD Modeling Technologies 7.2.3 Geometry Processing and Topology 7.2.4 Volume Model Types 7.2.5 Mathematical Representation 7.3 Basic Technologies 7.3.1 Feature-Based Modeling 7.3.2 Parametric Modeling 7.4 Advanced Technologies References 8 Major Technology 2: Computer-Aided Industrial Design—CAID 8.1 Engineering Understanding of CAID 8.1.1 Why Does an Engineer Use CAID Instead of CAD? 8.1.2 Where is CAID Being Used? 8.2 How Does CAID Work? 8.2.1 How Does a Classical Design Process Use CAID? 8.2.2 Input Devices 8.2.3 Three-Dimensional Immersive Modeling 8.3 Advanced Technology of CAID References 9 Major Technology 3: CAPP, CAM and NC Technology 9.1 Computer-Aided Process Planning—CAPP 9.1.1 Engineering Understanding of CAPP 9.1.2 How Does CAPP Work? 9.1.3 CAPP Methodology and Technology 9.1.4 Requirements for CAPP 9.1.5 CAPP Challenges and Problems 9.2 Computer-Aided Manufacturing—CAM 9.2.1 CAD/CAM Integration 9.2.2 Engineering Understanding of CAM 9.2.3 Why Does an Engineer Use CAM? 9.2.4 What Are the Benefits of CAM? 9.2.5 CAM Technology and Process 9.3 Numerical Control—NC 9.3.1 Engineering Understanding of NC 9.3.2 How Does NC Work? References 10 Major Technology 4: Computer Aided Engineering—CAE 10.1 Background and Evolution of CAE 10.2 Engineering Understanding of CAE 10.2.1 Why Does an Engineer Use CAE? 10.2.2 What is CAE Doing for an Engineer? 10.3 How Does CAE Work? 10.4 CAE in Product Development 10.4.1 From CAD to CAE—CAE Model Build 10.4.2 Interfaces/Formats to Transfer CAD Models to CAE 10.4.3 Pre-processing of a FEA Model 10.4.4 Utilizing FEA Models Within Optimization Problems 10.5 Advanced CAE Technologies 10.6 Exemplary Automotive FEA Project Cases 10.7 Final Remarks References 11 Major Technology 5: Product Data Management and Bill of Materials—PDM/BOM 11.1 Introduction of PDM and BOM 11.2 Engineering Understanding of PDM and BOM 11.2.1 What is PDM Doing for an Engineer? 11.2.2 What is BOM Doing for an Engineer? 11.3 How Does PDM Work? 11.4 How to Integrate PDM in Large Scale PLM Environments? 11.5 How to Customize PDM/BOM to Company PLM and VPC Needs? 11.6 Expected Changes in Future Industrial PDM/PLM Operations References 12 Major Technology 6: Digital Mock-Up—DMU 12.1 Engineering Understanding of DMU 12.1.1 Why Does an Engineer Use DMU Instead of CAD? 12.1.2 What Does DMU Do for an Engineer? 12.2 The Role of a DMU in Product Development 12.3 Usage of Different DMU Types 12.3.1 Static Digital Mock-Up 12.3.2 Dynamic Digital Mock-Up 12.3.3 Functional Digital Mock-Up (“Functional Mock-Up”) 12.4 DMU Set-Up and Model Building 12.5 DMU Based Engineering Analysis Work References 13 Major Technology 7: Virtual Reality—VR 13.1 Engineering Understanding of Virtual Reality 13.1.1 Why Does an Engineer Use Virtual Reality? 13.2 How Does Virtual Reality Work? 13.3 Virtual Reality Technologies 13.3.1 Setup of the Overall Virtual Reality System Architecture 13.3.2 Head Mounted Displays, 3D Glasses, Projection Displays 13.3.3 Tracking 13.4 Human Interaction with VR 13.4.1 Development and Use of VR Applications 13.5 Use of VR for Engineering Working Tasks 13.5.1 Technological Limitations 13.5.2 VR Applications 13.5.3 Summary of the Technology’s Benefits and Main Trends References 14 Major Technology 8: Augmented Reality—AR 14.1 Engineering Understanding of AR 14.2 Why Does an Engineer Use AR? 14.2.1 What is AR Doing for an Engineer? 14.3 How Does AR Work? 14.4 AR Technologies 14.4.1 Setup of AR HMDs/System Architecture 14.4.2 Tracking 14.5 Human Interaction 14.6 Development for AR Applications 14.6.1 System Selection for Industrial AR 14.6.2 Implementation Design 14.7 Technological Limitations to Overcome 14.8 Summary of the Technology’s Benefits and Main Trends References 15 Major Technology 9: Digital Factory—DF 15.1 Engineering Understanding of the Digital Factory 15.1.1 Why Does an Engineer Use Digital Factory? 15.1.2 What is Digital Factory Doing for an Engineer? 15.2 How Does the Digital Factory Work? 15.3 Process and System Implementation of the Digital Factory 15.3.1 Logistics- and Production Flow Simulation 15.3.2 Automation Technologies/Robotics 15.3.3 Simulation of Manual Labor/Ergonomics 15.4 Digital Factory Technologies 15.4.1 Digital Factory Basic Modeling Technologies 15.4.2 Layout Planning 15.4.3 Factory-Digital Mock-Up (DMU) 15.4.4 Behavior Models 15.4.5 Electronics and Controls 15.4.6 Basic Simulation Technologies 15.4.7 Virtual Commissioning and Robotic Simulation 15.4.8 Material Flow Simulation 15.4.9 Ergonomics Validation 15.5 Advanced Technologies 15.5.1 Consistent Data Modeling and Exchange 15.5.2 Virtual Reality Used in the Context of Digital Factory 15.5.3 Human–Robot-Collaboration References 16 Major Technology 10: Artificial Intelligence (AI) in Virtual Product Creation 16.1 What is Intelligence? What is Artificial Intelligence? 16.2 Knowledge-Based Systems and Their Application in Industry 16.3 Machine Learning—The Most Widely Used AI Subfield in Industry 16.3.1 Deep Learning 16.3.2 Standard Process for Machine Learning Projects 16.4 (Big) Data in Product Lifecycle Management 16.5 Internet of Things 16.6 Example of a Virtual Product Creation AI Application 16.6.1 The Main Function Description 16.6.2 Best Practice References 17 The Hidden Demands of the Engineering Community 17.1 Hidden Engineering Demand #1: Intra Company Competence to Drive the Digital Future 17.2 Hidden Engineering Demand #2: Robust and Professional IT Application Integration 17.3 Hidden Engineering Demand #3: Digital Simplicity and Joy 17.4 Hidden Engineering Demand #4: Personal Assistance to Avoid Failure Intrinsic Work 17.5 Hidden Engineering Demand #5: Self-modifiable Personal Digital Working Environments 17.6 Hidden Engineering Demand #6: Quick and Continuous Improvement 17.7 Hidden Engineering Demand #7: Flexible Digital Test Beds in Production IT Environments 17.8 Hidden Engineering Demand #8: True Appreciation for Digital Responsibilities 17.9 Hidden Engineering Demand #9: Upfront Simulation of Digital Engineering Collaboration 17.10 Hidden Engineering Demand #10: New Advanced Human Interfaces 18 The Challenge of Modifying Management Leadership Behavior Towards Virtual Product Creation in Industry 18.1 Needs for Improved Digital Leadership of Management in Virtual Product Creation 18.2 Management Behavior Do’s and Don’ts in Digital Leadership 18.3 Development of Future Digital Leaders in Management Reference 19 The Role of Digital Technology Vendors 19.1 The Set-Up of Digital Technology Vendors 19.2 The Role of Digital Technology Vendors in Virtual Product Creation 19.3 Transformations in Digital Technology Vendor Business 19.4 Perspectives by Digital Technology Vendors References 20 Industrie 4.0 and IoT Technologies 20.1 Industrie 4.0 20.1.1 The Concept, the Initiative and the Vision 20.1.2 The Platform Initiative 20.1.3 The Industrie 4.0 Roadmap Ahead 20.2 Digital Twin Concept 20.2.1 Digital Twin Definition 20.2.2 Digital Twin Classification 20.2.3 Digital Twin Use Case Examples 20.3 The Internet of Things (IoT) 20.3.1 The Global Internet and Its Evolution 20.3.2 Internet of Things (IoT) 20.3.3 IoT Connectivity Stacks 20.4 Cloud, Edge and Platform Technologies 20.4.1 Cloud Computing 20.4.2 Edge Computing 20.4.3 Interaction of Cloud and Edge Computing and Platform Technologies 20.5 Exemplary Industry Application of Industrie 4.0 20.5.1 Efficiency in Manual Assembly Through Connected Processes 20.5.2 Agility and Flexibility Through Autonomy— The Matrix Production References 21 Future Virtual Product Creation Solutions with New Engineering Capabilities 21.1 Model-Based Systems Engineering (MBSE) 21.1.1 Motivation and Needs for MBSE as New Extension of VPC 21.1.2 MBSE Foundation on and Differences to Systems Engineering Principles 21.1.3 Theory and Principles of MBSE 21.1.4 Disciplines of MBSE 21.1.5 Core Elements of the New MBSE Approach 21.1.6 Co-existence and Interaction with VPC Major Technologies 21.1.7 Examples of New MBSE Methods and Tools 21.1.8 The Challenge of Integrating MBSE into Industry 21.2 Data Engineering and Analytics (DEA) 21.2.1 Data Value Understanding (DVU) 21.2.2 Data Need Definition (DND) 21.2.3 Data Collection (DC) 21.2.4 Data Modeling and Management (DMM) 21.2.5 Data Contextualization (DCx) 21.2.6 Data Identification and Interpretation (DII) 21.2.7 Data Modeling and Data Analytics (DMDA) 21.2.8 Data Visualization (DV) 21.2.9 Conclusions 21.3 Digital Twin Engineering (DTE) 21.4 Digital Platform Engineering (DPE) 21.5 Human Skill Sets for Future Virtual Product Creation 21.6 The Engineering System of the Future References Acknowledgement