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Pegasus: e-Design and Realization SystemPegasus: e-Design and Realization System

National Science FoundationNational Science FoundationIndustry/University Cooperative Research CenterIndustry/University Cooperative Research Centerfor e-Design: IT-Enabled Design and Realizationfor e-Design: IT-Enabled Design and Realization

of Engineered Products and Systemsof Engineered Products and Systems

ByBart O. Nnaji,Ph.D.

Alcoa Foundation Professor in ManufacturingEngineering & Director of NSF I/UCRC

University of Pittsburgh

NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems

Structure/Organization of CenterUPitt

Management

Center DirectorParticipatingUniversitiesManagement

CenterCo-Directors

AcademicPolicy Comm.

Office of TechManagement

(IP)

ResearchCommittee

PEGASUSCommittees

NSF

IndustrialAdvisory Board

CenterEvaluator

Research Thrust AInformation Infrastructure &

Architecture

Research Thrust BNew Design System Paradigm

Research Thrust CPreferences, Constraints,

Representation & Optimization

Research Thrust DFrom Preference &

Constraints to Form

Research Clusters Research Clusters Research Clusters Research Clusters


Academic Partners

§Department of Mechanical and Industrial Engineering§Department of Computer Science

University of Massachusetts at Amherst

University of Pittsburgh

§Department of Industrial Engineering§Department of Mechanical Engineering§Department of Material Science Engineering§Department of Computer Engineering§Department of BioEngineering

Carnegie Mellon University

§ Robotics Institute§ Center for e-Commerce


Sample Partners of CenterINDUSTRIAL FEDERAL ACADEMC


e-Design Center Motivation§ Discrete mechanical products:è$1 trillion in U.S. revenues per year

§ 70 - 80% of product’s acquisition costs committed atdesign time

§ Government and consumers need faster and costeffective product acquisition

§ Industry needs to respond quickly with cost effective,high quality products

§ E.g. Automotive design cycle now 36 – 48 months:èneeds to be 12 months

§ Internet-based design studio will achieve this§ Physics-based virtual prototyping will significantly

reduce complex product design and realization time


Industry Technology Needs

§ Design paradigm that is virtual service orientedwith plug-and-play capability

§ Interoperability among heterogeneous systems§ Collaboration among stakeholders (e.g. suppliers)§ Remote and distributed design via Internet§ Functionality-based conceptual design§ From concept to form§ Direct constraint imposition§ Multidisciplinary constraints§ Scalable, flexible and efficient platform


Industry Technology Needs(Contd.)

§ Agent-based models for simulation§ Operation Research-based Optimization tools§ Virtual product prototyping with Physical laws

realization


Research AreasResearch Thrusts and Clusters

Information Infrastructure & ArchitectureInformation Management

Communication ProtocolsCollaboration MethodsInformation RepresentationInformation RepositorySecurity & AccessibilityIntellectural property rights

Transition/Migration Strategy

Conceptual Design ToolsNew Design Process

Design CycleProduct decompositionUncertainty & risk managementIncentive structuresDesign Information Representation

Design Tool InterfacesDesign SimulationHuman/Computer Interface

Multidisciplinary Constraint Management& Optimization

Design RepresentationSetting of StandardsKnowledge Representation&Retrieval

Preferences

Virtual Prototyping & Simulation

From function to form

Constraints

Optimization

Visualization tool

Virtual test & simulation

Virtual PrototypingConflict Resolution


New Design System Views

§Functionality-based design and reasoning§New networking capabilities to reduce designcycle times§Systematic product decomposition for effectivedistributed product development§Definition of specification for the decompositionelements§Product data management in the supply network


Design Data Presentation

§Form generation§Functionality embodiment and productbehavior tests§Computer visualization§Human/computer interaction§Design reasoning§Semantics§Modeling accuracy, precision, and resolution


Customer View

§Direct participation of customers§Automatic accommodation of preferences§Scalability§Flexibility§Efficient collaboration§Multidisciplinary product design evolution


Design Optimization

§Constraint representation§Constraint propagation§Constraint integrity§Conflict management and negotiation§Result interpretation§Simulation


Conflict Management andNegotiation

Manufacturing Assembly

Material Supply Chain

Manufacturing Assembly

Material Supply Chain

Conflict !!


Information Infrastructure andArchitecture

§What is the information needed throughout the life cycle?§ Information protection and security (at the product attribute,

characterization and specification levels)§ Seamless sharing of information across international

boundaries§ Information storage/retrieval and data mining strategies§ Creation of a knowledge depository§ Classification of Information in the depository (Proprietary,

Public and Shared)§Maintaining and representing the interpretation of

information for use by down stream applications andprocesses.§ Record of Reasoning process, how results were derived


Service Triangle Relation

ServiceManager

ServiceConsumer

ServiceProvider

3. Service

2. Service Lookup 1. Service Publication

ServiceManager

ORB

Skel

ServiceProvider

ORB

Stub

ServiceConsumer

ORB

Service Bindingrequest

Service Resolutionrequest

Service Bindingprovide

Servicerequest

Serviceprovide

Service Resolutionprovide

Service Manager

Name Publication Catalog Publication ImplementationPublication

Interface LookupName Lookup Catalog Lookup


eProduct Design & RealizationCenter ServerService Security

ServiceBrokerage

ServiceUpdate

Service Meta-Protocol

Service

Pu

blicatio

n

Service

Lo

oku

p

ServicePlanning&Scheduling

SecurityAccessControl

ServiceTransparency

Client Modeler(Design Environment)

Functionality-basedConceptual Engine

Resident GeometricModeler

Constraint Manager(Representation & Imposition)

ServiceInteroperability

Plug-and-Play

Client DataSource

Data Security

ServiceTransparency

Service Provider

Service Specification

Service Protocol

Service Linkage &Reference

ServiceInteroperability

Plug-and-Play

Service DataSource

Service Security

Internet

Engineering Service InformationAdministrative Information

The Structure of the e-DesignSystem Platform


Supply Chain Interaction in Pegasus

Pegasus Platform

• Conceptualization• Virtual Prototyping• Virtual Simulation• Transparent Analysis• Design Repository

• Conceptualization• Virtual Prototyping• Virtual Simulation• Transparent Analysis• Design Repository

• Collaboration• Product Specification• Design Constraints• Design Validation

Service ProvidersFEA (ANSYS)

Material (ALCOA)

System Integrators(e.g., GE, Ford, Pratt & Whitney,

Boeing, Respironics)

OEMs(e.g., Delphi, ALCOA)


System Architecture§ Interoperable§ Portable§ Extensible§ Scalable

§ Transparent§ Compatible§ Peer-to-peer§ Plug-and-play

INTERNET

ConceptualModeler

DetailedModeler

AssemblyTool

MaterialSelector

ManufacturingTool

CognitiveTool

ErgonomicsTool

Supply ChainManager

OptimizationEngine

FEATool

FunctionReasoning

ServiceManager

WWWBrowser


Heterogeneous Data Interoperability§ Issues of interoperability for CAD/CAM/Analysis§ Heterogeneous data wrapped or indexed by XML,

including various CAD data (.igs, .step, .sat, .x_t, .prt,…), texts, graphs, images, etc.§ Product information linkage§ Encourage collaboration, knowledge reuse, lean

engineering information exchange.

TEXT GRAPH .txt IMAGE .gif IGES .jpg STEP .igs PML .stp .pml …

XML


Universal Linkage Model

PART:Part1

SURFACE:S0 SURFACE:S1 SURFACE:S2 SURFACE:S3 SURFACE:S4 SURFACE:S5 SURFACE:S6 SURFACE:S7

LINE:L0 LINE:L1 LINE:L2 LINE:L3 LINE:L4 LINE:L5 LINE:L6 LINE:L7 LINE:L8 LINE:L9 LINE:L10 LINE:L11

FACE:F0 FACE:F1 FACE:F2 FACE:F3 FACE:F4 FACE:F5 FACE:F6 FACE:F7

EDGE:E0 EDGE:E1 EDGE:E2 EDGE:E3 EDGE:E4 EDGE:E5 EDGE:E6 EDGE:E7 EDGE:E8 EDGE:E9 EDGE:E10 EDGE:E11

ELLIPSE:C12

EDGE:E12 EDGE:E13

ELLIPSE:C13

POINT:P0

VERTEX:V0

POINT:P1

VERTEX:V1

POINT:P2

VERTEX:V2

POINT:P3

VERTEX:V3

POINT:P4

VERTEX:V4

POINT:P5

VERTEX:V5

POINT:P6

VERTEX:V6

POINT:P7

VERTEX:V7

POINT:P8

VERTEX:V8

conPARALLEL

conPARALLEL

conPARALLEL conPARALLEL

conDISTANCEconDISTANCE

conDISTANCE conDISTANCE

conANGLE conANGLE

conMATERIAL

P0

P1

P2

P4

P5

P6

P7

L0

L1

L2

L3

L4

L5L6

L7

L8

L9

L10

L11S1

S0

S2

S3

S5

S4

S6S7

C12C13

d0d1

r0

L2//L0L3//L1S2//S0

S1-S4<angle0S3-S4<angle1

d2 d3

S5//S4P8

INTERNET


Product Markup Language

line0p0 p1

d

line0

distance = d

p0 p1

consists-of consists-of

UL ModelGeometry

<?xml version="1.0"?> <pml:GEOMETRY xmlns:pml="http://www.pitt.edu" xmlns:xsi="http://www.w3.org/2001/XMLSchema-instance" xsi:schemaLocation= "http://www.pitt.edu line.xsd"> <pml:POINT x="0.0" y="0.0" z="0.0" id="p0">p0</pml:POINT> <pml:POINT y="1.0" y="0.0" z="0.0" id="p1">p1</pml:POINT> <pml:LINE> <pml:refPOINT xlink:type="simple" xlink:href="#p0" xlink:show="embed" xlink:actuate="onLoad"/> <pml:refPOINT xlink:type="simple" xlink:href="#p1" xlink:show="embed" xlink:actuate="onLoad"/> </pml:LINE> </pml:GEOMETRY> <pml:CONSTRAINT> <pml:conDISTANCE xlink:type="extended">1.0 <loc1 xlink:type="locator" xlink:label="start" xlink:href="p0"/> <loc2 xlink:type="locator" xlink:label="end" xlink:href="p1"/> <arc1 xlink:type="arc" xlink:from="start" xlink:to="end" xlink:actuate="onRequest"/> <arc2 xlink:type="arc" xlink:from="end" xlink:to="start" xlink:actuate="onRequest"/> </pml:conDISTANCE> </pml:CONSTRAINT>

PML filePML file


Constraints Representation

Constraints

Non-geometric

Intra-feature Inter-feature Tolerance

MaterialReliabilityMaintainabilityHuman FactorsManufacturing Assembly Environment

•Multidisciplinary

•Directly support design participants

•Design knowledge exchange

•Directly support optimization

PROCESS/TOOLING

MATERIAL

TOLERANCE

…

PROCESS

MATERIAL

TOLERANCE

…

JIG/FIXTURE

ENVIRONMENTPROTECTION

…

RESOURCECONSERVATION

CHRONICRISK

ACCIDENTPREVENTION

RECYCLE

ANTHROPOMETRY

COGNITION

PHYCHOLOGY

BIOMECHANICS

PHYSIOLOGY

…

MTBM

…

MTBR

MTBF

SAFETY FACT

S-N RATIO

HAZARD RATE

…

STRUCTURALPROPERTY

…

THERMALPROPERTY

CHEMICALPROPERTY

FIXED

DISTANCE

ANGLE

RADIUS

OFFSET

CONCENTRIC

TANGENT

PERPENDICULAR

PARALLEL STRAIGHTNESS

ROUNDNESS

SQUARENESS

ANGULARITY

FLATNESS

CYLINDRICITY

CLEARANCE

Geometric


Product FunctionalityHow can components (PHow can components (P1,1, P P22 P P33) be ) be

described to capture functionality related described to capture functionality related issues in the design and operation issues in the design and operation

of the product?of the product?

How can the relationship of PHow can the relationship of P11 with components Pwith components P22 and P and P33

be described?be described?

How can functionality be propagated How can functionality be propagated to downstream design activities?to downstream design activities?

How can functionality description How can functionality description be modeled in computer system?be modeled in computer system?


Functionality Primitives

Recurring product functionalities can Recurring product functionalities can be modeled as a primitive, and used as be modeled as a primitive, and used as

a repository of reusable product knowledge.a repository of reusable product knowledge.

Specific products can be modeled through Specific products can be modeled through their constituent functionality primitives, their constituent functionality primitives,

providing a more natural basis of providing a more natural basis of interaction with the designer.interaction with the designer.

Transformation; Transmission; Joint; Transformation; Transmission; Joint; Load bearing; Energy Conversion; Load bearing; Energy Conversion; Frictional; Offset; Guard; and Block.Frictional; Offset; Guard; and Block.


Slider-Crank Functionality

Torque (T)

Force (F_in)

Force (F)

Crank Slider

Output Link


Output Link-Crank FunctionalityDefinition

FunctionalityEntity

Functionality object 1(j=1)

Functionality object 2(k = 2)

Object (O1) O11 = Force (F) O12 = Torque (T)

Attributes(Aiq)

A111 = |F|, A112 = dir,A113 = nature, A114 = location

A121 = |T|, A122 = dir

Attributevalue (V1qs)

e.g. V111 = [3, 12]N;V112 = (α, γ, λ) rad; etc

V121 = [12, 46]NmV122 = [clockwise]

Object StateS1q = (aiqs,viqs)

S11mag = {0, 3, …}S11dir = {(dir,(a,b,c)),(dir,(d,e,f)), …}

S12mag = {(T, 0), (T,18), …}S12dir = {(dir, clock), (dir, anti-clock),…}

Relation (R1) R1 = {r112 (o11, o12) | 1/l }

FormMapping (F1)

F1 = {(r112, f112l) | FFl=1, FF l=2, … }


w Generate design for assembly andjoining

w Represent an assembly and imply thevarious effects, i.e., physical andmathematical effects of joiningoperations

w Assembly operation analysis processimbedded into assembly designprocess

w Formalism to specify the assemblyrelations symbolically, which hasmathematically solvable implications.

w Designer’s intent preserved by usingspatial relationship-basedrepresentation

w “Plug and play” capability with adesigner system, such as Pegasus

Assist a designer during assemblyand joint design process

Assist a designer during assemblyand joint design process

Predict expected assembly problemPredict expected assembly problem

Provide design alternativesProvide design alternatives

Solve assembly and joiningproblems

Solve assembly and joiningproblems

Assembly Operation Tools (AOT)


Architecture of AOT

Assembly/JoiningAdvisor

ManufacturingKnowledge

Base

Assembly/Joining

KnowledgeBase

Geometric andAssembly Process

ConstraintsInteraction

Assembly Advisory (AsA) Engine

Assembly Implication (AsI) EngineAssembly Modeling (AsM) Engine

Spatial Relationship

Implication (SRI) Engine

Virtual Assembly Analysis (VAA)

Engine

Spatial RelationshipSpecification

AssemblyFeature

Formation

EngineeringRelation

Construction

Analysis Tools(ANSYS, ADINA,

CFX, etc.)

AssemblyGraphicEngine

Assembly ServiceRequest

Assembly ServiceResponse

Designer

Assembly Components & Assembly Operation

Ass

emb

lyM

od

el

Ass

em

bly

De

sig

nS

pe

cifi

cati

on

Ass

emb

lyIm

pli

cati

on

Assembly Implication

Ass

emb

ly D

esig

nA

lter

nat

ive

Ass

em

bly

Se

rvic

eR

esp

on

se

Assembly Operation Tools (AOT)


AsM Engine

§ Assembly generation based on the assemblydesign formalism§ Joining method specification§ Additional geometric feature generation (e.g.,

weld bead, rivet, etc.)§ Geometry preprocess for analysis


Procedures of the assembly designformalism

Spatial RelationshipSpecification

Mating FeatureExtraction

Assembly FeatureFormation

Joint Feature Formationand Extraction

Engineering RelationConstruction

Assembly Components

Assembly Model


Example of GARD – Generic Assembly Relationship Diagram

P1

P2

P3

P4

FF11

FF21

FF12

FF22FF31

FF41

plate_a

plate_c

plate_b

plate_d

FF11 FF21

FF31 FF41

FF12 FF22

DC4 DC5

MF1 MF2 JF1 DC1

MF3 MF4 JF2 DC2 MF5 MF6 JF3 DC3

P1 P2

P3 P4


Example of assembly design formalism

§ MB3 = {mating pair (mating features [form features ( parental relationships, dimensional constraints)])| mating conditions (S/R, [d.o.f.], [implied constraints])} = {MP3

(MF3 [FF11 (FF21, P1(100.72, 23.34, . ), ±∆1; FF12, P1(50, 20, . ), ±∆1), F31 (.)]) | MC3 (against, [{plane_z::rot_z}], [tolerance]))}§ MB4(aligned)= {MP4

(MF4 [FF11 (FF21, P1(100.72, 23.34, . ), ±∆1; FF12, P1(50, 20, . ), ±∆1), F31 (.)]) | MC4(aligned, [{lin_l1::lin_l1}], [tolerance]))}

MB

§ AF2 = {mating features | mating bonds | joint features | [material] | [implied d.o.f. before assembly],[implied d.o.f. after assembly] | [implied constraints]} = {MF3 , MF4 | MB3, MB4 | JF2 | [Aluminum Alloy 6061 - T6] | [{plate_z::rot_z}, {lin_l1:: lin_l1}], [{fix}]| [tolerance]}

AF

§ JF2 = {joining method | [joining components (joining entities)] |[ joining constraints]} = {GMAW | [P1(ea1), P3 (ec1) | P1 (ea2), P3 (ec2) | [welding_condition], [fixture_location]}

JF

§ MF3 = {S/R, [mating components (mating entities)]} = {against, [P1 (top_surface), P3 (bottom_surface)]}§ MF4 = {aligned, [P1 (l1), P3 (l1)]}

MF

§ Plate_a & plate_c§ welded joint


VAA Engine

Analysis Selection

Analysis Input Generation

Analysis Service Request

Analysis Response Interpretation

Virtual Assembly Analysis (VAA) Engine

DesignerClient

Assembly Specification

Engineering InformationService Provider

Analysis Service Provider

Analysis Tools(ANSYS, ABAQUS, ADINA, CFX, etc.)

Engineering Material Engine

Mat

eria

l Ser

vice

Req

ues

t

Mat

eria

l Ser

vice

Res

po

nse Assembly

Service ResponseA

nal

ysis

In

pu

t

Analysis ServiceResponsePegasus Architecture

CORBA

§ Analysis type specification§ Loading and B.C.’s

assignment§ Proper solver determination§ Analysis input generation§ Analysis result

interpretation


Thermo-structural analysis for arcwelded joints

§ Coupled by nonlinear heat conductionanalysis and steady-state structural analysis§ SOLID 70 element (for thermal analyses) and

SOLID 45 element(for structural analyses)


Structural analysis for rivet/bolted joints

§ Elastic-plastic structural analysis§ SOLID 45 element (for structural analysis)

and PRETS179 pretension element (forupsetting processes)


Supply Chain Network

Customer (DoD)OEM (e.g. Tier 1, Tier 2)Supplier (e.g.Tier 3)

System Integrators ( , , etc. )


Design Constraints

Design Constraints

AO Constraints

Functionality Constraints

Design Constraints

PegasusCenter

Homepage

ConceptualDesign

FunctionalityServiceProviderPlug-in

Software

e.g., FbD

AO AnalysisServiceManager

FEM ServiceProviders

e.g., ANSYS,ADINA

User 1

GeometricModeler

(e.g., ACIS-basedmodeler)

Solid ModelerAOT-AsM

1

3

5

6

7

8

9

Pegasus ArchitectureCORBA

GeometricModeler

(Parasolid-basedmodeler)

Solid ModelerAOT-AsM

+ + =

Work Site 1

Service Transaction

Collaboration ChannelF1 F2

ConstraintManager

Work Site 2

User 2VOT-VAAEngine

AI*WorkbenchApp

10

2

4

Work Site 3Work Site n

Pegasus System Version 1.0


Geometric Modeler


Analysis Service Request


Analysis Service Response


Joint DoD/Academia/IndustrySystem Engineering for SBA

DefenseContractors

DoD: System Engineering(Rapid product acquisition)

University of Iowa(Virtual Prototyping)

University of PittsburghCarnegie Mellon University

University of Mass. at Amherst(Pegasus: e-Design/Realization)

Other Centers

Univ. of Wisconsin/Univ. of Michigan

(Center for e-Maintenance)


Summary

§ A design paradigm that accommodates lifecycle considerations for a product§ Rapid product acquisition at significantly

reduced cost with six-sigma quality§ Virtual and transparent analyses and tests

that are physics-based and with ergonomicand cognitive attributes§ System-to-system interoperability and

collaboration

pegasus: e-design and realization system · pdf filed2 d3 s5//s4 p8 internet. nsf center for...

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