IPS Sealing. Capability. Benefits. Results
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- Warren Jordan
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1 IPS Sealing Capability Laydown simulation including the complex rheology of the material Extremely robust, accurate and fast algorithms with immediate visualization Straightforward and intuitive simulation setup that require no expertise on computational tools Coupling to path planning software for optimization of complete robot cells Export beads as CAD for additional analyses, such as packing, geometry assurance analysis and assembly simulations Add-on for glue and adhesives Benefits Power (detailed physical models and accurate results) Speed (apply one meter of sealing material per hour of simulation time, substantially shortened product preparation time) Easy to use (one day crash course, GUI tailored for the sealing process) Results First software on the market Successful validation campaigns
2 Sealing simulations Automatically generated adaptive octree grids and immersed boundary techniques Fast solvers using GPU acceleration running on standard computers Accurate simulation of the sealing process from nozzle to target and free surface flow after impact Input Simulation Results Geometry CAD Process cond. Applicator motions Sealant flow rates Air flow Reconstruction of the sealant in the air and prediction of impact on the target Applicator measurements Sealant shape in the air Surface flow Two-phase flow (sealant and air) predicting the free surface flow of the sealant after impact on target Geometry of sealing beads Visualization of bead geometry with powerful and intuitive post-processing tools Rheometer measurements Viscosity shear rate dependence
3 Adhesive simulations Automatically generated adaptive octree grids and immersed boundary techniques Fast solvers using GPU acceleration running on standard computers Advanced rheology models packaged in a streamlined, easy-to-use interface Input Simulation Results Geometry CAD Process cond. Applicator motions Adhesive flow rates Applicator measurements Nozzle diameter Physical simulation The physics of the adhesive extrusion are simulated, taking into account the complex rheology of the adhesive, the two-phase flow of adhesive and air,the dynamic motion of the robot and the adhesive flow on the target surface Geometry of sealing beads Visualization of bead geometry with powerful and intuitive post-processing tools Rheometer measurements Viscoelastic properties of the material
4 IPS Sealing Setting up and running a simulation Example case: Sealing bead in the engine room of a car Simulation method Deposit Physics-based Simulation performance Sealing bead length / simulation time 3.5m per hour 1m per hour Total simulation setup time: 53s
5 IPS Sealing Simulation methods Deposit simulation Physics-based simulation Very fast simulations Includes the reconstruction of sealant flow through the air and impact on target but does not take surface flow into account. Accuracy Includes the most important physics of sealing laydown: Reconstruction of sealant flow through the air and impact on target Simulation of two-phase surface flow of sealant after impact Accurate predicion of the sealing laydown for complex geometries and various process conditions Impact prediction Reasonable prediction of sealing bead especially in areas with high applicator speed High performance Runs on a standard computer and one meter of sealing bead can be simulated per hour
6 IPS Sealing Powerful and intuitive visualization and post processing tools Computational grid Visualization of the automatically generated adaptive grid. Bead analyzer View the bead in its cross section and obtain quick estimates of the bead width, thickness and cross section area. Bead geometry The resulting sealing bead is visualized in each time step by a contour surface and may be exported in CAD format, to be used in e.g. a packing study.
7 IPS Sealing and Adhesive Validation in laboratory and production Laboratory Comparison between simulation and measurement for test beads using different process parameters Measurement Production Comparison between simulation and 3D-scans of sealing beads from production. Simulation
8 IPS Sealing and Adhesive Technical advantages Extremely robust, accurate and fast algorithms with immediate visualization Running on standard computer Fully automatic mesh generation Easy accessible simulation input Process simulation and robot optimization in one environment for optimization of complete robot cells No special know-how of meshing and advanced simulation software necessary. Training in one-day Benefits Saves days of simulation time and time for correcting wrong setup Saves money for HW-resources Saves man days of preparation Fast simulation setup Substantially shortened product preparation and cycle time Ready for productive use in short time frame
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