CAE Driven Design of Forging Presses

Transcription

1 3rd European HyperWorks Technology Conference CAE Driven Design of Forging Presses At Present and in Future Dr. Heiko Baum FLUIDON GmbH COMPETENCE IN FLUID POWER SYSTEMS SIMULATION KOMPETENZ IN DER SIMULATION FLUIDTECHNISCHER SYSTEME Slide 1

2 Survey 1 Fluidtronic A design environment for fluid technical mechatronical systems 2 Forging Presses A Brief Introduction 3 CAE-Driven Forging Press Development at Present 4 An Outlook onto Future CAE-Driven Forging Press Development 5 Conclusion Slide 2

3 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. Central thoughts of the development environment: Required are reference processes, that define the workflow of the collaborative development Required are interfaces between simulation and project planning tools All data from the simulation and projekt planning environments will be exchanged and managed via PLMsupport More information is available under Slide 3

4 Survey 1 Fluidtronic A design environment for fluid technical mechatronical systems 2 Forging Presses A Brief Introduction 3 CAE-Driven Forging Press Development at Present 4 An Outlook onto Future CAE-Driven Forging Press Development 5 Conclusion Slide 4

5 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 5

6 Survey 1 Fluidtronic A design environment for fluid technical mechatronical systems 2 Forging Presses A Brief Introduction 3 CAE-Driven Forging Press Development at Present 4 An Outlook onto Future CAE-Driven Forging Press Development 5 Conclusion Slide 6

7 1 2 3 Limitations of a 1D system simulation of large production machines FG_WRC160 SWRC160 Pneu To simulate a working sequence, large parts of the original control strategy have to be included in the model. K OT K UT SMS xot MEER Korrektur_OT xut Korrektur_UT Schmieden Rueckzug Schmiedesteuerung1 ZPRS S1 Zaehler1 Huebe Dekompression1a S3 SWRC100 FG_WRC100 Geschwindigkeitsregler1a S3b S3a VSB Diffusor1 VS6 x f a c h L10 PT1NG160 Hyd Hochtank VS8 Diffusor2 VS7 x f a c h L9 Q_Tankklappe PT1NG100 Tankklappe S2 p Q H2S VS2 xwrce160 VS4 Q_WRCE160 K xwrce100 VS5 Q_WRCE100 K NS100_WRC100 NS100_WRC160 S4 WRCE160 S5 WRCE100 VS3 QNS130L QNS250 QNS130R NS130L RZL NS250 RZR NS130R VZL VS3a VZR x f a c h L1 RF vpresse M2 2 1 RM Schmiedezylinder5Flaechen1 Speicherblock1 Pneu Vol1 M1 VR4 x f a c h L2 SG_FOut XPresse WK5 VR5 x f a c h L3 The elasticity of the frame is merely represented by a linear springdamper. QSL2 x-fach The work piece behavior is described by characteristics or empirical equations. VS1 RSP VS0 Q_DBV_SP DBV_SP SL2 Hyd x-fach VA2 VA1 Gaskolben SL1 QSL1 Summe1 QSL Blende1 QSVA VR2 VR1 x f a c h RRP L4 ZPRH1 Solldruck WRCE32 Q_WRCE32 Q_DBV_RP Q_SP VR0 AntriebS npumpes SchmiedePumpen npumper Q_RP DBV_RP AntriebR RueckzugPumpen Slide 7

8 First steps to a mechatronic system simulation Multy-Body Co-Simulation Set-up Results Co-Simulation of Mechatronic Systems Université du Luxembourg Dipl.-Ing. C. Hostert, Prof. Dr.-Ing. S. Maas, Prof. Dr.-Ing. A. Zürbes, Slide 8

9 Survey 1 Fluidtronic A design environment for fluid technical mechatronical systems 2 Forging Presses A Brief Introduction 3 CAE-Driven Forging Press Development at Present 4 An Outlook onto Future CAE-Driven Forging Press Development 5 Conclusion Slide 9

10 A vision for a CAE-driven development of production machines CAD geometries for models project data exchange EPLAN documentation flexibility of components PLM supported design level CAE supported design level RADIOSS Finite Element data for stress analysis MotionSolve Multi-Body co-simulation of mechatronic systems DSH plus hydraulics OptiStruct geometry optimization HyperStdy parameter optimization PLC controls Measurements validation validation level Fluidtronic Slide 10

11 Step1: Initial System Design with EPLAN Fluid System Documentation DSH plus Automated derivation of the simulation model Pre-configuration of the press in the design template DSH plus Iterative customization and improvement of the configuration with the results of simulation DSH plus Check of the configuration with a hydraulic simulation Development template = EPLAN design template and DSHplus simulation template Slide 11

12 Step 2: Set-up of the DSH plus Hydraulic Model of the Forging Press Implementation of DSH plus -OPC Interface Implementation of DSH plus -STC Interface Slide 12

13 Step 3: Preparation of the CoDeSys PLC-Controller and Visualization Slide 13

14 Step 4: Set-up of the MotionView Mechanical Model Slide 14

15 Fluidtronic CAE Driven Design Demonstrator M2 DSH plus -OPC M1 M4 M3 DSH plus -STC 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. Monitor 1 DSH plus Hydraulic Model Monitor 2 DSH plus -EPLAN (ca. 1700) 2000 CoDeSys PLC-Controller and Visualization Monitor MotionView Mechanical Model Monitor 4 EPLAN Fluid System Documentation Slide 15

16 Survey 1 Fluidtronic A design environment for fluid technical mechatronical systems 2 Forging Presses A Brief Introduction 3 CAE-Driven Forging Press Development at Present 4 An Outlook onto Future CAE-Driven Forging Press Development 5 Conclusion Slide 16

17 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. CAE Driven Design Demonstrator A CAE Design Demonstrator has been builded in 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. Slide 17