The Analysis of design and manufacturing tasks using haptic and immersive VR - Some case studies

The use of virtual reality in interactive design and manufacture has been researched extensively but the practical application of this technology in industry is still very much in its infancy. This is surprising as one would have expected that, after some 30 years of research commercial applications of interactive design or manufacturing planning and analysis would be widespread throughout the product design domain. One of the major but less well known advantages of VR technology is that logging the user gives a great deal of rich data which can be used to automatically generate designs or manufacturing instructions, analyse design and manufacturing tasks, map engineering processes and, tentatively, acquire expert knowledge. The authors feel that the benefits of VR in these areas have not been fully disseminated to the wider industrial community and - with the advent of cheaper PC-based VR solutions - perhaps a wider appreciation of the capabilities of this type of technology may encourage companies to adopt VR solutions for some of their product design processes. With this in mind, this paper will describe in detail applications of haptics in assembly demonstrating how user task logging can lead to the analysis of design and manufacturing tasks at a level of detail not previously possible as well as giving usable engineering outputs. The haptic 3D VR study involves the use of a Phantom and 3D system to analyse and compare this technology against real-world user performance. This work demonstrates that the detailed logging of tasks in a virtual environment gives considerable potential for understanding how virtual tasks can be mapped onto their real world equivalent as well as showing how haptic process plans can be generated in a similar manner to the conduit design and assembly planning HMD VR tool reported in PART A. The paper concludes with a view as to how the authors feel that the use of VR systems in product design and manufacturing should evolve in order to enable the industrial adoption of this technology in the future

Virtual bloXing - assembly rapid prototyping for near net shapes

Virtual reality (VR) provides another dimension to many engineering applications. Its immersive and interactive nature allows an intuitive approach to study both cognitive activities and performance evaluation. Market competitiveness means having products meet form, fit and function quickly. Rapid Prototyping and Manufacturing (RP&M) technologies are increasingly being applied to produce functional prototypes and the direct manufacturing of small components. Despite its flexibility, these systems have common drawbacks such as slow build rates, a limited number of build axes (typically one) and the need for post processing. This paper presents a Virtual Assembly Rapid Prototyping (VARP) project which involves evaluating cognitive activities in assembly tasks based on the adoption of immersive virtual reality along with a novel nonlayered rapid prototyping for near net shape (NNS) manufacturing of components. It is envisaged that this integrated project will facilitate a better understanding of design for manufacture and assembly by utilising equivalent scale digital and physical prototyping in one rapid prototyping system. The state of the art of the VARP project is also presented in this paper

Virtual assembly rapid prototyping of near net shapes

Virtual reality (VR) provides another dimension to many engineering applications. Its immersive and interactive nature allows an intuitive approach to study both cognitive activities and performance evaluation. Market competitiveness means having products meet form, fit and function quickly. Rapid Prototyping and Manufacturing (RP&M) technologies are increasingly being applied to produce functional prototypes and the direct manufacturing of small components. Despite its flexibility, these systems have common drawbacks such as slow build rates, a limited number of build axes (typically one) and the need for post processing. This paper presents a Virtual Assembly Rapid Prototyping (VARP) project which involves evaluating cognitive activities in assembly tasks based on the adoption of immersive virtual reality along with a novel non-layered rapid prototyping for near net shape (NNS) manufacturing of components. It is envisaged that this integrated project will facilitate a better understanding of design for manufacture and assembly by utilising equivalent scale digital and physical prototyping in one rapid prototyping system. The state of the art of the VARP project is also presented in this paper

Automated knowledge capture in 2D and 3D design environments

In Life Cycle Engineering, it is vital that the engineering knowledge for the product is captured throughout its life cycle in a formal and structured manner. This will allow the information to be referred to in the future by engineers who did not work on the original design but are wanting to understand the reasons that certain design decisions were made. In the past, attempts were made to try to capture this knowledge by having the engineer record the knowledge manually during a design session. However, this is not only time-consuming but is also disruptive to the creative process. Therefore, the research presented in this paper is concerned with capturing design knowledge automatically using a traditional 2D design environment and also an immersive 3D design environment. The design knowledge is captured by continuously and non-intrusively logging the user during a design session and then storing this output in a structured eXtensible Markup Language (XML) format. Next, the XML data is analysed and the design processes that are involved can be visualised by the automatic generation of IDEF0 diagrams. Using this captured knowledge, it forms the basis of an interactive online assistance system to aid future users who are carrying out a similar design task

Automated design analysis, assembly planning and motion study analysis using immersive virtual reality

Previous research work at Heriot-Watt University using immersive virtual reality (VR) for cable harness design showed that VR provided substantial productivity gains over traditional computer-aided design (CAD) systems. This follow-on work was aimed at understanding the degree to which aspects of this technology were contributed to these benefits and to determine if engineering design and planning processes could be analysed in detail by nonintrusively monitoring and logging engineering tasks. This involved using a CAD-equivalent VR system for cable harness routing design, harness assembly and installation planning that can be functionally evaluated using a set of creative design-tasks to measure the system and users' performance. A novel design task categorisation scheme was created and formalised which broke down the cable harness design process and associated activities. The system was also used to demonstrate the automatic generation of usable bulkhead connector, cable harness assembly and cable harness installation plans from non-intrusive user logging. Finally, the data generated from the user-logging allowed the automated activity categorisation of the user actions, automated generation of process flow diagrams and chronocyclegraphs