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Finite Element Modeling and Optimization of a Robot Boomer
KTH, Superseded Departments, Machine Design.
1999 (English)Report (Other academic)
Abstract [en]

In a complex system, there are several sources of physical uncertainty, as well as there are many unintended interactions between the sub-systems. To predict the physical behavior of such a system, there is a need to treat the uncertainties in the physical quantities as well as there is a strong need for scaleable and reusable models that are easy to adapt and to modify. The essence of the MOSAIC approach to behavior modeling of complex systems is to support behavior analysis and simulation in an iterative and thus complex engineering process, by using encapsulated sub-models of components and of their interfaces. Various modeling and simulation aspects of an Atlas Copco Robot Boomer are presented in this report. The rig, which is an Atlas Copco product that is used for tunneling applications, is a complex system with long and slender mechanical parts, hydraulic actuators, sensors and a control system. The system is highly stressed during normal operations, and there are increasing customer demands for performance, with precision and speed as crucial parameters. Due to the modular structure of the product, it is advantageous to configure also the numerical models of the physical behavior of the design system in a modular way. An existing Ansys based FE model of a boomer has been reorganized, modularized, and adapted to allow for a wide range of simulations and analyses of the physical behavior. Methods and techniques to configure and to connect FE submodels, and techniques to utilize optimization techniques available in the FE software Ansys are elaborated on. Movements of the boomer to a target position is accomplished by changing the state of the actuator elements. Positioning errors due to dead weight and preloading and the sensitivity to some selected feature properties are also studied. It is shown that the Ansys optimization routines can be used to find a specified target position by minimizing the positioning error for the boomer. Modal extraction is used as a tool to study the stability limits for the hydraulic cylinders. A component within the system is studied with an ESO based Ansys macro routine that has been developed as a general tool for topological optimization.

Place, publisher, year, edition, pages
Stockholm: KTH , 1999.
Series
Trita-MMK, ISSN 1400-1179 ; 1999:21
Identifiers
URN: urn:nbn:se:kth:diva-24045OAI: oai:DiVA.org:kth-24045DiVA: diva2:342944
Note
QC 20100811Available from: 2010-08-11 Created: 2010-08-11 Last updated: 2010-08-11Bibliographically approved
In thesis
1. Simulation-driven design: Motives, Means, and Opportunities
Open this publication in new window or tab >>Simulation-driven design: Motives, Means, and Opportunities
1999 (English)Doctoral thesis, comprehensive summary (Other scientific)
Abstract [en]

Efficiency and innovative problem solving are contradictory requirements for productdevelopment (PD), and both requirements must be satisfied in companies that strive to remainor to become competitive. Efficiency is strongly related to ”doing things right”, whereasinnovative problem solving and creativity is focused on ”doing the right things”.Engineering design, which is a sub-process within PD, can be viewed as problem solving or adecision-making process. New technologies in computer science and new software tools openthe way to new approaches for the solution of mechanical problems. Product datamanagement (PDM) technology and tools can enable concurrent engineering (CE) bymanaging the formal product data, the relations between the individual data objects, and theirrelation to the PD process. Many engineering activities deal with the relation betweenbehavior and shape. Modern CAD systems are highly productive tools for conceptembodiment and detailing. The finite element (FE) method is a general tool used to study thephysical behavior of objects with arbitrary shapes. Since a modern CAD technology enablesdesign modification and change, it can support the innovative dimension of engineering aswell as the verification of physical properties and behavior. Concepts and detailed solutionshave traditionally been evaluated and verified with physical testing. Numerical modeling andsimulation is in many cases a far more time efficient method than testing to verify theproperties of an artifact. Numerical modeling can also support the innovative dimension ofproblem solving by enabling parameter studies and observations of real and syntheticbehavior. Simulation-driven design is defined as a design process where decisions related tothe behavior and performance of the artifact are significantly supported by computer-basedproduct modeling and simulation.A framework for product modeling, that is based on a modern CAD system with fullyintegrated FE modeling and simulation functionality provides the engineer with tools capableof supporting a number of engineering steps in all life-cycle phases of a product. Such aconceptual framework, that is based on a moderately coupled approach to integratecommercial PDM, CAD, and FE software, is presented. An object model and a supportingmodular modeling methodology are also presented. Two industrial cases are used to illustratethe possibilities and some of the opportunities given by simulation-driven design with thepresented methodology and framework.

Place, publisher, year, edition, pages
Stockholm: KTH, 1999. vi, 42 p.
Series
Trita-MMK, ISSN 1400-1179 ; 1999:26
Keyword
CAD, CAE, FE method, Metamodel, Object model, PDM, Physical behavior, System
Identifiers
urn:nbn:se:kth:diva-2875 (URN)99-3055738-5 (ISBN)
Public defence
1999-12-01, 00:00
Note
QC 20100810Available from: 2000-01-01 Created: 2000-01-01 Last updated: 2010-08-11Bibliographically approved

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