Testing and verification through virtual product models: A survey and look ahead
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paper_title: Interactive Virtual Prototypes for Testing the Interaction with new Products

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AbstractToday, the tests of a new product in its conceptual and design stage can be performed by using digital models owning various levels of complexity. The level of complexity depends on the nature and on the accuracy of the tests that have to be performed. Besides, the tests can involve or not the interaction with humans. Particularly, this second aspect must be taken into account when developing the simulation model. In fact, this introduces a different kind of complexity with respect to simulations where humans are not involved. Simulation models used for numerical analyses of the behavior of the product (such as Finite Element Analysis, multi- body analysis, etc.) are typically named Digital Mock- Ups. Instead, simulations that are interactive in their nature, requiring humans- in- the- loop, are named interactive Virtual Prototypes. They cannot be intended as a simple upgrade of a CAD model of a product, but they are instead a combination of functional models, mapped into sensorial terms and then ...
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paper_title: Theoretical Foundations for the Computer-Aided Design System

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This work has been made possible through the support extended to the Massachusetts Institute of Technology, Electronic Systems Laboratory, by the Manufacturing Technology Laboratory, ASD, Wright-Patterson Air Force Base, under Contract No. AF-33(600)- 42859. It is published for technical information only and does not necessarily represent the recommendations or conclusions of the sponsoring agency.
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paper_title: Design verification and validation in product lifecycle

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The verification and validation of engineering designs are of primary importance as they directly influence production performance and ultimately define product functionality and customer perception. Research in aspects of verification and validation is widely spread ranging from tools employed during the digital design phase, to methods deployed for prototype verification and validation. This paper reviews the standard definitions of verification and validation in the context of engineering design and progresses to provide a coherent analysis and classification of these activities from preliminary design, to design in the digital domain and the physical verification and validation of products and processes. The scope of the paper includes aspects of system design and demonstrates how complex products are validated in the context of their lifecycle. Industrial requirements are highlighted and research trends and priorities identified. © 2010 CIRP.
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paper_title: Integrating virtual and physical testing to accelerate the engineering product development process

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Testing is essential in developing a successful complex engineering product. System level integration and testing can use between 35% and 50% of development resources. External factors such as legislation and customer requirements drive essential testing whilst internal factors such company experience, affordability and organisational practice profoundly affect the overall testing plan. The main objective of this paper is to understand how testing is integrated into the product development process and how different types of testing are scheduled across the stages of product development. The paper reports a case study in a diesel engine company where the balance of virtual and physical testing is a key concern in reducing design time and cost. Integrating physical and virtual testing is more than process optimisation of time and cost. It contributes to recasting the design process in response to changes in customer requirements as well as to design changes which arise during testing. The importance of dependencies across components, subsystems and tests is highlighted using a model using design structure matrices and the advantages of integrating physical and virtual testing are analysed particularly in facilitating task overlap to reduce product development duration.
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paper_title: Product Lifecycle Management: Closing the Knowledge Loops

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Competitive success of manufacturing firms is by and large determined by the success of the products they introduce to the market. This is why companies continuously try to improve the efficacy of their product realization process. Product Lifecycle Management (PLM) is a business solution which aims to streamline the flow of information about the product and related processes throughout the product’s lifecycle such that the right information in the right context at the right time can be made available. Yet, few organizations are positioned to reap the true benefits of PLM. One major reason for this is a lack of clear understanding of what PLM is, its core features and functions, and its relationship to the myriad of current software tools. This paper aims to do that and also elaborates on the role of PLM as a knowledge management system.
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paper_title: Real‐time integration of prototypes in the product development process

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Purpose – The purpose of this paper is to identify the strengths and weaknesses associated with physical and virtual prototyping and propose an approach that utilises a real‐time integration of both methods through an automated process.Design/methodology/approach – Following a literature review, the paper presents the results of a survey investigating the current use of prototyping. It then discusses a series of trials that were developed for the proposed tool.Findings – Physical and virtual prototypes are not competitive but rather complementary. An integrated real‐time system would reduce cost and shorten the product design process.Originality/value – This paper provides recommendations on how real‐time integration of both physical and virtual prototypes could potentially streamline the new product development process.
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paper_title: Real-time finite element structural analysis in augmented reality

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Abstract Conventional finite element analysis (FEA) is usually carried out in offsite and virtual environments, i.e., computer-generated graphics, which does not promote a user’s perception and interaction, and limits its applications. With the purpose of enhancing structural analysis with augmented reality (AR) technologies, the paper presents a system which integrates sensor measurement and real-time FEA simulation into an AR-based environment. By incorporating scientific visualization technologies, this system superimposes FEA results directly on real-world objects, and provides intuitive interfaces for enhanced data exploration. A wireless sensor network has been integrated into the system to acquire spatially distributed loads, and a method to register the sensors onsite has been developed. Real-time FEA methods are employed to generate fast solutions in response to load variations. As a case study, this system is applied to monitor the stresses of a step ladder under actual loading conditions. The relationships among accuracy, mesh resolution and frame rate are investigated.
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paper_title: The role of testing in the engineering product development process

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Testing is essential in developing a successful complex engineering product. System level integration and testing can use between 25 and 50% of development resources. External factors such as legislation and customer requirements drive essential testing whilst internal factors such company experience, affordability and organizational practice frame the overall testing plan. The main objective of this paper is to understand how testing is integrated into the product development process and how different types of testing are scheduled across the stages of product development. The paper reports a case study in a diesel engine company where the balance of virtual and physical testing is a key concern in reducing design time and costs. The importance of dependencies across components, subsystems and tests is highlighted and a model using Design Structure Matrices is proposed. Of particular interest are requirements analysis and FMEA stages where testing is planned and resourced. Integrating physical and virtual testing is more than process optimization of time and cost. It contributes to recasting the design process in response to change, both in new customer requirements and contingently in design changes which arise during product development.
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paper_title: Collaborative Engineering: An Airbus Case Study☆

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Abstract This document introduces the main concepts of Collaborative Engineering as a new methodology, procedures and tools to design and develop an aircraft, as Airbus Military is implementing. Airbus designs and industrializes aircrafts under Concurrent Engineering techniques since decades with success. The introduction of new PLM methodologies, procedures and tools, mainly in the industrialization areas, and the need to reduce time-to-market conducted Airbus Military to push the engineering teams to do things in a different way. Traditional Engineering works sequentially, Concurrent Engineering basically overlaps tasks between teams using maturity states and taking assuming risks. Collaborative Engineering promotes a single team to develop product, processes and resources from the conceptual phase to the start of the serial production. The deliverable of the team is an iDMU (industrial DMU), a complete definition and verification of the virtual manufacturing of the product.
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paper_title: Interactive Virtual Prototypes for Testing the Interaction with new Products

paper_content:

AbstractToday, the tests of a new product in its conceptual and design stage can be performed by using digital models owning various levels of complexity. The level of complexity depends on the nature and on the accuracy of the tests that have to be performed. Besides, the tests can involve or not the interaction with humans. Particularly, this second aspect must be taken into account when developing the simulation model. In fact, this introduces a different kind of complexity with respect to simulations where humans are not involved. Simulation models used for numerical analyses of the behavior of the product (such as Finite Element Analysis, multi- body analysis, etc.) are typically named Digital Mock- Ups. Instead, simulations that are interactive in their nature, requiring humans- in- the- loop, are named interactive Virtual Prototypes. They cannot be intended as a simple upgrade of a CAD model of a product, but they are instead a combination of functional models, mapped into sensorial terms and then ...
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paper_title: Collaborative Engineering Paradigm Applied to the Aerospace Industry

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Airbus designs and industrializes aircrafts using Concurrent Engineering techniques since decades. The introduction of new PLM methods, procedures and tools, and the need to reduce time-to-market, led Airbus Military to pursue new working methods. Traditional Engineering works sequentially. Concurrent Engineering basically overlaps tasks between teams. Collaborative Engineering promotes teamwork to develop product, processes and resources from the conceptual phase to the start of the serial production. The CALIPSOneo pilot project was launched to support the industrialization process of a medium size aerostructure. The aim is to implement the industrial Digital Mock-Up (iDMU) concept and its exploitation to create shop floor documentation. In a framework of a collaborative engineering strategy, the project is part of the efforts to deploy Digital Manufacturing as a key technology for the industrialization of aircraft assembly lines. This paper presents the context, the conceptual approach and the methodology adopted.
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paper_title: Virtual verification of the AIRBUS A400M final assembly line industrialization

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This document describes the experience gained from the project of implementing the Digital Manufacturing methodology to validate the industrial design of the AIRBUS A400M Final Assembly Line (FAL) in a virtual environment using state of the art Product Lifecycle Management (PLM) tools. The project has generated a remarkable innovation in the industrialization methods and tools used in AIRBUS Military, contributing to the A400M program success. The document presents: the background and reasons motivating the project, the context and the main barriers identified, and the definition of a Final Assembly Line. An innovative concept of industrial Digital Mock-Up (iDMU) was coined, representing the interoperable grouping of product, processes and manufacturing resources data.
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paper_title: Future Internet-based Collaboration in Factory Planning

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As the design, development and execution of manufacturing processes continue to spread out across the world, globally distributed enterprises demand new paradigms. Distance collaboration tools are becoming increasingly important in order to maintain synergies between spatially distributed entities enabling effective cooperation over large distances. Virtual Reality (VR) technologies offer unique possibilities for the exchange of planning stages as well as for the identification and collective resolution of problems. This paper discusses the requirements of manufacturing engineers for distance collaboration tools and the challenges associated with the creation of such systems through a working prototype implemented in the VirCA NET frame- work. This pilot solution is a novel application in the field of VR-enhanced spatially distributed collaboration via shared virtual spaces using immersive visualization. Typical scenarios are provided to highlight the capabilities offered by VirCA NET. The paper identifies and classifies the challenges of distance collaboration from a cognitive infocommunications (CogInfoCom) perspective. The challenges are presented with respect to the theoretical background of CogIn- foCom engines and channels emphasising the link between virtual collaboration and the aim of CogInfoCom.
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paper_title: Design, programming and orchestration of heterogeneous manufacturing systems through VR-powered remote collaboration

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Modern manufacturing systems are often composed of a variety of highly customized units and specifically designed manufacturing cells. Optimization of assembly and training of staff requires a series of demo installations and excessive use of costly operational resources. In some cases, components are located at different sites, making the orchestration of the whole system even more difficult.Virtual Reality (VR) collaboration environments offer a solution by enabling high fidelity testing and training of complex manufacturing systems. On the other hand, such platforms are difficult to implement in an engineering perspective, as they are required to provide reliable, standard interfaces towards both robotic components and human operators.The VirCA (Virtual Collaboration Arena) platform is a software framework that supports various means of collaboration through the use of 3D augmented/virtual reality as a communication medium. VirCA offers functions for the high-level interoperability of heterogeneous components in a wide range of domains, spanning from research & development, through remote education to orchestration and management of industrial processes in manufacturing applications. This paper provides an overview of the industrial requirements behind high-fidelity virtual collaboration and demonstrates how the VirCA platform meets these requirements. Use cases are provided to illustrate the usability of the platform. HighlightsThe paper identifies the synergies of recent advances in Future Internet and ICT.Surveys the need of high-fidelity virtual collaboration for industrial robotics.Introduces the VirCA platform as a remote collaboration and orchestration framework.Shows the integration of ontologies and CogInfoCom methods into industrial setups.Presents use case examples of knowledge-driven automation scenarios based on VirCA.
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paper_title: Design and implementation of a cloud computing service for finite element analysis

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This paper presents an end-to-end discussion on the technical issues related to the design and implementation of a new cloud computing service for finite element analysis (FEA). The focus is specifically on performance characterization of linear and nonlinear mechanical structural analysis workloads over multi-core and multi-node computing resources. We first analyze and observe that accurate job characterization, tuning of multi-threading parameters and effective multi-core/node scheduling are critical for service performance. We design a ''smart'' scheduler that can dynamically select some of the required parameters, partition the load and schedule it in a resource-aware manner. We can achieve up to 7.53x performance improvement over an aggressive scheduler using mixed FEA loads. We also discuss critical issues related to the data privacy, security, accounting, and portability of the cloud service.
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paper_title: ENGINEERING APPLICATIONS OF VIRTUAL REALITY

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This chapter introduces the techniques involved in the design and development of virtual reality (VR) systems. It describes the main techniques and applications of the VR technology, including its hardware, software, and engineering applications. The chapter reviews various VR applications in engineering, including concept design, data visualization, virtual manufacturing, driving simulation, and construction engineering. Dani and Gadh presented an approach for creating shape designs in a VR environment called Conceptual VIRtual Design System (COVIRDS). This system uses VR technology to provide a 3D virtual environment in which the designer can create and modify 3D shapes with an interface based on bimodal voice and hand tracking. There are four areas of VR in manufacturing applications: process simulation, factory layout, assembly method prototyping, and part flow simulation. By immersing the user in the virtual environment (VE), VR reveals spatially complex structures in a way that makes them easy to understand and study. ::: ::: ::: Keywords: ::: ::: construction engineering; ::: data visualization; ::: driving simulation; ::: engineering applications; ::: virtual environment (VE); ::: virtual manufacturing; ::: virtual reality (VR) systems
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paper_title: A web service-based multi-disciplinary collaborative simulation platform for complicated product development

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In a ubiquitous computing environment, computer-aided engineering (CAE) software packages can be encapsulated as a service and be accessible through networks, which is essential to small and medium enterprises (SMEs) for complex product design with limited computing resources. In this paper, a web service-based platform for the multi-disciplinary collaborative simulation (MDCSS) is proposed, which is a software-sharing environment. In MDCSS, although the CAE software packages reside in their remote application program servers, they are registered in the service center to be accessible according to the computing requests. Given the increasing CAE services with the same function, a quality of service (QoS)-aware scheduling method with real-time and countable parameters is proposed to adaptively select the most efficient web service among alternatives. Through an additional layer and an application broker for service scheduling, MDCSS allows allocating services automatically, keeping load balance, and minimizing human intervention. This platform is reusable, scalable, and efficient for implementation, which enables the end user to invoke the remote CAE software ubiquitously in a “pay-as-you-use” fashion.
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paper_title: VirCA NET: A case study for collaboration in shared virtual space

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To take up the challenge of global distributed companies, Manufacturing Engineering has to be accomplished in a worldwide collaborative way. Design and development of production processes and their execution are nowadays spread all over the world. To ensure quality standards and to create synergies between spatially distributed entities, distance collaboration tools must be provided to allow cooperation even over large distances. The Virtual Reality (VR) is thereby offering beneficial capabilities to exchange current planning stages, identify problems and solve them cooperatively. This paper introduces a new approach for distance collaboration, which enables users to work in a joint virtual space, nearly as if they were working together in the same place. Therefore two full-immersive CAVE-like systems are interconnected using the VirCA (Virtual Collaboration Arena) platform. The paper describes the requirements of Mechanical Engineers towards distance collaboration tools and the technical challenges solved with the enhanced VirCA framework. This working prototype is one premier application in the field of VR-enhanced spatially distributed collaboration. A typical use case scenario is provided to highlight the interaction and cooperation capabilities offered by VirCA NET.
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paper_title: Virtual reality applications in manufacturing industries: Past research, present findings, and future directions

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Today, manufacturing industries are trying to improve their competitiveness by combining manufacturing per se with information technology. Virtual reality is being used in product development processes in manufacturing enterprises as a helpful technology to achieve rapid consolidation of information and decision-making through visualization and experience. In this article, 154 articles relevant to virtual reality’s application to manufacturing were surveyed and analyzed. For this, (1) an analysis map was created, based on a virtual reality technology classification and the new product development process; (2) the articles investigated were located on the map; and (3) bibliometric analyses were carried out. Trends in past and present research were examined and future virtual reality research directions and application plans for manufacturing enterprises are discussed.
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paper_title: Robot Reliability and Safety

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Contents: Introduction.- Introduction to Reliability and Safety.- Introduction to Robotics.- Robot Accidents.- Fundamentals of Robot Safety.- Topics in Robot Safety.- Human Factors in Robotics.- Robot Reliability.- Robot Maintenance.- Failure Data and Analysis.- Robot Economics.- Robot Testing and Information Related to Robots.- Appendix.
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paper_title: Safety of Industrial Robots: From Conventional to Collaborative Applications

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Industrial robots, previously completely separated from human access when in operation in the factory, are acquiring control capabilities rendering them capable of conforming to new forms of operation, with suitably controlled risks to allow human workers access to the robot work space during operation. We survey the developments of industrial robots and of the robot safety standards, outlining the steps that have brought us to the present status, the opening of possibilities for human-robot collaboration in industrial production. The four basic types of collaborative operation are summarized and open research questions in this area are formulated.
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paper_title: Design, programming and orchestration of heterogeneous manufacturing systems through VR-powered remote collaboration

paper_content:

Modern manufacturing systems are often composed of a variety of highly customized units and specifically designed manufacturing cells. Optimization of assembly and training of staff requires a series of demo installations and excessive use of costly operational resources. In some cases, components are located at different sites, making the orchestration of the whole system even more difficult.Virtual Reality (VR) collaboration environments offer a solution by enabling high fidelity testing and training of complex manufacturing systems. On the other hand, such platforms are difficult to implement in an engineering perspective, as they are required to provide reliable, standard interfaces towards both robotic components and human operators.The VirCA (Virtual Collaboration Arena) platform is a software framework that supports various means of collaboration through the use of 3D augmented/virtual reality as a communication medium. VirCA offers functions for the high-level interoperability of heterogeneous components in a wide range of domains, spanning from research & development, through remote education to orchestration and management of industrial processes in manufacturing applications. This paper provides an overview of the industrial requirements behind high-fidelity virtual collaboration and demonstrates how the VirCA platform meets these requirements. Use cases are provided to illustrate the usability of the platform. HighlightsThe paper identifies the synergies of recent advances in Future Internet and ICT.Surveys the need of high-fidelity virtual collaboration for industrial robotics.Introduces the VirCA platform as a remote collaboration and orchestration framework.Shows the integration of ontologies and CogInfoCom methods into industrial setups.Presents use case examples of knowledge-driven automation scenarios based on VirCA.
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paper_title: Safety issues in human-robot interactions

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Safety is an important consideration in human-robot interactions (HRI). Robots can perform powerful movements that can cause hazards to humans surrounding them. To prevent accidents, it is important to identify sources of potential harm, to determine which of the persons in the robot's vicinity may be in greatest peril and to assess the type of injuries the robot may cause to this person. This survey starts with a review of the safety issues in industrial settings, where robots manipulate dangerous tools and move with extreme rapidity and force. We then move to covering issues related to the growing numbers of autonomous mobile robots that operate in crowded (human-inhabited) environments. We discuss the potential benefits of fully autonomous cars on safety on roads and for pedestrians. Lastly, we cover safety issues related to assistive robots.
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paper_title: Merged physical and virtual reality in collaborative virtual workspaces: The VirCA approach

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Recently emerging paradigms of the so called Future Internet induce significant changes in consumer and industrial ICT applications. Remote collaboration in mixed physical and virtual realities made possible thanks to the increasing network bandwidth further empowered by the achievements of Internet of Things, Cloud Computing and Internet of Services. This enticing vision brings benefits for several application fields ranging from STEM education to smart factories. The paper discusses some new possibilities through the VirCA (Virtual Collaboration Arena) framework as a pilot realization. A brief introduction is given to VirCA focusing on the basic concepts and features that make it well suited for collaborative work in mixed virtual and physical reality. Through a concrete life-like example, the paper illustrates the way of involving real industrial devices into remote collaboration scenarios and reviews the typical uses of such a shared infrastructure considering the relationship of the virtual and real entities.
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Title: Testing and Verification through Virtual Product Models: A Survey and Look Ahead

Section 1: INTRODUCTION
Description 1: Discuss the history, current state, and significance of virtual product models in product testing and verification.

Section 2: INDUSTRIES
Description 2: Describe the various industries that have adopted virtual verification practices and the changes in standards and procedures over time.

Section 3: INTEGRATED ONLINE ECOSYSTEM FOR AGILE DESIGN-VERIFICATION LOOP
Description 3: Explore the emerging paradigm of integrating virtual product design and testing using cloud-based online services and its benefits.

Section 4: INTERDISCIPLINARY UNDERPINNINGS OF VIRTUAL VERIFICATION
Description 4: Explain the interdisciplinary foundations required for model-based product testing and the importance of precise parametrization for virtual verification.

Section 5: CONCLUSION
Description 5: Summarize the challenges and potential global impacts of virtual verification technologies on production processes and standardization practices.