Virtual Reality & Prototypes

Engineering is a victim of it's own success. In the late 20th century, the advent of Computer Aided Design, Computer Aided Engineering, and Finite Element Analysis managed to ring the death knell of the "engineering development prototypes". Sure we still have physical prototypes being produced for validation purposes, but those often don't arrive until the computer based development or the part and process planning is completed. "Production Intent" prototypes are created as a validation that the math based models can, in fact, produce an acceptable product. Any findings from these prototypes result in late product or process changes, which are costly and largely not anticipated in budgeting.

The challenge is, that with CAD, CAE, and FEA we have managed to reproduce and replace many of the discovery and learning points that we used the prototypes to discover, but what is often missed is the integration aspect of the design. Integration issues are those that arise at the intersection of the Product, Process, and People.

• We can use CAD to create highly accurate models of the part geometry that is used to program the machines that produce the parts or produce the tools for making the parts
• We can use CAE to validate the product performance for attributes like strength, fatigue life, stiffness, durability, and other characteristics
• We use FEA to validate the manufacturing processes of the parts whether they are stamped, molded, machined, welded, joined or 3D printed
• But have those solutions addressed how the individual parts, components, and sub assemblies will work in the larger environment of the world as the product is used, or in the assembly plant as the product is produced, or in the garage as the product is serviced? Not really.

It still happens that during prototype build (or pilot build, depending on who you talk to) we are faced with the challenge of putting together all the parts that have up until that point only existed as bits and bytes in math models. And when the people who take those different parts and try to build the product for the first time we might find some new challenges. The component might be inaccessible during assembly, or the required hand tools for joining the component to the sub-assembly can't reach the fastener, or the assembly line tooling does not lift the component sufficiently to access for visibility during loading.

Evaluating product integration is a challenge that many CAD, CAE, and FEA strategies that have been implemented overlook. Until a person attempts to handle the component and perform the installation of that component into the product, we can't envision the challenges faced. Sure, it is possible to to use Digital Mock-Up (DMU) tools to show others how we envision the process of assembly, but those mock-ups are often scripted animations where talented "animators" perform digital puppet shows to illustrate to others how they envision the process proceeding. But they are not tools for engineering discovery; if it is unknown how the component should be loaded, the animation can be scripted to show that. In fact, unless the engineer considers that to be a challenge for the product, process, or people they won't know to take the time to illustrate it.

• How do you predict if your design decisions have negative downstream impact
• How do you get the input of other stakeholders on product and process development
• How do you address the shifting complexity and diversity of products and processes
• How do you evaluate immediate decisions for resolution of requested changes from cross functional reviews

Virtual Integration with VR should let the engineer or other stakeholders interact with the products and perform the same processes that the product will undergo. How is it supposed to move during use, how will installation and service be performed? These questions can be resolved when the prototype is built in the environment. Something that CAD, FEA, and CAE have not yet addressed as a system. To find out more please visit: https://virtualreality.esi-group.com