Virtual Product Creation in Industry: The Difficult Transformation from IT Enabler Technology to Core Engineering Competence

Contents
Abbreviations
List of Figures
List of Tables
1 Motivation and Approach
2 Prologue—Understanding the Difference in Approach
2.1 Pioneering in Self-made Mode by Technical Experts
2.2 Scaling-Up by Growing Digital Design and Analysis Groups with Customized Solutions
2.3 Desire to Restrict—The Dilemma of Limited Understanding of the Role of Virtual Product Creation
2.4 The New Digital Presence—Living a New Understanding of Information Based Value Creation
3 The Big Picture—Information Technology in Enterprises
3.1 Introduction and Basics
3.2 History of Information Technology (IT)
3.2.1 Hardware: From Numbering and Mechanics Towards Electronics
3.2.2 Software: The Key Role of Operating Systems of Modern Computers
3.3 The Set-Up of IT in Industrial Companies
3.3.1 History of IT Technical and Organizational Drivers in the Twentieth and Twenty-First Century
3.3.2 Today’s IT Factory Set-Up and Future Business Concepts
References
4 Virtual Product Creation (VPC) Explained
4.1 The New Engineering Discipline Virtual Product Creation
4.2 Virtual Product Creation Capabilities and Activities
References
5 The Technology History of Virtual Product Creation
5.1 The History of Computer Aided Design (CAD) Systems and Geometric Modeling
5.2 Digital Product Validation and Verification
5.2.1 Introduction into Validation and Verification (V&V)
5.2.2 Evolution of V&V Technologies and Computer Aided Engineering (CAE)
5.3 Product Data Management (PDM)
References
6 The Set-Up of Virtual Product Creation in Industry—Best Practices, Error Modes and Innovation Speed
6.1 Basics Awareness and Sense for Change
6.2 Understanding Ownership of Skillset—The Difference Between Traditional Engineering Skillset and New Digital Skillset
6.3 Understanding the Nature of Virtual Product Creation Collaboration in Development Project Execution
6.4 The Traditional Set-Up of Virtual Product Creation and Its Flaws
6.5 The New Role of Virtual Product Creation—Evolving from IT Technology Towards Engineering and Lifecycle Competence
6.6 Best Practices of Integrating Virtual Product Creation into Mainstreaming Engineering
References
7 Major Technology 1: Computer Aided Design—CAD
7.1 Engineering Understanding of CAD
7.1.1 Why Does an Engineer Use CAD?
7.1.2 What Does CAD Do for an Engineer?
7.2 How Does CAD Work?
7.2.1 System Architecture of a CAD System
7.2.2 CAD Modeling Technologies
7.2.3 Geometry Processing and Topology
7.2.4 Volume Model Types
7.2.5 Mathematical Representation
7.3 Basic Technologies
7.3.1 Feature-Based Modeling
7.3.2 Parametric Modeling
7.4 Advanced Technologies
References
8 Major Technology 2: Computer-Aided Industrial Design—CAID
8.1 Engineering Understanding of CAID
8.1.1 Why Does an Engineer Use CAID Instead of CAD?
8.1.2 Where is CAID Being Used?
8.2 How Does CAID Work?
8.2.1 How Does a Classical Design Process Use CAID?
8.2.2 Input Devices
8.2.3 Three-Dimensional Immersive Modeling
8.3 Advanced Technology of CAID
References
9 Major Technology 3: CAPP, CAM and NC Technology
9.1 Computer-Aided Process Planning—CAPP
9.1.1 Engineering Understanding of CAPP
9.1.2 How Does CAPP Work?
9.1.3 CAPP Methodology and Technology
9.1.4 Requirements for CAPP
9.1.5 CAPP Challenges and Problems
9.2 Computer-Aided Manufacturing—CAM
9.2.1 CAD/CAM Integration
9.2.2 Engineering Understanding of CAM
9.2.3 Why Does an Engineer Use CAM?
9.2.4 What Are the Benefits of CAM?
9.2.5 CAM Technology and Process
9.3 Numerical Control—NC
9.3.1 Engineering Understanding of NC
9.3.2 How Does NC Work?
References
10 Major Technology 4: Computer Aided Engineering—CAE
10.1 Background and Evolution of CAE
10.2 Engineering Understanding of CAE
10.2.1 Why Does an Engineer Use CAE?
10.2.2 What is CAE Doing for an Engineer?
10.3 How Does CAE Work?
10.4 CAE in Product Development
10.4.1 From CAD to CAE—CAE Model Build
10.4.2 Interfaces/Formats to Transfer CAD Models to CAE
10.4.3 Pre-processing of a FEA Model
10.4.4 Utilizing FEA Models Within Optimization Problems
10.5 Advanced CAE Technologies
10.6 Exemplary Automotive FEA Project Cases
10.7 Final Remarks
References
11 Major Technology 5: Product Data Management and Bill of Materials—PDM/BOM
11.1 Introduction of PDM and BOM
11.2 Engineering Understanding of PDM and BOM
11.2.1 What is PDM Doing for an Engineer?
11.2.2 What is BOM Doing for an Engineer?
11.3 How Does PDM Work?
11.4 How to Integrate PDM in Large Scale PLM Environments?
11.5 How to Customize PDM/BOM to Company PLM and VPC Needs?
11.6 Expected Changes in Future Industrial PDM/PLM Operations
References
12 Major Technology 6: Digital Mock-Up—DMU
12.1 Engineering Understanding of DMU
12.1.1 Why Does an Engineer Use DMU Instead of CAD?
12.1.2 What Does DMU Do for an Engineer?
12.2 The Role of a DMU in Product Development
12.3 Usage of Different DMU Types
12.3.1 Static Digital Mock-Up
12.3.2 Dynamic Digital Mock-Up
12.3.3 Functional Digital Mock-Up (“Functional Mock-Up”)
12.4 DMU Set-Up and Model Building
12.5 DMU Based Engineering Analysis Work
References
13 Major Technology 7: Virtual Reality—VR
13.1 Engineering Understanding of Virtual Reality
13.1.1 Why Does an Engineer Use Virtual Reality?
13.2 How Does Virtual Reality Work?
13.3 Virtual Reality Technologies
13.3.1 Setup of the Overall Virtual Reality System Architecture
13.3.2 Head Mounted Displays, 3D Glasses, Projection Displays
13.3.3 Tracking
13.4 Human Interaction with VR
13.4.1 Development and Use of VR Applications
13.5 Use of VR for Engineering Working Tasks
13.5.1 Technological Limitations
13.5.2 VR Applications
13.5.3 Summary of the Technology’s Benefits and Main Trends
References
14 Major Technology 8: Augmented Reality—AR
14.1 Engineering Understanding of AR
14.2 Why Does an Engineer Use AR?
14.2.1 What is AR Doing for an Engineer?
14.3 How Does AR Work?
14.4 AR Technologies
14.4.1 Setup of AR HMDs/System Architecture
14.4.2 Tracking
14.5 Human Interaction
14.6 Development for AR Applications
14.6.1 System Selection for Industrial AR
14.6.2 Implementation Design
14.7 Technological Limitations to Overcome
14.8 Summary of the Technology’s Benefits and Main Trends
References
15 Major Technology 9: Digital Factory—DF
15.1 Engineering Understanding of the Digital Factory
15.1.1 Why Does an Engineer Use Digital Factory?
15.1.2 What is Digital Factory Doing for an Engineer?
15.2 How Does the Digital Factory Work?
15.3 Process and System Implementation of the Digital Factory
15.3.1 Logistics- and Production Flow Simulation
15.3.2 Automation Technologies/Robotics
15.3.3 Simulation of Manual Labor/Ergonomics
15.4 Digital Factory Technologies
15.4.1 Digital Factory Basic Modeling Technologies
15.4.2 Layout Planning
15.4.3 Factory-Digital Mock-Up (DMU)
15.4.4 Behavior Models
15.4.5 Electronics and Controls
15.4.6 Basic Simulation Technologies
15.4.7 Virtual Commissioning and Robotic Simulation
15.4.8 Material Flow Simulation
15.4.9 Ergonomics Validation
15.5 Advanced Technologies
15.5.1 Consistent Data Modeling and Exchange
15.5.2 Virtual Reality Used in the Context of Digital Factory
15.5.3 Human–Robot-Collaboration
References
16 Major Technology 10: Artificial Intelligence (AI) in Virtual Product Creation
16.1 What is Intelligence? What is Artificial Intelligence?
16.2 Knowledge-Based Systems and Their Application in Industry
16.3 Machine Learning—The Most Widely Used AI Subfield in Industry
16.3.1 Deep Learning
16.3.2 Standard Process for Machine Learning Projects
16.4 (Big) Data in Product Lifecycle Management
16.5 Internet of Things
16.6 Example of a Virtual Product Creation AI Application
16.6.1 The Main Function Description
16.6.2 Best Practice
References
17 The Hidden Demands of the Engineering Community
17.1 Hidden Engineering Demand #1: Intra Company Competence to Drive the Digital Future
17.2 Hidden Engineering Demand #2: Robust and Professional IT Application Integration
17.3 Hidden Engineering Demand #3: Digital Simplicity and Joy
17.4 Hidden Engineering Demand #4: Personal Assistance to Avoid Failure Intrinsic Work
17.5 Hidden Engineering Demand #5: Self-modifiable Personal Digital Working Environments
17.6 Hidden Engineering Demand #6: Quick and Continuous Improvement
17.7 Hidden Engineering Demand #7: Flexible Digital Test Beds in Production IT Environments
17.8 Hidden Engineering Demand #8: True Appreciation for Digital Responsibilities
17.9 Hidden Engineering Demand #9: Upfront Simulation of Digital Engineering Collaboration
17.10 Hidden Engineering Demand #10: New Advanced Human Interfaces
18 The Challenge of Modifying Management Leadership Behavior Towards Virtual Product Creation in Industry
18.1 Needs for Improved Digital Leadership of Management in Virtual Product Creation
18.2 Management Behavior Do’s and Don’ts in Digital Leadership
18.3 Development of Future Digital Leaders in Management
Reference
19 The Role of Digital Technology Vendors
19.1 The Set-Up of Digital Technology Vendors
19.2 The Role of Digital Technology Vendors in Virtual Product Creation
19.3 Transformations in Digital Technology Vendor Business
19.4 Perspectives by Digital Technology Vendors
References
20 Industrie 4.0 and IoT Technologies
20.1 Industrie 4.0
20.1.1 The Concept, the Initiative and the Vision
20.1.2 The Platform Initiative
20.1.3 The Industrie 4.0 Roadmap Ahead
20.2 Digital Twin Concept
20.2.1 Digital Twin Definition
20.2.2 Digital Twin Classification
20.2.3 Digital Twin Use Case Examples
20.3 The Internet of Things (IoT)
20.3.1 The Global Internet and Its Evolution
20.3.2 Internet of Things (IoT)
20.3.3 IoT Connectivity Stacks
20.4 Cloud, Edge and Platform Technologies
20.4.1 Cloud Computing
20.4.2 Edge Computing
20.4.3 Interaction of Cloud and Edge Computing and Platform Technologies
20.5 Exemplary Industry Application of Industrie 4.0
20.5.1 Efficiency in Manual Assembly Through Connected Processes
20.5.2 Agility and Flexibility Through Autonomy— The Matrix Production
References
21 Future Virtual Product Creation Solutions with New Engineering Capabilities
21.1 Model-Based Systems Engineering (MBSE)
21.1.1 Motivation and Needs for MBSE as New Extension of VPC
21.1.2 MBSE Foundation on and Differences to Systems Engineering Principles
21.1.3 Theory and Principles of MBSE
21.1.4 Disciplines of MBSE
21.1.5 Core Elements of the New MBSE Approach
21.1.6 Co-existence and Interaction with VPC Major Technologies
21.1.7 Examples of New MBSE Methods and Tools
21.1.8 The Challenge of Integrating MBSE into Industry
21.2 Data Engineering and Analytics (DEA)
21.2.1 Data Value Understanding (DVU)
21.2.2 Data Need Definition (DND)
21.2.3 Data Collection (DC)
21.2.4 Data Modeling and Management (DMM)
21.2.5 Data Contextualization (DCx)
21.2.6 Data Identification and Interpretation (DII)
21.2.7 Data Modeling and Data Analytics (DMDA)
21.2.8 Data Visualization (DV)
21.2.9 Conclusions
21.3 Digital Twin Engineering (DTE)
21.4 Digital Platform Engineering (DPE)
21.5 Human Skill Sets for Future Virtual Product Creation
21.6 The Engineering System of the Future
References
Acknowledgement