Browse Topic: Augmented / virtual reality

Items (393)
Small, highly maneuverable Urban Air Mobility (UAM) air taxis might exhibit motions during hover and low-speed flight that are unfamiliar to many passengers, and for which there are no established guidelines to predict passenger comfort. Researchers performed a study in the Armstrong Virtual Reality Passenger Ride Quality Laboratory to identify relationships between sudden motion characteristics and UAM passenger comfort and acceptance. Twenty-three volunteer test subjects from the Armstrong workforce each completed a 15-minute experience as a passenger in a virtual air taxi simulation. Subjects evaluated a series of flight maneuvers with varying levels of sudden motion using a five-point rating scale and indicated which motion(s) they found uncomfortable. Researchers then administered a post-test questionnaire to relate the passengers’ ratings to their willingness to fly on a real air taxi with similar levels of motion. The study results relate peak heave acceleration and jerk to passenger acceptance.
Hanson, CurtRamia, SaravanakumaarBarnes, Kyle
The complex and turbulent ship airwakes make shipboard rotorcraft launch and recovery difficult for even the most seasoned pilots. One of the main challenges to using flight simulation to train pilots is the real-time accurate prediction of the ship airwake. A real-time, accurate methodology that is able to operate on personal computers without computational meshing is being developed for Advanced Air Mobility (AAM) applications. The early success of this novel approach indicates that it may be well-suited to meet the challenge of dynamic interface (DI) applications as well. To explore this, a novel reduced-order model (ROM) to represent unsteady airwakes for shipboard operations is underway. This ROM will be integrated into an ocean-based representative environment model (REM) to close the gap in real-time simulations without significant computational investment. The ROM effort presented here specifically investigates which superstructure wake characteristics are dominant in different regions where flight operations are conducted. Canonical ship geometries that have been significantly studied experimentally and computationally provide the substantiation of this approach. Evaluation of the accuracy of the approach is presented, correlated with Lattice-Boltzmann simulations, theoretical and experimental data.
Oates, BrendenVera Garcia, BraulioSmith, MarilynRauleder, Juergen
This paper investigates the use of multi-modal cueing through full-body haptic feedback to enhance pilot-vehicle system (PVS) performance, reduce mental workload (MWL), and increase situational awareness (SA) in both good and degraded visual environments (GVE/DVE). Piloted simulations were conducted using an H-60-like flight dynamics model in a virtual reality (VR) motion-based simulator, evaluating two ADS-33-like mission task elements (MTEs) – precision hover and slalom – under visual-only and combined visual and haptic feedback conditions in both GVE and DVE. The H-60 flight dynamics were augmented with a dynamic inversion (DI)- based stability augmentation system (SAS), implementing rate-command/attitude hold (RCAH) response type on the roll, pitch, and yaw axes and altitude hold response type on the vertical axis. The SAS was designed to achieve Level 1 handling qualities per ADS-33 standards. The full-body haptic cueing strategy leveraged an outer-loop DI control law, which provided vibrotactile feedback to cue desired roll, pitch, and yaw attitudes to the pilot. Roll cues were delivered via tactors mounted on the upper arms, pitch cues via tactors on the chest and back, and yaw cues via tactors on the calves. Eight test subjects participated in the piloted simulations, including three U.S. Navy test pilots and five subjects with different flying experiences. Results indicated that haptic feedback significantly improved hover performance, reducing MWL and enhancing SA, particularly in DVE. However, in the slalom task, predefined haptic guidance misaligned with pilots’ individual control strategies, leading to performance degradation. This finding highlights the need for pilot-specific adaptive haptic feedback to mitigate inconsistencies in dynamic maneuvering tasks.
Morcos, Michael T.Saetti, UmbertoGeiger, Derek H.Kubik, Stephen T.Breed, Adam R.Crane, Clifton J.Luzzani, GabrieleFischer, Madeline R.Jun, DogyuGary, Evan
ABSTRACT Northrop Grumman has developed a software and hardware solution to provide enhanced 360 degree local situational awareness (LSA) to enable the warfighter with an overmatch capability on today’s modern battlefield. The architecture exploits technological gains in cameras, video processing, and video compression. The approach allows rapid comprehension of local and remote situational views presented with operational relevance for a ground combat platform or tactical wheeled platform crew. The 360 Degree LSA approach provides direct visualization of relative positioning of targets, threats, and lines of fire; and additionally offers common situational understanding / operational picture from the dismounted soldier to higher echelon commands. The approach provides prioritized information through LSA software to provide an enhanced view to the warfighter whereas the squad leader becomes an integral part of the crew with a view of the common operating picture (mounted) and additional sensors on tablet or handheld device (dismounted via wireless). The approach uses a platform agnostic form factor with components that can be selected and applied to legacy or new platforms based on their size, weight, power, and mission constraints.
Viscovich, ChristopherGeoghegan, SusanWorthy, David
This paper describes development and testing of a low-cost device mounted on in the pilot seat of a rotorcraft simulator with the aim of improving the perceived realism of the flight. The device acting vertically from the bottom of the seat is used to communicate changes of acceleration in the vertical direction corresponding to heave movement of the simulated aircraft. A bespoke flight simulator system was developed, featuring modular design and virtual reality (VR) visualisation to enable comparative testing with a full motion system. Objective analyses have shown similarities between the two motion cueing configurations when contrasted with only using visual cues.
Lukasiewicz, MarekQuaranta, GiuseppeZanoni, Andrea
Refueling mid air is considered as important force multiplier for e.g. conducting search and rescue operations. Due to close proximity to the tanker, the refueling hose and drogue as well as the receiver can be strongly affected by the tanker's wake. Thus, the refueling drogue extended from the tanker by a hose is often oscillating from turbulence. Contact with the tanker has to be established by positioning the receiver's refueling probe within the tanker's drogue. During qualification training pilots are instructed to not focus on the drogue, due to its oscillations. This is done since chasing the drogue often leads to over-controlling and therefore mostly to a failed contact attempt. The presented research aims for improving today's Helicopter Air-to-Air Refueling (HAAR) as well as related training efficiency by a gain of understanding in this phenomenon. Therefore, the HAAR real-time simulation scenario at German Aerospace Center's (DLR) Air Vehicle Simulator (AVES) was extended with a multi body hose and a probe/drogue contact model to enable realistic contact initiation. During a piloted campaign, a total of six pilots with different levels of HAAR experience conducted the maneuver. This paper presents an analysis of obtained eye tracking data with regards to gaze entropy, total fixation duration on defined areas of interest and corresponding time history of control inputs. Potential links between gaze entropy and perceived workload that might be observed in the data are also discussed. Results show that the metrics can highlight differences in successful and unsuccessful attempts for contact of HAAR experienced and inexperienced pilots.
Schmidt, SvenJusko, TimGreiwe, Daniel
The National Research Council of Canada (NRC) has recently developed an Integrated Reality In-flight Simulator (IRIS) that allows helicopter pilots to fly the NRC's Bell 412 Advanced Systems Research Aircraft (ASRA) while wearing a commercial off-the-shelf (COTS) virtual reality headset. IRIS is the first airborne simulator of its kind that combines COTS virtual reality and Fly-By-Wire (FBW) synthetic turbulence for helicopter operations. Simulations are not exact replications of actual environments; therefore, a methodology of comparing pilot workload with respect to an analysis of the differences between the simulated and actual environments is required. During a recent flight trial, NRC validated the effectiveness of IRIS to replicate a pilot's workload during ship landing tasks using these workload scales. During the analysis, NRC took initial steps in developing methodologies to examine environmental characteristics and then correlate them to an associated pilot workload. The work also included the initial development of methodologies to analyze pilot workload and alternative prediction methods that better map subjective or quantitative pilot workload data to DIPES.
Comeau, PerryJennings, SionLaw, AndrewWall, Alanna
Flight mechanics modeling and real-time simulation of rotorcraft have many challenges including the aerodynamics and dynamics of the rotor system, rotor inflow, and wake-airframe interactions. Furthermore, interactional aerodynamic effects are difficult to characterize, in particular during early configuration down-selection. Rotorcraft configurations under consideration for advanced air mobility applications are trending toward designs with coaxial rotor systems and multiple distributed propellers / rotors in close-proximity with one another and the airframe. This proximity leads to strong coupling between the rotor inflow and lifting surfaces (e.g., tiltwing and lift+cruise urban air mobility concepts). This paper describes recent work toward the development of a general-purpose modeling framework for flight mechanics analysis and simulation of rotorcraft and aircraft configurations proposed for advanced air mobility applications. This modeling framework was developed for assessment of aircraft ride qualities during urban flight operations; however, the focus of this paper is on the modeling framework development and application. Model validation with experimental data is another focus, examining scaled model data and flight test results.
Keller, Jeffrey D.McKillip, Jr., Robert M.Theron, Jean-PierreSharma, Abhinav
Piloted simulation has been used for decades to support flight test activities at the Naval Air Warfare Center Aircraft Division located at Naval Air Station Patuxent River, MD. Conventional lab stations at the Manned Flight Simulator facility have been used effectively to support a wide range of flight test requirements. However, there were limitations with these conventional lab stations when the purpose was to assess handling qualities and pilot workload while landing rotorcraft aboard a ship. Two critical simulation elements were determined to be necessary: (1) an expanded field of view so the pilot could see the ship deck below the aircraft and (2) a motion system to provide the pilot with vital proprioceptive cueing in the turbulent ship environment. A new Virtual Reality Lab was developed at Patuxent River that included these key features. The primary components of the lab included virtual reality headsets, an Unreal Engine image generator, ocean and ship visual models, a six degree-of-freedom motion platform, and a generic cockpit. This paper describes development of the lab, various issues that were encountered, and plans for future improvements.
Gaublomme, Donald P.Zinchiak, Andrew G.Meyers, Kyle J.Smith, Zachary F.Calvillo, Robert V.
DiNoia, EvaCasanova, RemyBergeonneau, Marie-LineMestre, Daniel
Gladfelter, MatthewMalpica, CarlosHe, ChengjianSaberi, HosseinJohnson, WayneSilva, Christopher
Abstract The tightening of emission standards and homologation rules lead car manufacturers to rely on simulation testing in early development phases. Coupling an engine to a testbench controlled by a real-time simulation environment allows flexible, reliable, and reproducible testing for consumption and emission studies. However, interest in this method referred to as engine-in-the-loop (EiL) is relatively recent and few details can be found regarding the simulation environment. Following previous work, this study details a driver model based on the PI structure and augmented with preview and anti-windup. The focus is set on a conventional powertrain with a manual transmission for which the driver must also manage the clutch pedal during gearshift and take-off phases. Extended analysis of vehicle tests allows defining the driver’s behavior during these phases for different profiles. The driver model is then tested in the EiL environment and the impact of the gearshift profile on fuel consumption and pollutant emissions can be assessed. Besides the slight increase in fuel consumption, results show that increasing the gearshift duration degrades the regulation of the richness by the ECU, thus increasing CO engine-out emissions as well as decreasing NOx emissions. Finally, results suggest that a longer gearshift also affects the catalyst efficiency, which results in higher NOx tailpipe emissions.
Gilormini, ThomasChessé, PascalTauzia, XavierColin, Hervé
Virtual Simulation-Based Training for Aviation Maintenance Technicians: Recommendations of a Panel of Experts2021-01-00383/2/2021
A well implemented and suitable training plan makes a company's operations more effective. In the aviation industry, qualified maintenance technicians are one of the most significant assets to improve safety of passengers and reliability of air transportation. This paper investigated the effectiveness of virtual simulation-based training in the aviation maintenance. It garnered data from a panel of experts to discover if virtual simulation-based training can be used instead of the traditional training techniques to train maintenance technicians. From the aviation industry in Saudi Arabia, 11 experts were selected and interviewed. Experts were asked 9 questions seeking their opinions on utilizing the virtual reality technology on the aviation maintenance training, and if it can overcome the limitations of utilizing traditional methods while providing the needed skills. The panel of experts agreed that this technology is an efficient, practical, and doable method to be used in the aviation maintenance training. It provides a risk-free technique to train technicians. However, they stated that this technology should be used in combination with the traditional training methods to avoid potential problems and limitations, such as lack of equipment, time consuming, and exposing trainees to dangerous situations when using the traditional methods, and to avoid challenges, such as information technology (IT) infrastructure, high cost of implementation, lack of accountability, and more importantly, not offering a real sense of equipment when using the virtual reality technology. Therefore, the panel of experts recommended that this technology should be used as a Recurrent Technical Training (RTT) for maintenance technicians who already received an Initial Technical Training (ITT) using traditional techniques, hands-on training, for instance.
Alasim, FahadAlmalki, Hamed
Helicopters are routinely used to transport crew to and from maritime wind farms. Inclement weather situations and demanding tasks put a high workload on pilots during these missions. This paper describes two test campaigns assessing the utility of a low cost Head-mounted display (HMD) to reduce workload for commercial maritime operations. This system was implemented within the Air Vehicle Simulator (AVES) at the German Aerospace Center (DLR). Three tasks were flown with experienced offshore pilots, performed in a realistic scenario. Independent subjective assessments of both workload and situational awareness were obtained. Results from the studies show that the overall workload for all missions decreased when using the HMD. Opinions regarding overall benefit and advantages of the system were found to vary between pilots and missions.
Maibach, Malte-JörnJones, MichaelWalko, Christian
A pilot-in-the-loop simulation environment aimed at increasing pilot visual cues without the need of expensive visualization hardware is presented. The proposed solution relies on Virtual Reality (VR) to enhance the pilot immersion in the simulated environment. The project is integrated in the development of the complete simulation framework FRAME-Sim, focused on simulating rotorcraft in early conceptual design stages, and therefore relying on physics-based multibody simulation of the rotorcraft flight dynamics and free/open source software. FRAME-Sim visual environments that are being used include products available to the market as well as homemade solutions developed to obtain the highest level of versatility during the simulation.
Daniele, MatteoZanoni, AndreaQuaranta, GiuseppeMasarati, Pierangelo
A deep-learning powered single-strained electronic skin sensor can capture human motion from a distance. The single strain sensor placed on the wrist decodes complex five-finger motions in real time with a virtual 3D hand that mirrors the original motions. The deep neural network boosted by rapid situation learning (RSL) ensures stable operation regardless of its position on the surface of the skin.
Nonlinear Model Predictive Control of Autonomous Vehicles Considering Dynamic Stability Constraints2020-01-14004/14/2020
Autonomous vehicle performance is increasingly highlighted in many highway driving scenarios, which leads to more priorities to vehicle stability as well as tracking accuracy. In this paper, a nonlinear model predictive controller for autonomous vehicle trajectory tracking is designed and verified through a real-time simulation bench of a virtual test track. The dynamic stability constraints of nonlinear model predictive control (NLMPC) are obtained by a novel quadrilateral stability region criterion instead of the conventional phase plane method using the double-line region. First, a typical lane change scene of overtaking is selected and a new composited trajectory model is proposed as a reference path that combines smoothness of sine wave and comfort of linear functional path. Reference lateral velocity, azimuth angle, yaw rate, and front wheel steering angle are subsequently taken into account. Then, by establishing a nonlinear vehicle dynamics model where Magic Formula of nonlinear tire model is adapted, the quadrilateral vehicle stability region is defined in consideration of designed velocity, road adhesion coefficient, and front wheel steering angle. Working condition-variant constraints determined by the boundaries of the quadrilateral region are subsequently obtained to guarantee the stability and vehicle performance. Finally, a nonlinear motion state space model with measured and unmeasured disturbance for NLMPC tracking maneuver is proposed, Meanwhile, a multi-objective cost function based on track error, ride comfort, and the smoothness of control derivative is established. Laguerre functions are applied to design optimal control trajectory and Hildreth’s quadratic programming procedure is introduced to find converged solutions meeting constraints derived from previously investigated quadrilateral stability region for sake of lightening computation load and finding better numerically conditioned solutions of control when NLMPC is implemented online. The configuration of a real-time virtual test track is explained and the NLMPC algorithm is validated. The simulation and experiment results are illustrated to show the effectiveness of the designed nonlinear model predictive control scheme under the test of the overtaking scene compared with the conventional driver control. This work may provide a useful basis for researches of autonomous vehicle lane change in terms of track accuracy, ride comfort as well as stability.
Chen, XunjieWu, GuangqiangRen, Meng
Hardware-in-the-Loop Testing of Electric Traction Drives with an Efficiency Optimized DC-DC Converter Control2020-01-04624/14/2020
In order to reduce development cost and time, frontloading is an established methodology for automotive development programs. With this approach, particular development tasks are shifted to earlier program phases. One prerequisite for this approach is the application of Hardware-in-the-Loop test setups. Hardware-in-the-Loop methodologies have already successfully been applied to conventional as well as electrified powertrains considering various driving scenarios. Regarding driving performance and energy demand, electrified powertrains are highly dependent on the dc-link voltage. However, there is a particular shortage of studies focusing on the verification of variable dc-link voltage controls by Hardware-in-the-Loop setups. This article is intended to be a first step towards closing this gap. Thereto, a Hardware-in-the-Loop setup of a battery electric vehicle is developed. The electric powertrain consists of an interior permanent magnet synchronous machine and an inverter, which are set up as real components at a laboratory test bench. The test bench is connected to a real-time vehicle simulation including a battery model and the dc-dc converter model. The entire Hardware-in-the-Loop setup is successfully validated by vehicle measurements performed on a chassis dynamometer. Thereafter, the battery electric vehicle is tested at this Hardware-in-the-Loop setup for the worldwide harmonized light vehicle test cycle class 3. The tests are performed for electric powertrain configurations with and without dc-dc converter. For the application with dc-dc converter, reductions in energy losses of the traction machine by 5.4% and of the traction inverter by 37.6% are determined. This leads to an efficiency improvement of the entire electric powertrain by 1.5 percentage points, which results in a total energy reduction by 0.28 kWh/100km for the investigated test cycle. This use case demonstrates the efficiency improvements of a variable dc-link voltage and how Hardware-in-the-Loop tests can support the verification of dc-dc converter controls during frontloading phases of automotive development programs.
Etzold, KonstantinScheer, RenéFahrbach, TimmZhou, ShuangGoldbeck, RafaelGuse, DanielFrie, FabianSauer, Dirk UweDe Doncker, Rik W.Andert, Jakob
High Altitude Platform System Airship for Telecommunication and Border Monitoring Design and Physical Model2020-01-00443/10/2020
This paper presents an accurate analysis of an innovative high altitude platform with an unconventional ellipsoidal shape during the most critical operation. The airship is designed accordingly to the specifications, which have been analyzed in terms of the required CONOPS (Concepts of Operations) which are associated with the proposed High Altitude Pseudo-Satellite (HAPS) technology and special operations and to analyze the operational scenarios. An innovative cruiser feeder system is defined and studied. The CONOPS includes communications relays, support of intelligence, surveillance, target acquisition monitor “mobile targets”, and reconnaissance, including long-range ISTAR missions performed by the feeder, combining satellite vision and HAPS vision for a forest fire, disasters, naval accidents, maritime and ground borders. The paper realizes a multidisciplinary analysis that allows creating the design of the HAPS, referring to both cruiser and feeder in different operative scenarios. It is expected to produce the preliminary basis for a future digital twin based design to generate the best possible configuration by mean of implementing multiphysics simulations. Structured object-oriented design processes involve developing several different system models and configurations. The modular design of the core modules is necessary for both ensuring the adequate performances, the capability of satisfying the operative necessities which have been defined by the CONOPS and fulfilling the requirements.
Trancossi, Michele
An IMPC Based Parking Assistance System2019-01-261410/22/2019
This paper summarizes progress and outcome from our research projects on IMPC-based parking management system, including parking motion planning and control strategy, as well as a searching strategy for parking spot. IMPC here refers to interactive model predictive control regime, which is characterized in that multiple agents implementing separate MPC strategy are incorporating information about their state, objective, and constraints. To predict future parking parameters, we proposed a practical framework which integrates anticipatory techniques with a model predictive approach that robustly models the stochastic parking environment. The framework is able to take into account the interactions between vehicle subsystems, and can optimize trajectory under complex traffic patterns in real-world scenarios. Adaptive model predictive control is utilized to optimally minimize a cost function regarding performance, energy efficiency and drivability with regard to surrounding vehicle states. Dynamic programming was used to solve the control objective under multiple constraints, which yielded superior performance in comparison with convex programming. An original navigation system was developed for leading user to the parking spot in case of forgetting exact location, which is characterized in that swift location and path are generated by BLE-based sensor fusion. After successful parking action, the system beacons the parking location and transmits data to mobile equipment of user, which serves as goal of searching task. Simulation results show promising expected cost minimization in typical parking environments under consideration of fuel efficiency, parking time and distance to destination. Meanwhile, the state of art park spot search module is able to shorten the time for drivers to locate their vehicle with positioning error of less than 1.5 meter.
Ouyang, QianyuJia, Xianzhe
Advanced Mathematical Modelling for Glass Surface Optimization with PSO2019-28-010410/11/2019
In automotive door engineering, fitting the side door glass surface from styling into the cylinder or torus is the basic requirement. Optimization is required to do this, which requires a solver which could be efficacious for best surface fitting. This paper propounds a methodology which could be used for fitting a side door glass surface from styling into the cylinder or torus. The method will significantly help in developing the required surface and can successfully eliminate the cumbersome manual calibrations. The mathematical model mentioned is a novel approach based on “Particle Swarm Optimization” (“PSO” will be used to represent in the paper) towards surface optimization technique. VB script is used to make it applicable in CATIA but could be easily applied in any other programming language like python, java etc. Usually the surface fitting problems deals with the initial guess of the required surface and then its further optimization. Herewith we have discussed some geometrical methods to find the initial guess of the cylindrical and toroid surface and then Particle Swarm Optimization for refining of the obtained data. This article aims at providing the best surface fit at the initial stage itself so that the faster output convergence rates are achieved. The proposed algorithm is efficient and easy to code, and the experiment results indicate its effectiveness. Since we have avoided analytical method and used an evolutionary stochastic approach in the process in which the chances of getting stuck in local minimum are very limited.
Pandey, PawanAskari, HasanRaadhaasaminathan, Sreebalajinarayanan
Cooperative Ramp Merging System: Agent-Based Modeling and Simulation Using Game Engine12-02-02-00085/16/2019
Agent-based modeling and simulation (ABMS) has been a popular approach for modeling autonomous and interacting agents in a multi-agent system. Specifically, ABMS can be applied to connected and automated vehicles (CAVs) since CAVs can operate autonomously with the help of onboard sensors, and cooperate with each other through vehicle-to-everything (V2X) communications. In order to improve energy efficiency and mobility of traffic, we have developed an online feedforward/feedback longitudinal controller for CAVs to cooperatively merge at ramps. Agent-based CAV models were built in the Unity3D environment, where vehicles are given connectivity and autonomy through C#-based scripting application programming interface (API). Agent-based infrastructure model is also built as a Unity3D simulation network based on the city of Mountain View, California. A simulation of cooperative on-ramp merging is carried out with a distributed consensus-based protocol, and then compared with the human-in-the-loop simulation where the on-ramp merging vehicle is driven by four different human drivers on a driving simulator. The benefits of introducing the proposed protocol are evaluated in terms of travel time, energy consumption, and pollutant emissions. The results show that the proposed cooperative on-ramp merging protocol can reduce average travel time, energy consumption, and pollutant emissions by 7%, 8%, and 58%, respectively, when compared to the human-in-the-loop scenario.
Wang, ZiranWu, GuoyuanBoriboonsomsin, KanokBarth, Matthew J.Han, KyungtaeKim, BaekGyuTiwari, Prashant
Robust Validation Platform of Autonomous Capability for Commercial Vehicles2019-01-06864/2/2019
Global deployment of autonomous capability for commercial vehicles is a big challenge. In order to improve the robustness of autonomous approach under different traffic scenarios, environments, road conditions, and driver behaviors, a combined approach of virtual simulation, vehicle-in-the-loop (VIL) testing, proving ground testing, and final field testing have been established for algorithms validation. During the validation platform setup, different platforms for different functionalities have been studied, including open source virtual testing environment (CARLA, AirSim), and commercial one (IPG). We also cooperate with MCity to do proving ground validation. In virtual testing, the functionality of sensors (camera, radar, Lidar, GPS, IMU) and vehicle dynamic models can be applied in the virtual environment. In VIL testing, real world and virtual test will be connected for different validation purposes. The proving ground testing will be performed in real environment with rich scenarios and high safety. Several challenges have been overcome during implementation, including data transmission, computing time, sensor system consistency, vehicle dynamic model consistency and etc. In this paper, a robust autonomous driving validation platform, including perception, planning and control algorithm, will be introduced in different virtual and physical validation approaches. Several test case studies for algorithm testing will be discussed. And conclusions will be made on the established validation platforms and next steps for the development and improvement of commercial vehicle’s autonomous capability.
Sun, YongLi, HanxiangPeng, Weilun
Tolerance Management in a Semi-Automated and Collaborative Human-Robot Aircraft Riveting Process2019-01-13733/19/2019
Large aircraft sizes with high precision requirements combined with complex joining tasks are typical challenges for aircraft production. To increase competitiveness and effectiveness, the automation of such production processes seems a viable solution for companies in the aircraft sector. When implementing automation, in order to handle small batch sizes and high variation while adhering to tight tolerances, the production equipment must meet high quality standards and flexibility requirements. To achieve the objectives above, tolerance management is essential: deviations are acceptable within limits, as long as they do not result in quality losses and expensive rework. For these reasons, all the interactions between the product, production process and production equipment used must be analyzed in detail. The importance of this analysis is evident in assembly where new technologies are used, such as (semi-)automation using Human-Robot-Collaboration. Despite its innovative value, this approach must be robust, within tolerances and have minimal deviations from the outset. However, current planning and optimization of deviations and tolerances lack properly developed methods and approaches. This paper proposes a method for securing and achieving proper tolerance in assembly processes: characteristic trees and tolerance chains are simple methods to make tolerance management more effective and attractive. The method combination promotes understanding of interactions and communication between all those involved in the development of products and the associated processes. The methods developed are validated using a semi-automated riveting process, with Human-Robot-Collaboration, to complete a joining process in the assembly of the aft section. In this scenario the pressure bulkhead is mounted to the section barrel by means of hundreds of rivets. The intention is to implement a semi-automated production process to improve ergonomics, increase process traceability and efficiency, and minimize rework while meeting tolerance requirements.
Mueller, RainerVette-Steinkamp, MatthiasSchirmer, LeonieMasiak, Tobias
Collaboration in a Hybrid Team of Human and Robot for Improving Working Conditions in an Aircraft Riveting Process2019-01-13723/19/2019
Aircraft production is facing various technical challenges, such as large product dimensions, complex joining processes, and organization of assembly tasks. Overcoming such challenges, as well as maintaining low tolerances and small batch sizes, is often difficult to achieve whilst retaining economic viability. ZeMA believes that a semi-automated approach is the most effective way to optimize aircraft section assembly. This can be achieved with a semi-automated riveting process for solid rivets, using Human-Robot-Collaboration in combination with an intuitive Human-Machine-Interaction operating concept. In the assembly of aircraft structures - in this scenario the aircraft aft section - the pressure bulk head is mounted to the section barrel. Two operators work collaboratively in uncomfortable, non-ergonomic positions, yet of course have to maintain exacting quality standards. In order to improve this process, a dynamic task sharing strategy between human and robot according to their respective skills, with due consideration given to ergonomic factors is proposed. The ideal solution involves placing a robot inside the section barrel. The robot’s workspace is expanded by mounting it on top of a lifting unit so that it can position the anvil properly. In the meantime, the human performs the more complex tasks of inserting the solid rivets and operating the riveting hammer from outside the section barrel. In order to carry out the assembly tasks efficiently, the following components must be implemented: Human-Robot-Collaboration based on natural and intuitive interaction possibilities, and smart mixed reality devices for communication between human and robot in the hybrid team. By implementing a modular control system for configuration and operation of the assembly station with a variety of interaction possibilities, human and robot can perform the collaborative riveting process more efficiently than human operators alone. Additionally, due to the high forces and vibrations applied by the riveting hammer, a process-specific tool has been developed to prevent damage to the robot system. The implementation of natural and intuitive interaction within the Human-Robot-Collaboration achieves operator acceptance, improves ergonomics and therefore effectively optimizes aircraft production. The results are part of the European Union’s Horizon 2020 research and innovation program, and present semi-automation as shown in the HRC riveting process.
Mueller, RainerVette-Steinkamp, MatthiasKanso, AliMasiak, Tobias
Automotive Engineering: March 201919AUTP033/1/2019
Rethinking the HUD Advanced tech solutions move toward augmented reality to bring greater capability to head-up displays. Motor matters New designs and materials are key to the next generation of electric machines for EV propulsion. Harnessing the power of Sim Serious cost savings could come from eliminating vehicle- and systems-level tests. Powerful simulation tools may be the only way to tackle the increasing complexity in mobility development. An OBE for the SAE Meet Paul Mascarenas-SAE International's 2019 president. He's a staunch advocate for professional development for engineers amid the mobility industry's transformation. Solving the propulsion puzzle Must-attend expert panels at SAE's WCX '19 will cover the propulsion-tech future like no other. Editorial Kill the EV tax credit by 2025 SAE Standards News SAE and Synopsys collaborate on cyber study Supplier Eye New Co. vs. Old Co. What We're Driving Supra's revival is Toyota's spin on German engineering 2020 Explorer is the first product to emerge-more quietly-from Ford's newest NVH lab Nissan concept sport sedan is all-electric, driver-optional MEET a new propulsion proposition for Mahle Continental's new CTO to lead retooled R&D pillar New V8, big towing, trick features and tech for 2020 Chevy Silverado HD FCA debuts new Ram Heavy Duty pickups 2020 Ford Super Duty debuts all-new OHV V8 2019 Chevrolet Blazer just right for the voracious SUV market Q&A Mazda's Masahiro Moro
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