Virtual Prototype of the Tunnel Boring Machine and

Movement Simulation in DIVISION MOCKUP2000i2

Lun Li, Jishun Li, Wei Ma, Yujun Xue, and Yonggang Liu

Henan University of Science and Technology,

Henan Key Lab for Machinery Design and Transmission System
lilunxn@tom.com, li_jishun@163.com, mawei-mail@163.com,
xue_yujun@163.com, martin_lyg@163.com

Abstract. The virtual reality is a multi-functional, interactive and immersible

technology. As an advanced engineering design technology, the virtual reality
technology (VRT) has been widely used in large mining machinery design and
manufacturing. The system is based on DIVISION Mockup2000i2 software.
Virtual prototype of the Tunnel Boring Machine (TBM) is studied in this paper.
In addition, the movement simulation of TBM is completed in DIVISION
Mockup2000i2. Firstly, CATIA software is adopted to build the parts of TBM.
The TBM is assembled in CATIA too. Secondly, the THEOREM software is
applied to convert the assembled model of TBM to another format which can be
identified in DIVISION MOCKUP2000i2 software.
In order to make the TBM image living, life-like and easy to browse, the
light of surface, virtual materials and landmark scenes are set up in DIVISION
MOCKUP2000i2 software environment. All motion parameters of the parts are
defined before the simulation. Then, the virtual movement simulation of TBM
components is analyzed with the behaviors property of MOCKUP. The virtual
movement of cutting wheel, screw conveyor machinery and the door of mud out
are studied. The virtual movement of segments and segment erector machine
are completed by setting up virtual parts and virtual event. Five segments are
fixed accurately in a cycle. The relations and interference of the parts move-
ment are examined simultaneity. The hotkey is defined before the simulation,
which can trigger the continuous implementation of virtual motion.
In addition, a virtual voice is used to enhance the performance of movement
simulation. The virtual prototype of TBM being set up and simulated will have
positive significance for design inspection, structural analysis and product in-
troduction without TBM physical prototype being manufactured.

Keywords: Virtual Prototype, Simulation, Tunnel Boring Machinery, DIVI-

SION MOCKUP2000i2.

1 Introduction

In traditional mechanical design and manufacturing process, first of all, the concept of
program design and plan demonstration will be completed, and then the product

G. Huang et al. (Eds.): DET2009 Proceedings, AISC 66, pp. 525–532.

springerlink.com © Springer-Verlag Berlin Heidelberg 2010
526 L. Li et al.

design is carried out. When the design has been completed, the physical prototype
usually needs to be made for test. In order to verify the design, sometimes even these
tests are destructive. When the defects in physical prototype were found out by ex-
periment, the engineers need to modify the design and to make prototype again. And
then, the engineers can verify the design further. Only through much more cycles
which include of design, making physical prototype and testing, the product perform-
ance would meet the user’s requirement. This process of design and manufacturing is
too long, especially for complex machinery systems. The traditional design process
not only delay the design periods, but also unable to adapt to the market's rapid re-
sponse mechanism (VISUAL ADVANTAGE International ltd, 2003; Burdea, 2003;
Ron, 1998; Yosh, 1996; Cui, 2005). So with this traditional concept of the design and
manufacture of machinery, it will increase the enterprises cost of design and manufac-
turing, and postpone the time of new products to enter market (Ron, 1998; Yosh,
1996; Cui, 2005; Xiong, 2004).
The virtual reality technology (VRT) is a multi-functional, interactive and im-
mersible technology, which create a life-like image of the entire product and three-
dimensional figure of the whole model (VISUAL ADVANTAGE International ltd,
2003; You, 2004; Gibson, 1993; Gomes, 2001; Bov, 2000). The product model cre-
ated in computer is called digital mockup (DMU). With interaction between the user
and a variety of peripheral equipment, it can be actualized for complex product’s dis-
playing, kinematic analyzing and assemble simulation. The vision, hearing and other
feedback information would be created, which make people same feeling as in real
world. As an advanced design concept, Virtual reality technology is a practical means
in the field of machinery design and manufacture (Wang, 2002; Huang, 2004).
As one of the large-scale mining machinery and equipment, Tunnel Boring Ma-
chine (TBM) includes many areas of science and technology, such as machine, elec-
tricity, hydraulic pressure and control etc (VISUAL ADVANTAGE International
ltd, 2003; Bauer, 2008; McKean, 2005; Mroueh, 2008). Designing and analyzing of
the TBM relate to mechanical, electronic, hydraulic and control many technology
areas, and need an integrated platform for development and analysis. The traditional
development model of physical prototype can not meet a complex product, such as
TBM. Virtual prototyping technology is applied to development and designing of
TMB, which can effectively overcome the defects of traditional research and design
model of the physical prototype, reduce development costs, shorten the test period,
and accelerate research and development of TBM process (VISUAL ADVAN-
TAGE International ltd, 2003; Cui, 2005; McKean, 2005; Mroueh, 2008; Zhang,
2008).

2 The Process Route of Creating TBM Virtual Prototype

The process route of creating TBM virtual prototype and softwares which is used in
this paper are shown in Fig .1.
 Virtual Prototype of the Tunnel Boring Machine and Movement Simulation 527

Creating model of TBM in CATIA software environment

Checking drawings Modeling parts of TBM Product assembly

of TBM

Creating virtual
prototype Model conversion
Mockup2000i2
software

Virtual prototype Data conversion

Theorem
software

Creating functional simulation

Mockup2000i2
software

Functional simulation
dv/MPO model

Fig. 1. The process route of creating TBM virtual prototype

3 Modeling and Assembling of TBM in CATIA Environment

In the environment of CATIA software, the module of part design is used to establish
the parts of TBM’s three-dimensional parameter model with the characteristics of
physical and geometric. The assembly of TBM mainly includes some component as-
sembly, such as the cutting wheel assembly, the shield tail, segment erector machine,
screw conveyor machine, door of mud out, cutting ring, driven box, supporting ring,
segments, swivel joint of center etc. In modeling process of TBM’s parts, it is very
important to choose coordinate system. The direction of modeling parts’ coordinate
system should be ensured to be identical with the general direction of the TBM as-
sembly as far as possible, which is to provide more conveniency of movement simula-
tion in Mockup environment. In product assembly module of the CATIA software,
applying relationship of constrain within the various parts, the components assembly
of TBM are completed. Finally, the integrity prototype of the TBM is obtained.
Figure.2 shows the TBM’s three-dimensional solid model created in the environment
of CATIA.

4 Data of TBM’s Model Created in CATIA Environment

Conversion
The solid model of the TBM's three-dimensional created in CATIA environment
could not be imported directly into the Mockup2000i2's virtual environment to estab-
lish virtual prototype. The reason is that the Mockup2000i2 software can only use its
own file format to describe and display the virtual prototype [1,2]. The standard docu-
ment format of Mockup2000i2 is "*.vdi" or "*.el". But the model file format created
in CATIA environment is"*. CATProduct". Therefore, the special data conversion
528 L. Li et al.

Fig. 2. Three-dimensional solid model of TBM created in environment of CATIA

software must be applied to convert CATIA data model to virtual format vdi , “ ”
which the Mockup2000i2 can identify. In this paper, the software used for virtual
format conversion is Theorem10.0.

5 Building Virtual Prototyping of TBM and Simulation

5.1 Creating Model Virtual Prototype of TBM

Three-dimensional solid model of TBM built in the CATIA environment can be

opened in the mockup2000i2 software's virtual environment after the model file has
been transformed with Theorem10.0 software. Then the preliminary virtual prototype
has been created.
In order to browse the relevant main view of the TBM quickly, CAMERAS and
LANDMARKS in Mockup2000i2 software must be applied to establish shortcut
icon of the view. At the same time, MATERIALS and LIGHTING should be se-
lected so as to make the virtual prototype achieve effect of unfeigned image. To
avoid spectators wildering position and direction in the infinite frame of axes, we
must add grid to be the background of TBM as reference objects. Adding moving
segments and assemblied segments, it could improve view and unfeigned sense of
TBM. Using moving sections and interference query in Mockup2000i2 Tools can
achieve dynamic section and interference checking, showing internal structures of
TBM further, and checking components interference of sub-assembly. Figure.3
shows the virtual prototype of TBM just created. Figure.4 shows moving section
plane created in 3D view window.
 Virtual Prototype of the Tunnel Boring Machine and Movement Simulation 529

Fig. 3. The virtual prototype of TBM in Mockup

Fig. 4. Showing dynamic section plane in TBM 3D view window

5.2 The Motion Simulation of Virtual Prototype of TBM

5.2.1 Defining the Sequence and Parameters of TBM’s Moving Parts

→
The working sequence of TBM: the cutting wheel running pushing 32 cylinder pis-
tons going ahead, door of mud out opening and screw conveyor machinery turning at
530 L. Li et al.

→
the same time (after one cycle) the cutting wheel stop running; then shutting the
door of mud out; the segments erector machinery catches the first segments, hoisting,
moving, turning and pushing it to the proper position pushing cylinder pistons →
which are matching with the first segment fixed just going back, elongating and im-
→
pacting the first fixed segments the segment erector machinery fixes the second
segment (go on in turn). After a cycle of segments been fixed, the pushing cylinder
pistons supporting the segments just have been fixed, going ahead, starting another
cycle. The orders of moving component and parameters of TBM are shown in Fig.5.

TBM pushing (hotkey a) Segments being fixed (hotkey z)

Cutting wheel running segmen The acetabulum of segments erector The acetabulum of segments erector
¶=455e, machinery down, -Z, v=0.2m/s, s=- machinery down, -Z, v=0.2m/s, s=-
¹=30e/s 0.2m 0.2m
The acetabulum and segment1 up,+Z, The acetabulum and segment2 up,+Z,
segmen v=0.2m/s, s=0.2m v=0.2m/s, s=0.2m
Segments erector machinery and Segments erector machinery and
Cylinder pistons push segment1 moving, -Y, v=0.3m/s, segment1 moving, -Y, v=0.3m/s,
TBM going ahead s=-1.51m s=-1.51m
segmen
V=0.1m/s,s=1.51m After Other 4 segments moving, -Y, Other 3 segments moving, -Y,
15.1s v=0.3m/s, s=-1.51m v=0.3m/s, s=-1.51m
The acetabulum and segment1 down,- Turnplate and segment2 rotation
The door of mud out segmen Z, v=0.2m/s, s=-0.6m around Y,¶=72e,
opening Cylinder pistons group1 moving ¹=24e/s
v=0.2m/s, s=-0.4m The along Y axis to and fro,v=0.2m/s, The acetabulum and segment2 down,-
door of segmen s1=-1.81m,s2=0.3m Z, v=0.2m/s, s=-0.6m
mud Acetabulum up,+Z, v=0.2m/s, Cylinder pistons group2 moving along
Screw conveyor out s=0.6m Y axis to and fro, v=0.2m/s, s1=-
machinery Closing Segments erector machinery moving 1.81m,s2=0.3m
Turning v=0.2m along Y, v=0.3m/s, s=1.51m Acetabulum up,+Z, v=0.2m/s, s=0.6m
¶=1510e /s,s=0.4 Turnplate rotation around Y,
¹ =100e/s ¶=-72e,¹=24e/s
Segments erector machinery moving
8 gears in gearbox along Y, v=0.3m/s, s=1.51m
turning The movement of segment 3,4,5 are
¶=2718e similar to segment2

Fig. 5. The orders of moving component and parameters of TBM

5.2.2 Motion Simulation

During the conversion process where date is taken from the CATIA system and trans-
lated for use in Mockup2000i2, all constraint information created by the CATIA system
is forfeited. New constrains will need to be placed before any movement simulation can
be tested. So, we have to define all constrains for moving parts of TBM.
The function of property being created in Mockup2000i2 must be applied to adding
Pivots, Constraints to define the rotation central axis and direction of linear motion
for the single motion simulation parts. At the same time, the functional simulation can
be performed with Behavior Property, adding events and editing actions parameters.
Finally, all the moving events would be linked with delayed events to realize every
part consecutive movement in working sequence. In addition, the hot key defined
beforehand in the advanced options of the part property is used for triggering the
movement of part functional simulation. The single movement parts created in motion
simulation are: rotation of cutting wheel, the propelling movement of pushing cylin-
der piston, the rotation of helix lamina in screw conveyor machinery, the rotation of
driven box and main bearing, open/close of the door of mud out etc.
For the parts which have complex relations of motion, the virtual parts need to be
created at the root directory of assembly in order to realize simulation. According to
the needs of simulation, many children virtual parts would be created under the virtual
 Virtual Prototype of the Tunnel Boring Machine and Movement Simulation 531

parts you just created too. For the virtual parts just created, virtual behavior property
and virtual event are added, and parameters are edited to realize composite motion
simulation of parts. Notice the virtual parts are not real parts, so the initial position
path of moving parts needs to be designated. Furthermore, the hot key must be de-
fined to trigger movement of virtual parts in the advanced options of the part’s prop-
erty. The composite motion parts in motion simulation are: the hoisting, translation,
rotation, radial movement of the five segments; the linearity alternate motion of seg-
ment erector machinery in bracket; slewing ring rotary motion of segment erector
machinery; the cylinder piston hoisting and down-turn movement. The following pic-
ture is the motion simulation of TBM’s virtual prototype in Mockup environment. As
shown in Fig.6.

Fig. 6. Motion simulation of TBM’s virtual prototype in Mockup

With a variety of peripheral equipment, such as stereo glasses, glove system, 3D-
mouse, i-glasses PC and Flock of birds, we can enter the virtual prototype of TBM
inside anywhere to inspect. Using interference queries in MOCKUP tools, setting up
query name and query types, we can test collisions between sets of assemblies.
Audio files,”*.WAV”format, is added to the virtual prototype of TBM. In addition,
a new Environment Variable is set. They enhance the sound effects of the virtual pro-
totype in the working state.

6 Conclusion
Virtual Reality technology is not only a multi-functional interactive technology, but
also an advanced design concepts. Using virtual reality technology to build TBM vir-
tual prototype and doing digital simulation, can provide an effective new method to
develop of new products for TBM’s optimal design, rapid development, and
532 L. Li et al.

independent innovation. As a new designing technology, VRT can greatly shorten the
product development periods, improve design quality, decrease test costs, and reduce
development costs and development risk.

Acknowledgments
The authors gratefully acknowledge the National Key Technology R&D Program of
China (No. 2006BAF01A45), the National High-tech R&D Program of China (No.
2007AA041801), the Major Project of Basic and Advanced Technology Research of
Henan Province of China (No. 082300413202), and the Opening Foundation of the
Henan Key Lab for Machinery Design and Transmission System (No: KFJZ200705)
for financial support of this research work.

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