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VirtualAidedDesign VortragSummerWorkshopKreta
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Peter Zimmermann
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P. Zimmermann
1 Virtual Development
Virtual development started in early 1970 with the first CAD software
packages. They were very bulky, not interactive and the users worked with
punch cards. The computers of those days were as big as 100 PC’s and the
power was really poor. But nevertheless 20 years later nobody in the in-
dustry would relinquish the new technique because CAD became highly
successful in shortening times, offering the possibilities of concurrent en-
gineering and enhancing quality of the results. Thus, CAD and all other
CAx tools were a success.
After the establishment of CAx technology there was the necessity to
extend virtual development by enhancing visualization quality and real-time
intuitive applications by means of Virtual Reality.
As we are now in a virtualized world it seems to be quite simple to in-
stall new virtual technologies with enhanced possibilities. The problem is
that the difficulties of human-machine-interface are rising overpropor-
tional.
The original meaning of VR is the definition as a real-time human-
machine-interface which should work perfectly with all human senses.
Today we are far away from this, it is still a vision [8].
277
D. Talabă and A. Amditis (eds.), Product Engineering: Tools and Methods
Based on Virtual Reality, 277–296.
© Springer Science + Business Media B.V. 2008
278 P. Zimmermann
In the early sixties there were some guys who had a vision, too (visions are
very important for mankind). The first head mounted displays were under
development. Some years later the first data gloves were designed. The
early experiments look quite funny for the today’s observer.
Since about 1990 there were the first public demonstrations of VR on
fairs and exhibitions. Like the CAD experiments they were very bulky,
too. But the outlook was quite promising for some of the observers from
industry and they started their own experiments.
At Volkswagen we began 1994, after a visit at the New York Virtual Real-
ity exhibition and in the Silicon Valley. First of all one had to look for some
software and hardware. Speaking of software, a co-operation was started
with the Fraunhofer Institute in Darmstadt, headed by Prof. Encarnacao. The
next step was buying a Silicon Graphics computer and some other stuff in-
cluding spacemouse, data glove and HMD.
But there were nearly no applications available at that time apart from
visualization of some data (the most popular tea pot and some animals).
Resolution of data was some thousand triangles, real-time was about
5–10 fps.
In the course of time some start-ups were founded, mainly as spin-offs
from academia in US (Virtual Tool Kit, VPS) and Europe (vrcom, ICIDO).
Most of them continued developing existent software from their institutes.
The companies which developed hardware (mainly US, e.g. n-vision,
Polhemus, Virtual Technologies) were rather small companies too and
without the power to put a lot of money in the development of new features.
In the beginning market and business volume were restricted because only
big companies were able to finance the expensive equipment.
Silicon Graphics was the shooting star of the computer suppliers with
their new technologies for graphic boards. They were big enough to de-
velop new concepts especially for military customers. 1996 the famous
SGI Onyx IR was presented and was a big success because of their out-
standing power.
1997 and the following years more and more virtual studios were built
in the automotive and aerospace industry. The first attempts to productize
applications were started. The typical studio in these years consisted of a
SGI Onyx, a powerwall, a tracking system and some other equipment. In
the first hype stereoscopic view was in favor.
During this first attempt to enable VR technology as a productive tool it
became clear that supplying just technology is not enough. Data manage-
ment, data acquisition, change of process chains became important factors.
Virtual Reality Aided Design 279
On the other hand it was obvious that there was a lack in interfaces and
usability of the tools [4, 13].
3.1 Prerequisites
3.1.1 Technical
Especially for personal computers the product cycle is much shorter than
in the past with the big old computers and therefore both is a blessing and
a curse. On the one hand, one has to change hardware and drivers all the
time, on the other hand, the systems supply more power in a shorter period
of time. Thus, there is no other way to live with these circumstances.
Dependent on the application, single and multi processor systems as
well as cluster systems are used today. They have to be compatible as
much as possible in order to keep the software more simple.
In the past there were mainly 3 operating systems in use, Unix, Linux
and Windows. With the use of PC’s Unix plays no longer a role. Linux had
the advantage to be cheap, relatively independent and to support 64-bit
technology. But it seems to be that long term Windows and successors will
be the favorite system because of the overall usability of the hardware and
the compatibility. Another fact is the availability of drivers for new hard-
ware, especially new graphic cards. An important part of a virtual studio is
the display. In industry one can observe several types of displays.
280 P. Zimmermann
For some of the studios where displays are mainly used for visualization
tracking is dispensable. For all other, especially those which have CAVE
or 2-sided projections, tracking systems are necessary. In the last couple of
years, optical trackers became the favorite systems. They are normally
much more accurate than magnetic field trackers (about 10 times) and they
have no problems with ferrous metals. One small disadvantage may be
line-of-sight if there are not enough cameras [9].
For desktop interaction the spacemouse is the most used interface,
sometimes simply a mouse. But if the user is inside a CAVE or in front of
an L-shape projection the use of mouses is problematic. In these cases fly-
sticks in conjunction with the optical tracking are often the best solution. If
finger movement is important, e.g. in a seating buck, new developed data
gloves with a certain tactile feedback are appropriate [1].
Regarding the software one has to distinguish between pure visualiza-
tion with limited interaction and real-time Virtual Reality with lots of dif-
ferent interactions and collision detection.
Here we have the choice between many vendors and systems. Table 2
shows an extract of companies and where they are focusing on.
Virtual Reality Aided Design 281
3.1.2 Organizational
Within the PDP there are many milestones where VRAD could be de-
ployed. In fact there are less milestones where VRAD really substitute
completely physical and/ or CAD development.
This discrepancy follows from the reasons mentioned before, namely
the acceptance from users and management and the imperfectness of
VRAD itself. Nevertheless it is impressive to see current VRAD activities
in the PDP in figure 3.
It is evident that the earlier these concepts could be proofed the better
and cheaper the solution would be at the end of development. For these
tasks ergonomic software [15] as well as VRAD are used. Virtual experi-
ments are carried out in seating bucks or inside a CAVE [3]. In table 4
selected items are compared with the more conventional way.
Table 4 shows that planning and proof of ergonomics and concepts has
to carefully consider strengths and weaknesses of the respective technol-
ogy. But basically VRAD is a very cost effective way for a lot of early
investigations.
It is quite obvious to try to solve those problems with VRAD but the
devil is in the details. Virtual Assembly is very challenging because it is
not just visualization but highly interactive. At least the software has to
have a real-time collision detection module and even more challenging a
suitable user interface and some additional feedbacks, primarily force
and tactile feedback. For simple assemblies it might be sufficient to show
collisions with red color blinking but if the assembly size exceeds the
view volume it is nearly impossible to successfully simulate the sequence.
In addition there is the necessity to not just include the hands but also
other body parts like arms and the tools or parts have to be grasped in a
natural and correct way [2, 3, 7, 11, 14].
Fortunately there exist many assemblies which can be successfully per-
formed even without the above mentioned techniques and therefore virtual
assembly is a much used tool within the PDP. Advances in the computer
power (which is the field of PC cluster) make it possible to visualize mil-
lions of polygons at real-time speed on stereoscopic multi-sided displays.
Table 5 shows some items in comparison to conventional assembly try-out.
Hose laying is one of the seldom applications where data are generated
in VRDP. They are designed according to the regulations for shape, radii
and fitting length, radii can be varied over the length. If they are flexible,
material properties can be included and the flexible behavior can be simu-
lated through FEM algorithms either in real-time or near real-time.
The output of the simulation will be either the center line in STEP format
for the export into CAD or coordinates for a bending machine.
Hose laying with VRAD software is really simple. Within the displayed
environment the user is acting with a cordless flystick and a 3D menu. Re-
strictions are included automatically, parallel pipes generation and asymp-
totic approximation to neighbor parts are completing this software tool.
4 Summary
Virtual technologies like CAx are heavily used in industry for a long time.
Some years ago Virtual and Augmented Reality too started to play a
relevant role in the product development process. But there are high re-
quirements on the quality of software, hardware and user interfaces as well
as on the quality of results achieved with these techniques.
We are on the way to fulfill some of these requirements. Many VRAD
applications have entered the product processes of automotive and aero-
space industries. Some of these applications have been described and
marked as very useful and have been compared to more conventional tech-
niques. In many cases they have advantages. Normally they will be used in
collaboration with other tools and hardware. In conclusion VRAD adds
additional benefit for time-to-market reductions, quality enhancements and
cost savings to the product development process.
5 Outlook
References
Internet Resources
8. http://interreality.org/static/docs/manual-html/x49.html
9. www.ar-tracking.de
10. www.arvika.de
11. www.haption.com
12. www.metaio.com
13. www.mpi-inf.mpg.de/conferences/eg2002/programme/ industrial.html#IS03,
Virtual and Augmented Reality in Industry, 2002
14. www.percro.org
15. www.ramsis.de
296 P. Zimmermann
Notes
Glossary
AR Augmented Reality
CAD Computer Aided Design
CAx Computer Aided
CAVE Cave Automatic Virtual Environment
CFD Computational Fluid Dynamics
DMU Digital Mock Up
EOP End Of Production
FEM Finite Element Method
HMD Head Mounted Display
LOD Level Of Detail
PDM Product Data Management
ROI Return Of Invest
SOP Start Of Production
STEP Standard for The Exchange of Product model data
VR Virtual Reality