Digital Twin Modeling and Simulation Optimization of Transmission Front and Middle Case Assembly Line

As the take-off of China’s macro economy,as well as the rapid development of infrastructure construction,real estate industry,and highway logistics transportation industry,the demand for heavy vehicles is increasing rapidly,the competition is becoming increasingly fierce,and the digital transformation of the production line is imminent.As one of themost important components of heavy vehicles,the transmission front andmiddle case assembly lines have a high degree of automation,which can be used as a pilot for the digital transformation of production.To ensure the visualization of digital twins(DT),consistent control logic,and real-time data interaction,this paper proposes an experimental digital twin modeling method for the transmission front and middle case assembly line.Firstly,theDT-based systemarchitecture is designed,and theDT model is created by constructing the visualization model,logic model,and data model of the assembly line.Then,a simulation experiment is carried out in a virtual space to analyze the existing problems in the current assembly line.Eventually,some improvement strategies are proposed and the effectiveness is verified by a new simulation experiment.

Numerical simulation analysis for deformation deviation and experimental verification for an antenna thin-wall parts considering riveting assembly with finite element method

In the process of thin-wall parts assembly for an antenna,the parts assembly deformation deviation is occurring due to the riveting assembly.In view of the riveting assembly deformation problems,it can be analyzed through transient and static simulation.In this work,the theoretical deformation model for riveting assembly is established with round head rivet.The simulation analysis for riveting deformation is carried out with the riveting assembly piece including four rivets,which comparing with the measuring points experiment results of riveting test piece through dealing with the experimental data using the point coordinate transform method and the space line fitting method.Simultaneously,the deformation deviation of the overall thin-wall parts assembly structure is analyzed through finite element simulation;and its results are verified by the measuring experiment for riveting assembly with the deformation deviation of some key points on the thin-wall parts.Through the comparison analysis,it is shown that the simulation results agree well with the experimental results,which proves the correctness and effectiveness of the theoretical analysis,simulation results and the given experiment data processing method.Through the study on the riveting assembly for thin-wall parts,it will provide a theoretical foundation for improving thin-wall parts assembly quality of large antenna in future.

Accuracy Analysis of Assembly Success Rate with Monte Carlo Simulations

Monte Carlo simulation was applied to Assembly Success Bate (ASK) analyses. ASR of two peg-in-hole robot assemblies was used as an example by taking component parts' sizes, manufacturing tolerances and robot repeatability into account. A statistic arithmetic expression was proposed and deduced in this paper, which offers an alternative method of estimating the accuracy of ASR, without having to repeat the simulations. This statistic method also helps to choose a suitable sample size, if error reduction is desired. Monte Carlo simulation results demonstrated the feasibility of the method.

Force Feedback Coupling with Dynamics for Physical Simulation of Product Assembly and Operation Performance

Most existing force feedback methods are still difficult to meet the requirements of real-time force calculation in virtual assembly and operation with complex objects. In addition, there is often an assumption that the controlled objects are completely flee and the target object is only completely fixed or flee, thus, the dynamics of the kinematic chain where the controlled objects are located are neglected during the physical simulation of the product manipulation with force feedback interaction. This paper proposes a physical simulation method of product assembly and operation manipulation based on statistically learned contact force prediction model and the coupling of force feedback and dynamics. In the proposed method, based on hidden Markov model （HMM） and local weighting learning （LWL）, contact force prediction model is constructed, which can estimate the contact force in real time during interaction. Based on computational load balance model, the computing resources are dynamically assigned and the dynamics integral step is optimized. In addition, smoothing process is performed to the force feedback on the synchronization points. Consequently, we can solve the coupling and synchronization problems of high-frequency feedback force servo. low-frequency dynamics solver servo and scene rendering servo, and realize highly stable and accurate force feedback in the physical simulation of product assembly and operation manipulation. This research proposes a physical simulation method of product assembly and operation manipulation.

Three-Dimensional and Cross-sectional Characteristics of Normal Grain Growth Based on Monte Carlo Simulation

An appropriate Monte Carlo method was developed to simulate the three-dimensional normal grain growth more completely. Comparative investigation on the three-dimensional and the cross-sectional characteristics of normal grain growth was done. It was found that the time exponent of grain growth determined from cross-section exhibits the same rule of increasing slowly with time and approaching the theoretical value n = 0.5 of steadygrain growth as the three-dimensional (3-D) system. From change of the number of grains per unit area with timemeasured in cross-section, the state of 3-D normal grain growth may be predicted. The gtain size distribution incross-section is different from that in 3-D system and can not express the evolution characteristic of the 3-D distribution. Furthermore, there exists statistical connection between the topological parameters in cross-section and thosein three-dimensions.

Experimental study on jet pulse assembly design and numerical simulation

Jet pulse assembly is one of the main components of jet hydraulic oscillator.The pressure wave characteristics produced by jet pulse assembly have an important influence on the performance of the tool.In this paper,the structure and working principle of jet pulse assembly are studied,the mechanical analysis model of piston rod is established,the dynamic resistance ratio formula of jet pulse assembly is deduced,and the numerical simulation test of 89-mm jet pulse assembly structure parameters is carried out.The results show that the piston rod downward stroke is driven by both the jet element driving force and the throttle plate load driving force,and can stably descend.The driving force of the piston rod upward stroke jet element is opposite to the load acting force of the throttle disc,and the jet driving force needs to be greater than the load resistance of the throttle disc to stably ascend.The dynamic resistance ratio formula is deduced.When the area of the end of the piston rod is reduced,the resistance of the throttle disc is reduced and the jet power is increased,thus solving the problem of insufficient power of the piston rod in the upstroke and ensuring the normal operation of the tool.Ten groups of numerical simulation tests were carried out,and it was found that the pressure amplitude and pressure drop of the tool decreased significantly with the increase of the tool size,and the error between the numerical simulation value and the theoretical calculation value was less than 9%,which verified the correctness of the theory.It is suggested to select tools on site according to the drilling construction situation to ensure the drilling effect.

QUICK ASSESSMENT METHODOLOGY FOR RELIABILITY OF SOLDER JOINTS IN BALL GRID ARRAY(BGA)ASSEMBLY——PART Ⅱ:RELIABILITY EXPERIMENT AND NUMERICAL SIMULATION

In the present study,a facility,i.e.,a mechanical deflection system (MDS),was established and applied to assess the long-term reliability of the solder joints in plastic ball grid array (BGA) assembly.It was found that the MDS not only quickly assesses the long-term reliability of solder joints within days,but can also mimic similar failure mechanisms in accelerated thermal cycling (ATC) tests. Based on the MDS and ATC reliability experiments,the acceleration factors (AF) were obtained for different reliability testing conditions.Furthermore,by using the creep constitutive relation and fatigue life model developed in part I,a numerical approach was established for the purpose of virtual life prediction of solder joints. The simulation results were found to be in good agreement with the test results from the MDS.As a result,a new reliability assessment methodology was established as an alternative to ATC for the evaluation of long-term reliability of plastic BGA assembly.

Three-dimensional visualization and virtual reality simulation role in hepatic surgery:Further research warranted

Artificial intelligence(AI)is the study of algorithms that enable machines to analyze and execute cognitive activities including problem solving,object and word recognition,reduce the inevitable errors to improve the diagnostic accuracy,and decision-making.Hepatobiliary procedures are technically complex and the use of AI in perioperative management can improve patient outcomes as discussed below.Three-dimensional(3D)reconstruction of images obtained via ultrasound,computed tomography scan or magnetic resonance imaging,can help surgeons better visualize the surgical sites with added depth perception.Preoperative 3D planning is associated with lesser operative time and intraoperative complications.Also,a more accurate assessment is noted,which leads to fewer operative complications.Images can be converted into physical models with 3D printing technology,which can be of educational value to students and trainees.3D images can be combined to provide 3D visualization,which is used for preoperative navigation,allowing for more precise localization of tumors and vessels.Nevertheless,AI enables surgeons to provide better,personalized care for each patient.

Three-Dimensional Finite Element Numerical Simulation and Physical Experiment for Magnetism-Stress Detecting in Oil Casing

The casing damage has been a big problem in oilfield production. The current detection methods mostly are used after casing damage, which is not very effective. With the rapid development of China's offshore oil industry, the number of offshore oil wells is becoming larger and larger. Because the cost of offshore oil well is very high, the casing damage will cause huge economic losses. What's more, it can also bring serious pollution to marine environment. So the effective methods of detecting casing damage are required badly. The accumulation of stress is the main reason for the casing damage. Magnetic anisotropy technique based on counter magnetostriction effect can detect the stress of casing in real time and help us to find out the hidden dangers in time. It is essential for us to prevent the casing damage from occurring. However, such technique is still in the development stage. Previous studies mostly got the relationship between stress and magnetic signals by physical experiment, and the study of physical mechanism in relative magnetic permeability connecting the stress and magnetic signals is rarely reported. The present paper uses the ANSYS to do the three-dimensional finite element numerical simulation to study how the relative magnetic permeability works for the oil casing model. We find that the quantitative relationship between the stress' s variation and magnetic induction intensity's variation is: Δδ =K* ΔB, K = 8.04×109, which is proved correct by physical experiment.

Three-dimensional discrete element numerical simulation of Paleogene salt structures in the western Kuqa foreland thrust belt

Taking the Paleogene salt strata in the west of Kuqa foreland thrust belt as study object, the deformation features of salt structure in the compression direction and perpendicular to the compression direction were examined to find out the control factors and formation mechanisms of the salt structures. By using the three-dimensional discrete element numerical simulation method, the formation mechanisms of typical salt structures of western Kuqa foreland thrust belt in Keshen and Dabei work areas were comprehensively analyzed. The simulation results show that the salt deformation in Keshen and Dabei work areas is of forward spread type, with deformation concentrated in the piedmont zone;the salt deformation is affected by the early uplift near the compression end, pre-existing basement faults, synsedimentary process and the initial salt depocenter;in the direction perpendicular to the compression direction, salt rocks near the compression end have strong lateral mobility with the velocity component moving towards the middle part, and the closer to the middle, the larger the velocity will be, so that salt rocks will aggregate towards the middle and deform intensely, forming complex folds and separation of salt structures from salt source, and local outcrop with thrust faults. Compared with 2 D simulation, 3 D simulation can analyze salt structures in the principal stress direction and direction perpendicular to the principal stress, give us a full view of the formation mechanisms of salt structures, and guide the exploration of oil and gas reservoirs related to salt structures.

Study on Surface Electric Field Simulation of High Voltage Transmission Line Assembly

For the studies in the field of high voltage power transmission, this paper has adopted the method of finite element node potential, and put forward two kinds of high pressure sensor-fixture modeling scheme for the sensor-fixture of the high voltage side, the simulation analysis shows that the sensor-fixture surface should be smooth, and should not appear the conclusion of edges and corners. While through establishing the four clamps assembly optimized model, and simulates the strain gages, fixtures and conductor surface field strength and electric field distribution in the model as a whole in turn, this paper Finally got the optimal size of fixture structure and assembly of each part reasonable location layout.

THE SYSTEM SIMULATION OF THREE-DIMENSIONAL RADAR

To provide a test platform for Electronic Warfare (EW) system, it is needed to simulate the radar received Intermediate Frequency (IF) signals and radar system functions.This letter gives a description of a radar system simulation software developed for frequencyphase scanning three-dimensional (3-D) radar. Experimental results prove that the software could be used for system evaluation and for training purposes as an attractive alternative to real EW system.

Three-Dimensional Simulations of RESET Operation in Phase-Change Random Access Memory with Blade-Type Like Phase Change Layer by Finite Element Modeling

An optimized device structure for reducing the RESET current of phase-change random access memory （PCRAM） with blade-type like （BTL） phase change layer is proposed. The electrical thermal analysis of the BTL cell and the blade heater contactor structure by three-dimensional finite element modeling are compared with each other during RESET operation. The simulation results show that the programming region of the phase change layer in the BTL cell is much smaller, and thermal electrical distributions of the BTL cell are more concentrated on the TiN/GST interface. The results indicate that the BTL cell has the superiorities of increasing the heating efficiency, decreasing the power consumption and reducing the RESET current from 0.67mA to 0.32mA. Therefore, the BTL cell will be appropriate for high performance PCRAM device with lower power consumption and lower RESET current.

Three-Dimensional Rigid-Plastic FEM Simulation of Bulk Forming Processes with New Contact and Remeshing Techniques

Some techniques such as die surface description, contact judgement algorithm and remeshing are proposed to improve the robustness of the numerical solution. Based on these techniques, a three-dimensional rigid-plastic FEM code has been developed. Isothermal forging process of a cylindrical housing has been simulated. The simulation results show that the given techniques and the FEM code are reasonable and feasible for three-dimensional bulk forming processes.

Numerical simulations and comparative analysis of two- and three-dimensional circulating fluidized bed reactors for CO2 capture

Carbon dioxide(CO2),the main gas emitted from fossil burning,is the primary contributor to global warming.Circulating fluidized bed reactor(CFBR)is proved as an energy-efficient method for post-combustion CO2 capture.The numerical simulation by computational fluid dynamics(CFD)is believed as a promising tool to study CO2 adsorption process in CFBR.Although three-dimensional(3D)simulations were proved to have better predicting performance with the experimental results,two-dimensional(2D)simulations have been widely reported for qualitative and quantitative studies on gas-solid behavior in CFBR for its higher computational efficiency recently.However,the discrepancies between 2D and 3D simulations have rarely been evaluated by detailed study.Considering that the differences between the 2D and 3D simulations will vary substantially with the changes of independent operating conditions,it is beneficial to lower computational costs to clarify the effects of dimensionality on the numerical CO2 adsorption runs under various operating conditions.In this work,the comparative analysis for CO2 adsorption in 2D and 3D simulations was conducted to enlighten the effects of dimensionality on the hydrodynamics and reaction behaviors,in which the separation rate,species distribution and hydrodynamic characteristics were comparatively studied for both model frames.With both accuracy and computational costs considered,the viable suggestions were provided in selecting appropriate model frame for the studies on optimization of operating conditions,which directly affect the capture and energy efficiencies of cyclic CO2 capture process in CFBR.

Simulation-Based Construction of Three-Dimensional Process Model for Punching Cartridge Cases

A method of constructing three-dimensional process model for the punching cartridge cases is presented based on DEFORM simulation analysis. Using DEFORM software,the finite element simulation models for the punching and forming process of cartridge cases are established,and the corresponding simulation result model of each intermediate procedure is obtained by continuously performing the forming process simulation. The simulation model cannot annotate size and process information due to poor interface between DEFORM software and CAD software. Thus,a 3D annotation module is developed with secondary development technology of UG NX software. Consequently,the final process model with dimension and process information is obtained. Then,with the current 3D process management system,the 3D punching and forming process design of cartridge cases can be completed further. An example is also provided to illustrate that the relative error between the simulation process model and the physical model is less than 2%,which proves the validity and reliability of the proposed method in this study.

Application of Three-Dimensional Visual Simulation in Tidal Defense Engineering

Any tidal defense engineering involves the collection and analysis of massive information about engineering structures and their surrounding environment. Traditional method, which is carried out mainly by means of twodimensional drawings and textures, is not efficient and intuitive enough to analyze the whole project and reflect its spatial relationship. Three-dimensional visual simulation provides an advanced technical means of solving this problem. In this paper, triangular irregular network (TIN) model simplified by non-uniform rational B-splines (NURBS) technique was used to establish the digital terrain model (DTM) of a super large region. Simulation of dynamic water surface was realized by combining noise function with sine wave superposition method. Models of different objects were established with different modeling techniques according to their characteristics. Application of texture mapping technology remarkably improved the authenticity of the models. Taking the tidal defense engineering in the new coastal region of Tianjin as a case study, three-dimensional visual simulation and dynamic roaming of the study area were realized, providing visual analysis and visible demonstration method for the management and emergency decision-making associated with construction.

Three-dimensional simulation of sintering crunodes of metal powders or fibers by level set method

The difference of sintering crunodes of metal powders and fibers is discussed. The mathematical model of the surface diffusion described by the difference in mean curvature is defined as a Hamilton-Jacobi-type equation, and the model is numerically solved by the level set method. The three-dimensional numerical simulations of two metal powders and fibers(the fiber angle is 0° or 90°) are implemented by this mathematical model, respectively. The numerical simulation results accord with the experimental ones. The sintering neck growth trends of metal powders and metal fibers are similar. The sintering neck radius of metal fibers is larger than that of metal powders. The difference of the neck radius is caused by the difference of geometric structure which makes an important influence on the curvature affecting the migration rate of atoms.

Numerical simulation of three-dimensional tidal current in the Bobal Sea

The model equations with tbree-dimensional, time-dependent, nonlinear Navier-Stokes equations are transformed by sigma-transformation.On the basis of the process splitting technique, the fluid flow problems are divided into two parts:the vertically-intopated equations (external mode) and the vertical structure equations(internal mace). The first set of equations being the propagation of the tidal weves and the ADI numerical scheme has ben chosen to solve them. Conerning the vertical structure equations, they are solved by means of leapfrog stepping procedure.The main features of the tide and associated tidal current in the Bohai Sea are examined with this 3-D model.To have a good reproduction of vertical structure, the column is divided into 10 layers and the M2 tidal current is computed in detail. The simulation reveal the spetial structure and some important characteristics of the tidal current of the Bohai Sea. The application of the 3-D madel to forecasting of the tidal current in the Bobal Sea has been Performed as an illustration.

A review of cable layout design and assembly simulation in virtual environments

The layout and assembly of flexible cables play important roles in the design and development of complex electromechanical products.The rationality of cable layout design and the reliability of cable assembly greatly affect product quality.In this paper,we review the methods of cable layout design,cable assembly process planning,and cable assembly simulation.We first review research on flexible cable layout design(both interactive and automatic).Then,research on the cable assembly process planning,including cable assembly path and manipulation planning,is reviewed.Finally,cable assembly simulation is introduced,which includes general cable information,cable collision detection data,and cable assembly process modeling.Current problems and future research directions are summarized at the end of the paper.