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Pegasus: e-Design and Realization SystemPegasus: e-Design and Realization System
National Science FoundationNational Science FoundationIndustry/University Cooperative Research CenterIndustry/University Cooperative Research Centerfor e-Design: IT-Enabled Design and Realizationfor e-Design: IT-Enabled Design and Realization
of Engineered Products and Systemsof Engineered Products and Systems
ByBart O. Nnaji,Ph.D.
Alcoa Foundation Professor in ManufacturingEngineering & Director of NSF I/UCRC
University of Pittsburgh
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Structure/Organization of CenterUPitt
Management
Center DirectorParticipatingUniversitiesManagement
CenterCo-Directors
AcademicPolicy Comm.
Office of TechManagement
(IP)
ResearchCommittee
PEGASUSCommittees
NSF
IndustrialAdvisory Board
CenterEvaluator
Research Thrust AInformation Infrastructure &
Architecture
Research Thrust BNew Design System Paradigm
Research Thrust CPreferences, Constraints,
Representation & Optimization
Research Thrust DFrom Preference &
Constraints to Form
Research Clusters Research Clusters Research Clusters Research Clusters
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Academic Partners
§Department of Mechanical and Industrial Engineering§Department of Computer Science
University of Massachusetts at Amherst
University of Pittsburgh
§Department of Industrial Engineering§Department of Mechanical Engineering§Department of Material Science Engineering§Department of Computer Engineering§Department of BioEngineering
Carnegie Mellon University
§ Robotics Institute§ Center for e-Commerce
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Sample Partners of CenterINDUSTRIAL FEDERAL ACADEMC
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
e-Design Center Motivation§ Discrete mechanical products:è$1 trillion in U.S. revenues per year
§ 70 - 80% of product’s acquisition costs committed atdesign time
§ Government and consumers need faster and costeffective product acquisition
§ Industry needs to respond quickly with cost effective,high quality products
§ E.g. Automotive design cycle now 36 – 48 months:èneeds to be 12 months
§ Internet-based design studio will achieve this§ Physics-based virtual prototyping will significantly
reduce complex product design and realization time
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Industry Technology Needs
§ Design paradigm that is virtual service orientedwith plug-and-play capability
§ Interoperability among heterogeneous systems§ Collaboration among stakeholders (e.g. suppliers)§ Remote and distributed design via Internet§ Functionality-based conceptual design§ From concept to form§ Direct constraint imposition§ Multidisciplinary constraints§ Scalable, flexible and efficient platform
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Industry Technology Needs(Contd.)
§ Agent-based models for simulation§ Operation Research-based Optimization tools§ Virtual product prototyping with Physical laws
realization
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Research AreasResearch Thrusts and Clusters
Information Infrastructure & ArchitectureInformation Management
Communication ProtocolsCollaboration MethodsInformation RepresentationInformation RepositorySecurity & AccessibilityIntellectural property rights
Transition/Migration Strategy
Conceptual Design ToolsNew Design Process
Design CycleProduct decompositionUncertainty & risk managementIncentive structuresDesign Information Representation
Design Tool InterfacesDesign SimulationHuman/Computer Interface
Multidisciplinary Constraint Management& Optimization
Design RepresentationSetting of StandardsKnowledge Representation&Retrieval
Preferences
Virtual Prototyping & Simulation
From function to form
Constraints
Optimization
Visualization tool
Virtual test & simulation
Virtual PrototypingConflict Resolution
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
New Design System Views
§Functionality-based design and reasoning§New networking capabilities to reduce designcycle times§Systematic product decomposition for effectivedistributed product development§Definition of specification for the decompositionelements§Product data management in the supply network
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Design Data Presentation
§Form generation§Functionality embodiment and productbehavior tests§Computer visualization§Human/computer interaction§Design reasoning§Semantics§Modeling accuracy, precision, and resolution
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Customer View
§Direct participation of customers§Automatic accommodation of preferences§Scalability§Flexibility§Efficient collaboration§Multidisciplinary product design evolution
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Design Optimization
§Constraint representation§Constraint propagation§Constraint integrity§Conflict management and negotiation§Result interpretation§Simulation
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Conflict Management andNegotiation
Manufacturing Assembly
Material Supply Chain
Manufacturing Assembly
Material Supply Chain
Conflict !!
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Information Infrastructure andArchitecture
§What is the information needed throughout the life cycle?§ Information protection and security (at the product attribute,
characterization and specification levels)§ Seamless sharing of information across international
boundaries§ Information storage/retrieval and data mining strategies§ Creation of a knowledge depository§ Classification of Information in the depository (Proprietary,
Public and Shared)§Maintaining and representing the interpretation of
information for use by down stream applications andprocesses.§ Record of Reasoning process, how results were derived
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Service Triangle Relation
ServiceManager
ServiceConsumer
ServiceProvider
3. Service
2. Service Lookup 1. Service Publication
ServiceManager
ORB
Skel
ServiceProvider
ORB
Stub
ServiceConsumer
ORB
Service Bindingrequest
Service Resolutionrequest
Service Bindingprovide
Servicerequest
Serviceprovide
Service Resolutionprovide
Service Manager
Name Publication Catalog Publication ImplementationPublication
Interface LookupName Lookup Catalog Lookup
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
eProduct Design & RealizationCenter ServerService Security
ServiceBrokerage
ServiceUpdate
Service Meta-Protocol
Service
Pu
blicatio
n
Service
Lo
oku
p
ServicePlanning&Scheduling
SecurityAccessControl
ServiceTransparency
Client Modeler(Design Environment)
Functionality-basedConceptual Engine
Resident GeometricModeler
Constraint Manager(Representation & Imposition)
ServiceInteroperability
Plug-and-Play
Client DataSource
Data Security
ServiceTransparency
Service Provider
Service Specification
Service Protocol
Service Linkage &Reference
ServiceInteroperability
Plug-and-Play
Service DataSource
Service Security
Internet
Engineering Service InformationAdministrative Information
The Structure of the e-DesignSystem Platform
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Supply Chain Interaction in Pegasus
Pegasus Platform
• Conceptualization• Virtual Prototyping• Virtual Simulation• Transparent Analysis• Design Repository
• Conceptualization• Virtual Prototyping• Virtual Simulation• Transparent Analysis• Design Repository
• Collaboration• Product Specification• Design Constraints• Design Validation
Service ProvidersFEA (ANSYS)
Material (ALCOA)
System Integrators(e.g., GE, Ford, Pratt & Whitney,
Boeing, Respironics)
OEMs(e.g., Delphi, ALCOA)
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
System Architecture§ Interoperable§ Portable§ Extensible§ Scalable
§ Transparent§ Compatible§ Peer-to-peer§ Plug-and-play
INTERNET
ConceptualModeler
DetailedModeler
AssemblyTool
MaterialSelector
ManufacturingTool
CognitiveTool
ErgonomicsTool
Supply ChainManager
OptimizationEngine
FEATool
FunctionReasoning
ServiceManager
WWWBrowser
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Heterogeneous Data Interoperability§ Issues of interoperability for CAD/CAM/Analysis§ Heterogeneous data wrapped or indexed by XML,
including various CAD data (.igs, .step, .sat, .x_t, .prt,…), texts, graphs, images, etc.§ Product information linkage§ Encourage collaboration, knowledge reuse, lean
engineering information exchange.
TEXT GRAPH .txt IMAGE .gif IGES .jpg STEP .igs PML .stp .pml …
XML
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Universal Linkage Model
PART:Part1
SURFACE:S0 SURFACE:S1 SURFACE:S2 SURFACE:S3 SURFACE:S4 SURFACE:S5 SURFACE:S6 SURFACE:S7
LINE:L0 LINE:L1 LINE:L2 LINE:L3 LINE:L4 LINE:L5 LINE:L6 LINE:L7 LINE:L8 LINE:L9 LINE:L10 LINE:L11
FACE:F0 FACE:F1 FACE:F2 FACE:F3 FACE:F4 FACE:F5 FACE:F6 FACE:F7
EDGE:E0 EDGE:E1 EDGE:E2 EDGE:E3 EDGE:E4 EDGE:E5 EDGE:E6 EDGE:E7 EDGE:E8 EDGE:E9 EDGE:E10 EDGE:E11
ELLIPSE:C12
EDGE:E12 EDGE:E13
ELLIPSE:C13
POINT:P0
VERTEX:V0
POINT:P1
VERTEX:V1
POINT:P2
VERTEX:V2
POINT:P3
VERTEX:V3
POINT:P4
VERTEX:V4
POINT:P5
VERTEX:V5
POINT:P6
VERTEX:V6
POINT:P7
VERTEX:V7
POINT:P8
VERTEX:V8
conPARALLEL
conPARALLEL
conPARALLEL conPARALLEL
conDISTANCEconDISTANCE
conDISTANCE conDISTANCE
conANGLE conANGLE
conMATERIAL
P0
P1
P2
P4
P5
P6
P7
L0
L1
L2
L3
L4
L5L6
L7
L8
L9
L10
L11S1
S0
S2
S3
S5
S4
S6S7
C12C13
d0d1
r0
L2//L0L3//L1S2//S0
S1-S4<angle0S3-S4<angle1
d2 d3
S5//S4P8
INTERNET
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Product Markup Language
line0p0 p1
d
line0
distance = d
p0 p1
consists-of consists-of
UL ModelGeometry
<?xml version="1.0"?> <pml:GEOMETRY xmlns:pml="http://www.pitt.edu" xmlns:xsi="http://www.w3.org/2001/XMLSchema-instance" xsi:schemaLocation= "http://www.pitt.edu line.xsd"> <pml:POINT x="0.0" y="0.0" z="0.0" id="p0">p0</pml:POINT> <pml:POINT y="1.0" y="0.0" z="0.0" id="p1">p1</pml:POINT> <pml:LINE> <pml:refPOINT xlink:type="simple" xlink:href="#p0" xlink:show="embed" xlink:actuate="onLoad"/> <pml:refPOINT xlink:type="simple" xlink:href="#p1" xlink:show="embed" xlink:actuate="onLoad"/> </pml:LINE> </pml:GEOMETRY> <pml:CONSTRAINT> <pml:conDISTANCE xlink:type="extended">1.0 <loc1 xlink:type="locator" xlink:label="start" xlink:href="p0"/> <loc2 xlink:type="locator" xlink:label="end" xlink:href="p1"/> <arc1 xlink:type="arc" xlink:from="start" xlink:to="end" xlink:actuate="onRequest"/> <arc2 xlink:type="arc" xlink:from="end" xlink:to="start" xlink:actuate="onRequest"/> </pml:conDISTANCE> </pml:CONSTRAINT>
PML filePML file
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Constraints Representation
Constraints
Non-geometric
Intra-feature Inter-feature Tolerance
MaterialReliabilityMaintainabilityHuman FactorsManufacturing Assembly Environment
•Multidisciplinary
•Directly support design participants
•Design knowledge exchange
•Directly support optimization
PROCESS/TOOLING
MATERIAL
TOLERANCE
…
PROCESS
MATERIAL
TOLERANCE
…
JIG/FIXTURE
ENVIRONMENTPROTECTION
…
RESOURCECONSERVATION
CHRONICRISK
ACCIDENTPREVENTION
RECYCLE
ANTHROPOMETRY
COGNITION
PHYCHOLOGY
BIOMECHANICS
PHYSIOLOGY
…
MTBM
…
MTBR
MTBF
SAFETY FACT
S-N RATIO
HAZARD RATE
…
STRUCTURALPROPERTY
…
THERMALPROPERTY
CHEMICALPROPERTY
FIXED
DISTANCE
ANGLE
RADIUS
OFFSET
CONCENTRIC
TANGENT
PERPENDICULAR
PARALLEL STRAIGHTNESS
ROUNDNESS
SQUARENESS
ANGULARITY
FLATNESS
CYLINDRICITY
CLEARANCE
Geometric
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Product FunctionalityHow can components (PHow can components (P1,1, P P22 P P33) be ) be
described to capture functionality related described to capture functionality related issues in the design and operation issues in the design and operation
of the product?of the product?
How can the relationship of PHow can the relationship of P11 with components Pwith components P22 and P and P33
be described?be described?
How can functionality be propagated How can functionality be propagated to downstream design activities?to downstream design activities?
How can functionality description How can functionality description be modeled in computer system?be modeled in computer system?
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Functionality Primitives
Recurring product functionalities can Recurring product functionalities can be modeled as a primitive, and used as be modeled as a primitive, and used as
a repository of reusable product knowledge.a repository of reusable product knowledge.
Specific products can be modeled through Specific products can be modeled through their constituent functionality primitives, their constituent functionality primitives,
providing a more natural basis of providing a more natural basis of interaction with the designer.interaction with the designer.
Transformation; Transmission; Joint; Transformation; Transmission; Joint; Load bearing; Energy Conversion; Load bearing; Energy Conversion; Frictional; Offset; Guard; and Block.Frictional; Offset; Guard; and Block.
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Slider-Crank Functionality
Torque (T)
Force (F_in)
Force (F)
Crank Slider
Output Link
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Output Link-Crank FunctionalityDefinition
FunctionalityEntity
Functionality object 1(j=1)
Functionality object 2(k = 2)
Object (O1) O11 = Force (F) O12 = Torque (T)
Attributes(Aiq)
A111 = |F|, A112 = dir,A113 = nature, A114 = location
A121 = |T|, A122 = dir
Attributevalue (V1qs)
e.g. V111 = [3, 12]N;V112 = (α, γ, λ) rad; etc
V121 = [12, 46]NmV122 = [clockwise]
Object StateS1q = (aiqs,viqs)
S11mag = {0, 3, …}S11dir = {(dir,(a,b,c)),(dir,(d,e,f)), …}
S12mag = {(T, 0), (T,18), …}S12dir = {(dir, clock), (dir, anti-clock),…}
Relation (R1) R1 = {r112 (o11, o12) | 1/l }
FormMapping (F1)
F1 = {(r112, f112l) | FFl=1, FF l=2, … }
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
w Generate design for assembly andjoining
w Represent an assembly and imply thevarious effects, i.e., physical andmathematical effects of joiningoperations
w Assembly operation analysis processimbedded into assembly designprocess
w Formalism to specify the assemblyrelations symbolically, which hasmathematically solvable implications.
w Designer’s intent preserved by usingspatial relationship-basedrepresentation
w “Plug and play” capability with adesigner system, such as Pegasus
Assist a designer during assemblyand joint design process
Assist a designer during assemblyand joint design process
Predict expected assembly problemPredict expected assembly problem
Provide design alternativesProvide design alternatives
Solve assembly and joiningproblems
Solve assembly and joiningproblems
Assembly Operation Tools (AOT)
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Architecture of AOT
Assembly/JoiningAdvisor
ManufacturingKnowledge
Base
Assembly/Joining
KnowledgeBase
Geometric andAssembly Process
ConstraintsInteraction
Assembly Advisory (AsA) Engine
Assembly Implication (AsI) EngineAssembly Modeling (AsM) Engine
Spatial Relationship
Implication (SRI) Engine
Virtual Assembly Analysis (VAA)
Engine
Spatial RelationshipSpecification
AssemblyFeature
Formation
EngineeringRelation
Construction
Analysis Tools(ANSYS, ADINA,
CFX, etc.)
AssemblyGraphicEngine
Assembly ServiceRequest
Assembly ServiceResponse
Designer
Assembly Components & Assembly Operation
Ass
emb
lyM
od
el
Ass
em
bly
De
sig
nS
pe
cifi
cati
on
Ass
emb
lyIm
pli
cati
on
Assembly Implication
Ass
emb
ly D
esig
nA
lter
nat
ive
Ass
em
bly
Se
rvic
eR
esp
on
se
Assembly Operation Tools (AOT)
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
AsM Engine
§ Assembly generation based on the assemblydesign formalism§ Joining method specification§ Additional geometric feature generation (e.g.,
weld bead, rivet, etc.)§ Geometry preprocess for analysis
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Procedures of the assembly designformalism
Spatial RelationshipSpecification
Mating FeatureExtraction
Assembly FeatureFormation
Joint Feature Formationand Extraction
Engineering RelationConstruction
Assembly Components
Assembly Model
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Example of GARD – Generic Assembly Relationship Diagram
P1
P2
P3
P4
FF11
FF21
FF12
FF22FF31
FF41
plate_a
plate_c
plate_b
plate_d
FF11 FF21
FF31 FF41
FF12 FF22
DC4 DC5
MF1 MF2 JF1 DC1
MF3 MF4 JF2 DC2 MF5 MF6 JF3 DC3
P1 P2
P3 P4
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Example of assembly design formalism
§ MB3 = {mating pair (mating features [form features ( parental relationships, dimensional constraints)])| mating conditions (S/R, [d.o.f.], [implied constraints])} = {MP3
(MF3 [FF11 (FF21, P1(100.72, 23.34, . ), ±∆1; FF12, P1(50, 20, . ), ±∆1), F31 (.)]) | MC3 (against, [{plane_z::rot_z}], [tolerance]))}§ MB4(aligned)= {MP4
(MF4 [FF11 (FF21, P1(100.72, 23.34, . ), ±∆1; FF12, P1(50, 20, . ), ±∆1), F31 (.)]) | MC4(aligned, [{lin_l1::lin_l1}], [tolerance]))}
MB
§ AF2 = {mating features | mating bonds | joint features | [material] | [implied d.o.f. before assembly],[implied d.o.f. after assembly] | [implied constraints]} = {MF3 , MF4 | MB3, MB4 | JF2 | [Aluminum Alloy 6061 - T6] | [{plate_z::rot_z}, {lin_l1:: lin_l1}], [{fix}]| [tolerance]}
AF
§ JF2 = {joining method | [joining components (joining entities)] |[ joining constraints]} = {GMAW | [P1(ea1), P3 (ec1) | P1 (ea2), P3 (ec2) | [welding_condition], [fixture_location]}
JF
§ MF3 = {S/R, [mating components (mating entities)]} = {against, [P1 (top_surface), P3 (bottom_surface)]}§ MF4 = {aligned, [P1 (l1), P3 (l1)]}
MF
§ Plate_a & plate_c§ welded joint
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
VAA Engine
Analysis Selection
Analysis Input Generation
Analysis Service Request
Analysis Response Interpretation
Virtual Assembly Analysis (VAA) Engine
DesignerClient
Assembly Specification
Engineering InformationService Provider
Analysis Service Provider
Analysis Tools(ANSYS, ABAQUS, ADINA, CFX, etc.)
Engineering Material Engine
Mat
eria
l Ser
vice
Req
ues
t
Mat
eria
l Ser
vice
Res
po
nse Assembly
Service ResponseA
nal
ysis
In
pu
t
Analysis ServiceResponsePegasus Architecture
CORBA
§ Analysis type specification§ Loading and B.C.’s
assignment§ Proper solver determination§ Analysis input generation§ Analysis result
interpretation
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Thermo-structural analysis for arcwelded joints
§ Coupled by nonlinear heat conductionanalysis and steady-state structural analysis§ SOLID 70 element (for thermal analyses) and
SOLID 45 element(for structural analyses)
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Structural analysis for rivet/bolted joints
§ Elastic-plastic structural analysis§ SOLID 45 element (for structural analysis)
and PRETS179 pretension element (forupsetting processes)
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Supply Chain Network
Customer (DoD)OEM (e.g. Tier 1, Tier 2)Supplier (e.g.Tier 3)
System Integrators ( , , etc. )
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Design Constraints
Design Constraints
AO Constraints
Functionality Constraints
Design Constraints
PegasusCenter
Homepage
ConceptualDesign
FunctionalityServiceProviderPlug-in
Software
e.g., FbD
AO AnalysisServiceManager
FEM ServiceProviders
e.g., ANSYS,ADINA
User 1
GeometricModeler
(e.g., ACIS-basedmodeler)
Solid ModelerAOT-AsM
1
3
5
6
7
8
9
Pegasus ArchitectureCORBA
GeometricModeler
(Parasolid-basedmodeler)
Solid ModelerAOT-AsM
+ + =
Work Site 1
Service Transaction
Collaboration ChannelF1 F2
ConstraintManager
Work Site 2
User 2VOT-VAAEngine
AI*WorkbenchApp
10
2
4
Work Site 3Work Site n
Pegasus System Version 1.0
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Geometric Modeler
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Analysis Service Request
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Analysis Service Response
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Joint DoD/Academia/IndustrySystem Engineering for SBA
DefenseContractors
DoD: System Engineering(Rapid product acquisition)
University of Iowa(Virtual Prototyping)
University of PittsburghCarnegie Mellon University
University of Mass. at Amherst(Pegasus: e-Design/Realization)
Other Centers
Univ. of Wisconsin/Univ. of Michigan
(Center for e-Maintenance)
NSF Center for IT-Enabled Design and Realization of Engineered Products and Systems
Summary
§ A design paradigm that accommodates lifecycle considerations for a product§ Rapid product acquisition at significantly
reduced cost with six-sigma quality§ Virtual and transparent analyses and tests
that are physics-based and with ergonomicand cognitive attributes§ System-to-system interoperability and
collaboration