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6035 |
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Wednesday, February 20, 2019, Hall Mailand 4:25 PM Digitalisation and Simulation |
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Real time physical simulation for virtual welding training |
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Marek Simon* / ISF - Institut für Schweisstechnik und Fügetechnik, RWTH Aachen, Deutschland Oleg Mokrov / ISF, Institute for Welding and Joining Technology, RWTH Aachen, Germany Andre Schmidt/ ISF, Institute for Welding and Joining Technology, RWTH Aachen, Germany Uwe Reisgen/ ISF, Institute for Welding and Joining Technology, RWTH Aachen, Germany Andreas Behmel/ CMI, Institute of Design & Communication, FH JOANNEUM, Austria Jochen Martin/ CMI, Institute of Design & Communication, FH JOANNEUM, Austria Daniel Rudolph/ AUDI AG, Germany Almedin Becirovic/ Fronius International GmbH, Austria |
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Modern visualization methods facilitate the user a better and deeper understanding of the welding process. Current methods and visualization systems are based on empirical groundwork. A simulation software on the basis of physical models is put at disposal of the user, which facilitates a visualization of the weld joint geometry and temperature distribution In this way corrupt weld joints can be detected and handled in advance. This leads to an increase of quality and profitability. For this reason this approach offers a new benchmark in the world of electric arc technology and sets a basis for a variety of future visions. Physical welding models are so far optimized and reduced in order to, together with the speedup of the numeric algorithms and a decomposition of the calculation mesh into several areas with different spatial resolutions, facilitate a real-time simulation. The reduction of the models was achieved by a combination of analytical solutions with optimized numerical algorithms for partial differential equations. These measures facilitate the execution of a welding simulation in very short time. Experimental support (provided by AUDI and Fronius) upon the calibration leads to well validated and reliable results. With modern visualization methods the results are user-friendly presentable. A demonstrator in form of an expansion of the Fronius Virtual Welding system was setup. The demonstrator contains an offline and an online mode. The offline mode performs the analysis after the welding. The online mode performs the real-time (simulation) analysis during welding. The development is based on results from preceding developments such as Virtual Welding System (Fronius, FH JOANNEUM) and SimWeld Software (RWTH Aachen). |