Design evaluation and modification of mechanical systems in virtual environments

Design is one of the most important stages in the manufacturing cycle and influences all the subsequent stages of product development. In the context of today’s iterative design methodology, the modification of any design is a process involving many evaluations and improvements to the solutions chosen in earlier stages. For this purpose, in the most recent decade, 3D computer simulations have become common tools used within industry. Whilst virtual reality (VR) technology is seen as the interaction technology of the future, much of the current research in this area is carried out to explore the potential benefits and added value brought by the integration of this into standard software technologies currently used at various stages in manufacturing life cycle. A lot of attention has been given to exploring the usability and benefits of interactive VR for assembly planning, knowledge elicitation and design and simulation. However, little research has focussed on the analytical aspects of the design process, for example in the use of VR as an interface for simulation software in finite element methods and multi-body systems. This paper introduces research focussing on applications of virtual environments (VEs) for interactive design evaluation and modification adapted and used with standard simulation software. The use of such interactive visualisation offers the engineer more realistic real-time representations of the design and advanced facilities to interact with the model during the design process. While design evaluation is based mainly on visualisation; design modification requires interactive changes of the model during the simulation, and the interfaces described here highlights such applications. In this work, two software prototypes have been developed using VR technology. First, a software tool called design evaluation in virtual environments is presented together with an application in civil engineering to illustrate the mode of operation and added value of the use of an interactive visualisation environment. Linking the simulation software with the VE provides real time bi-directional communication of graphical information which can be successfully achieved even within the limits of current computer technology. The tool includes a suite of software modules and a user interface to facilitate the link between the simulation results and the VE. The second tool facilitates the design modification in virtual environments system by providing real time dynamic simulation. Two dynamic approaches are investigated in order to study the real time simulation issues in the context of design modification and system performance: the classic approach based on rigid interconnected bodies, and a new and novel approach developed by the authors based on particles dynamics. Both implementations have been tested and compared on a mechanism application under the same computing conditions. The research applications presented demonstrate the practicality, flexibility and versatility of the visualisation in virtual environment in design evaluation and modification. However, the computer efficiency whilst carrying out real time dynamic simulation is limiting the range of applications to models of moderate size; however, this is an improvement on previous similar applications.