Machine Simulation for Component Stress and Bottleneck Analysis
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Solution Overview
Problem
Existing simulation technologies cannot calculate stress generated in each component of a machine with multiple components during simulation, limiting the ability to identify bottlenecks and optimize component combinations for safety and cost-effectiveness.
Innovation Solution
A simulation device and method that calculates stress in each component of a machine by simulating its operation, including contact with a work, and suggests optimized component combinations based on safety rates and cost considerations, such as reducing screw diameters and materials, to identify bottlenecks and reduce manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If simulation is executed using a machine including multiple components, then the operation behavior can be analyzed, but the stress generated in each component cannot be calculated
Solution Approach 1:
The simulation system is segmented into multiple specialized calculators: a motion calculator that computes motion equations for the entire machine, and individual stress calculators for each component that receive motion data and calculate stresses separately. This segmentation allows stress calculation in each component without requiring a complete redesign of the simulation system.
Solution Approach 2:
A motion calculator serves as an intermediary between the simulation input and the stress calculation processes. It receives simulation parameters, calculates motion equations for the machine, and provides motion data to individual component stress calculators, enabling stress analysis without direct coupling between simulation control and stress computation.
2Adaptability or versatility
If multiple types of screws and materials are used in the machine, then the design flexibility is improved, but the manufacturing cost increases
Solution Approach 1:
The system calculates safety rates for different component configurations by changing parameters such as screw diameter and material type. It identifies optimal configurations where fewer screw types and material varieties are used, maintaining required safety rates while reducing manufacturing complexity and cost.
Solution Approach 2:
The simulation suggests using uniform screw types and material specifications across components where possible, rather than varying specifications for each component. This homogenization reduces the number of unique parts needed, simplifying manufacturing and inventory management while meeting safety requirements.
3Reliability
If the machine components are designed with high safety rates, then the reliability is improved, but the manufacturing cost increases
Solution Approach 1:
Instead of uniformly increasing safety margins for all components, the system calculates and applies safety rate improvements only to specific components where stress analysis reveals bottlenecks or high-risk areas. This localized approach maintains reliability where needed while avoiding unnecessary cost increases in low-risk components.
Solution Approach 2:
The system provides feedback by calculating actual safety rates for each component based on simulated stress conditions. This feedback loop allows designers to identify which components require safety improvements and adjust designs iteratively, ensuring adequate reliability without excessive oversizing of all components.
Data Source
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AI summary
A stress generated in each of a plurality of components (151, 152, 153, 154) is calculated during simulation using a machine (150) including these components (151, 152, 153, 154). A simulation device (100) includes a storage (111) that stores assembly data of a machine (150) including a plurality of components (151, 152, 153, 154) and a program for control of a driver connected to machine (150), and a controller (102) configured to execute a simulation of machine (150). The controller (102) causes driver to operate in the simulation and calculates a stress generated in each of the plurality of components (151, 152, 153, 154) in the simulation in response to driver being driven.