Numerical Simulation of Object Release onto Manufacturing Surfaces
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Solution Overview
Problem
Existing methods for simulating the movement of arbitrarily-shaped objects in manufacturing processes are inefficient, often requiring prior knowledge and ad hoc design, and fail to accurately model the complex interactions between objects and surfaces in automated manufacturing environments.
Innovation Solution
A numerical simulation method using finite element analysis (FEA) and bonded discrete element models (BDEMs) to simulate the movement of arbitrarily-shaped objects from an egress area onto a receiving surface, where FEA models represent the surface and BDEMs represent the objects, allowing for the calculation of contact forces and updating of object positions over time, ensuring accurate mass flow rates and surface interactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If prior art approaches are used for simulating object movement in manufacturing processes, then the simulation can be performed, but the efficiency is poor and requires prior knowledge and ad hoc design
Solution Approach 1:
The patent applies preliminary action by pre-defining standardized object models with common geometries (spheres, cubes, cylinders, etc.) and their corresponding physical properties. These pre-configured models are stored in a database and can be directly selected for simulation without requiring prior knowledge or ad hoc design, thereby improving simulation efficiency and reducing setup time.
2Measurement precision
If FEA and DEM methods are combined to accurately model object-surface interactions, then simulation accuracy is improved, but computational complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the simulation domain into distinct regions: the egress area where objects are released, the transfer region where objects move, and the receiving surface where objects land. Each region can be modeled with appropriate methods (FEA for structural surfaces, DEM for granular objects), allowing accurate modeling of interactions while managing computational complexity through regional specialization.
Solution Approach 2:
The patent merges FEA and DEM methods into a unified simulation framework. FEA is used to model the receiving surface and its structural response, while DEM models the motion and interaction of discrete objects. The two methods are coupled through contact force calculations, enabling accurate prediction of object-surface interactions while leveraging the strengths of both approaches.
3Manufacturing precision
If detailed properties of various objects and surfaces are modeled, then simulation precision is improved, but the time required for simulation increases
Solution Approach 1:
The patent implements parameter changes by allowing users to selectively activate detailed material properties and interaction parameters based on the specific simulation requirements. For example, friction coefficients, restitution coefficients, and contact stiffness can be adjusted or simplified depending on the desired level of precision, enabling a trade-off between simulation precision and computation time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method provides a more efficient and accurate simulation of object movement, enabling better design and optimization of manufacturing processes by accounting for the properties and interactions of variously-shaped objects and surfaces, improving the precision and efficiency of manufacturing operations.
Implementation Method 1
simulating the motion of a large number of particles
Implementation Method 2
calculating a corresponding contact force in each detected contact amongst the activated BDEMs and/or between the activated BDEMs and the lower receiving surface
Data Source
AI summary
Numerical simulation method includes receiving a manufacturing process configuration specification for moving various types of arbitrarily-shaped objects from an egress area onto a lower surface with desired mass flow rate in a predefined time period; creating a FEA model representing the lower surface; creating respective bonded discrete element models (BDEMs) representing the various types of the objects, each BDEM containing discrete elements connected by connection bonds; generating a list of BDEMs each with randomly-chosen types and orientation, such that total mass of the list of BDEMs exceeds a target total mass; and obtaining numerically-simulated physical behaviors of the objects in a time-marching simulation. At each solution cycle of the simulation, placing respective objects into randomly-selected ‘open’ sub-regions by activating next relevant portion of the BDEMs based on the mass flow rate and time-step size; releasing activated BDEMs from the egress area onto the lower surface.