Virtual-Real Fusion Ergonomic Simulation for Assembly Analysis
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Solution Overview
Problem
Traditional assembly analysis methods are inefficient and inaccurate, requiring physical prototypes and consuming significant resources and time, leading to delayed product design and potential safety and comfort issues for assembly workers.
Innovation Solution
An ergonomic evaluation method and simulation system based on virtual-real fusion, using human motion capturing devices to obtain real-time joint position data, generating a character model, and integrating it into a virtual scene for comprehensive ergonomic analysis, ensuring accurate evaluation of ergonomic indices in assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If physical prototypes are used for assembly analysis, then ergonomic evaluation can be conducted, but it consumes significant material resources, manpower and time
Solution Approach 1:
The patent creates a virtual copy of the physical assembly environment, workers, and processes through digital twins and virtual reality technology. This virtual model allows ergonomic evaluation without requiring physical prototypes, thereby reducing material consumption and time while maintaining evaluation accuracy through realistic simulation of human-machine interactions.
Solution Approach 2:
The patent replaces the mechanical physical prototype system with a computational virtual simulation system. Instead of building and testing physical models, the system uses computer-based virtual environments to simulate assembly processes, enabling faster iteration and evaluation without the constraints of physical manufacturing and assembly.
2Reliability
If physical prototypes are used for assembly analysis, then worker safety and comfort can be evaluated, but the assembly process design lags behind product design
Solution Approach 1:
The patent enables ergonomic safety evaluation to be performed during the product design phase itself, rather than after assembly process design is complete. By integrating virtual ergonomic analysis into the CAD design workflow, potential safety issues are identified and resolved preliminarily, allowing concurrent development of product and assembly process designs without sequential delays.
3Productivity
If virtual assembly simulation is used, then concurrent design can be achieved, but ergonomic analysis accuracy is insufficient
Solution Approach 1:
The patent enhances virtual simulation by implementing dynamic, real-time ergonomic evaluation that adapts to actual worker movements and interactions. The system continuously updates ergonomic assessments based on captured motion data from multiple cameras and sensors, providing accurate, situation-specific feedback rather than static pre-defined evaluations, thereby maintaining high accuracy while enabling concurrent design.
Data Source
AI summary
Disclosed are an ergonomic evaluation method and simulation system based on virtual-real fusion. The system includes a user and device module, a virtual scene building module, and a data processing and analysis module. The method includes: obtaining real-time human joint point position data by means of a human motion capturing device, generating a character model of a current posture, and integrating the character model into a visual device and a personal computer (PC) terminal that are implanted with a virtual scene; obtaining comprehensive human joint point data through computation according to the real-time human joint point position data, and obtaining virtual scene data; and determining a human motion according to the comprehensive human joint point data and the virtual scene data, obtaining human posture data, obtaining human posture evaluation information through computation, and conducting analysis to determine whether an ergonomic evaluation index is rational.