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Step by Step Functional Virtual Prototyping
A typical M.D.S. mechanism involves three to six cams resulting
in complex high-speed motion. These mechanisms are assembled into
complex machinery. M.D.S does not cut any metal, mold any parts,
or construct a prototype for a machine until it has been simulated
with Dynamic Designer.
STEP 1. The process begins by modeling the kinematics of
a design concept. Dynamic Designer animations and plots are used
to make sure the model matches the timing specified in timing diagrams.
Tracing the output of cam-driven levers verifies stroke or displacement
characteristics.
Each mechanism may contain 3-6 cams and
each M.D.S machine contains multiple of these mechanisms.
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STEP 2. Dynamic studies are utilized to understand accelerations
at important locations. Acceleration information helps specify the
range of component masses required to keep the forces in check.
STEP 3. Next M.D.S. uses CAD to create a complete 3D model.
The accurate mass properties in the 3D model are critical to the
virtual prototyping process for the calculation of force quantities.
STEP 4. When the 3D model is complete, they utilize Dynamic
Designer to calculate forces on bearing levers and other locations.
STEP 5. In high speed machinery design, it is important
to minimize stroke, which often causes clearance problems. Typically,
design motions are not rectilinear and there may be three or four
cams contributing motions to the mechanism. It is very labor-intensive
to check the position of these mechanisms throughout each 360-degree
position of the machine timing. Viewing the Dynamic Designer animation
in 3D is often the only way to check for clearances around nests,
especially when the parts being picked and placed are oddly shaped.
Realizing the Benefits
By using Dynamic Designer M.D.S. is saving time, money and developing
better product.
M.D.S. uses animations to effectively communicates design concepts
and proposals to customers. "We often share animations with our
customers so that they can see the mechanism move and better and
understand what is happening," explains Jordan. In fact, M.D.S.
is now offering machine animation creation as a service to customers.
The animations can contain plots to show engineering information
or can be accompanied by an exported Microsoft Excel file containing
the plots.
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"I firmly believe that the work we
do using Dynamic Designer not only saves us money in the design
phase but also allows our equipment to run very reliably,
which is a cost benefit for our customers."
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Virtual prototypes can only replace physical tests if the results
are accurate. "We have checked the data we extracted from our Dynamic
Designer model against the actual machine and feel very comfortable
with the results," states Jordan. Jordan in turn can create accurate
proposals and make important design decisions without building and
testing a physical prototype.
"I am finding that as my confidence has grown using Dynamic Designer,
I have been able to do some projects lately that I may have walked
away from before because of the unknown cost of development," explains
Jordan. "I do virtual prototyping to get myself comfortable with
an idea for a mechanism, before I invest the time in pursuing a
more detailed study of the design details."
M.D.S. has embraced the power of virtual prototyping. In their
continual quest for the paperless office, they plan on integrating
more and more Dynamic Designer-type technologies into their processes.
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