Siemens NX Research Articles

Ultrasonic Sensor Modeling with Support Vector Regression

This study proposes a novel approach for predicting the output behaviors of the Pepperl+Fuchs 3RG6232-3JS00-PF ultrasonic sensor. The sensor, integrated into the Festo MPS-PA Didactic System, serves to monitor the water level in a tank, facilitating water extraction to bottles delivered via a conveyor belt. This modeling approach represents the initial phase in the creation of a digital twin of the physical sensor, providing the capability for users to observe the sensor’s response and forecast its life cycle for maintenance objectives. This study utilizes the Festo MPS-PA Compact Didactic System and support vector regression (SVR) for data acquisition (DAQ), preprocessing, and model training with hyperparameter optimization. The objective of this modeling approach is to establish a digital framework for transition towards Industry 4.0. It holds the potential for creating a digital counterpart of the entire MPS-PA System when combining the proposed sensor modeling technique with computer-assisted design (CAD) software such as Siemens NX in the future. This would enable users to oversee the entire process in a three-dimensional visualization engine, such as Tecnomatix Plant Simulation. This research significantly contributes to the comprehension and application of digital twins in the realm of mechatronics and sensor systems technology. It also underscores the importance of digital twins in enhancing the efficiency and predictability of sensor systems. The method used in this paper involves predicting the rate of change (RoC) of the water level and then integrating this rate to estimate the actual water level, providing a robust approach for sensor data modeling and digital twin creation. The result shows a promising 6.99% error percentage.

Complex Branch Pipe Layout Optimization Based on Machine Learning and Improved Grey Wolf Algorithm

Abstract Branch pipes are widely found in complex equipment, and its layout planning and design has an important impact on the quality and efficiency of equipment design. In this paper, a branch pipe layout planning method based on machine learning and improved grey wolf algorithm is proposed. Firstly, the branch pipe layout problem is decomposed into a series of “between two points” pipe layout and “point to line” pipe layout problems to reduce the complexity of the problem. Secondly, the Q-learning algorithm is applied to solve the “between two points” pipe layout path solving problem, and then combined with the improved grey wolf algorithm to optimize the “point to line” pipe path solving. Finally, a simulation system is built based on Siemens NX and MATLAB platform, and the validity of the proposed method is verified by simulation cases.

Structural Analysis of AlAinSat-1 CubeSat

This paper presents the process of conducting the structural analysis of AlAinSat-1 CubeSat through a numerical solution using Siemens NX. AlAinSat-1 is a 3U remote-sensing CubeSat carrying two earth observation payloads. The CubeSat is scheduled for launch on SpaceX Falcon 9 rocket. To ensure the success of the mission and its ability to withstand the launch environment, several scenarios should be analyzed. For AlAinSat-1 model the finite element analysis (FEA) method is used, and four types of structural analyses are considered: modal, quasi-static, buckling, and random vibration analyses. The workflow cycle includes idealizing, meshing, assembling, applying connections and boundary conditions, and eventually running the simulation utilizing the Siemens Nastran solver. The simulation results of all analysis types indicate that the model can safely withstand the loads exerted during launch. Also, the numerical results of the Command and Data Handling Subsystem (CDHS) module of AlAinSat-1 are experimentally validated through a vibration test conducted using an LV8 shaker system. The module successfully passed the test based on the test success criteria provided by the launcher.

A knowledge-driven, integrated design support tool for additive manufacturing

AbstractIncreasing adoption of additive manufacturing (AM) makes software support for design for additive manufacturing (DfAM) more relevant. This paper presents a novel, knowledge-driven design support tool for AM that leverages a central knowledge base to provide extensible and powerful DfAM support early in the development process. The approach was implemented using Python for the knowledge base and as a plugin for Siemens NX. It offers automated design checks, optimizations, and further information through an integrated Wiki. Evaluation confirms the feasibility and benefits of the approach.

Design and construction of the army unmanned aerial vehicle with a new generation launch system «RPSKD-2»

The scientific article presents the design and construction of a two-case army unmanned aerial vehicle with a launch system of a new generation «RPSKD-2», which can be used for combat purposes. The study lists the main design units of the launch system, army unmanned aerial vehicle and cases. The combat equipment of the RPSKD-2 UAV provides for suspended armed cases that will be attached to the lower part. When designing and constructing an army UAV, foreign and domestic experience in machine-building production in this field of knowledge was studied. When modeling the UAV, the Compass and Siemens NX software product was used. The following general scientific methods for studying research materials were used in the article: analysis, deduction and modeling. The purpose of the study is to develop a two-case UAV with a launch system. This article is the first part of the study, in a number of author's scientific articles. Further publications of the authors will be devoted to the UAV structural and functional control system, which includes: telemetry, gyroscopes, automatic control system, sensors, controllers, engine, etc.

Design and Strength Analysis of a New Construction of a Sweeper with an Independent Surface Copying System Dedicated to Small Loaders and Front Loaders

Most enterprises and farms have paved parking lots, yards, warehouses, or sidewalks that need to be cleaned or cleaned. There are many sweepers available on the Polish and European markets, but there is still a lack of a solution that would be mounted on pallet forks and would have an independent copying system to support sweeping surfaces with different inclinations. The aim of the work was to develop a conceptual design for a new sweeper equipped with an independent surface copying system dedicated to small loaders and front loaders, as a well as strength analysis of the main frame. The conceptual design included an analysis of available solutions, development of a 3D CAD model of the new sweeper, and a detailed strength analysis of the sweeper’s main frame using the finite element method (FEM). The sweeper model was made in the Autodesk Inventor program, while the FEM strength analysis was made in the Siemens NX program. The designed frame model did not have nodes in which the stresses would be greater than 25% of the allowable stress in the material structure and 33% of the maximum allowable stress in the structure of the joints. The sweeper developed new design fulfills all the assumed functions and has a good chance of application.

Comparison of computer-aided design systems KOMPAS-3D and Siemens NX

A comparison of Siemens NX 10 (2014) and KOMPAS-3D 21 (2022), widely used computer-aided design (CAD) systems in Russia, is made. The main features, advantages and disadvantages of these design systems are considered. The presented data can be used at justifying the choice of CAD for solving a specific type of problem. Keywords mechanical engineering, computer-aided design system (CAD), Siemens NX 10, KOMPAS-3D 21

Thermal Analysis of AlainSat-1: A 3U Cubesat for Earth Observation

AlainSat-1 is a remote sensing CubeSat carrying earth observation payloads developed by student teams from three international universities. Planned for launch in 2023 it is a direct result from the collaborative effort between the IEEE Geoscience and Remote Sensing Society (GRSS) and the National Space Science and Technology Center (NSSTC) at UAE University. CubeSats are popular among the research and academic communities as a space platform from which to perform related research and academic work connected to space technologies due to their compact size, shorter development time, and relatively low cost. However, because most CubeSats are built using off-the-shelf components, their capacity to resist the harsh environments of space must be proven. Aside from ensuring that structural criteria are met, thermal analysis is critical for ensuring that components or payloads stay functioning in extreme hot or cold environments. The thermal analysis results of AlainSat-1’s finite element model (FEM) functioning under the projected thermal environment associated to its mission are presented in this study. Preliminary results from the analysis using SIEMENS NX show that temperature measurements are within an acceptable range. However, more modification of the simulated environment and FEM in terms of mesh sizes and radiative and conductive thermal couplings is needed before conclusive results may be obtained. The approved simulated results and parameters will be tested experimentally in a Thermal Vacuum Chamber. In addition, challenges identified throughout the analysis and their remedies are discussed.

Automated Design of Experiments supporting Feature-based Optimisation of Manufacturing Processes

This paper presents a novel process design to enhance time and cost-efficient AI training in manufacturing. As an alternative to time and resource expensive trial-and-error loops, the data basis of the proposed design enables data-driven parameter selection, where the parameter range in which the optimal solution is likely to reside, can be explored in a reproducible and systematical manner. A full-factorial DOE is generated and implemented from within the CAM software. Necessary production artefacts, like NC code, bill-of-material or work plan, are supplied per experiment. The heterogeneous data of different product life cycle phases are collected and related to the according manufacturing feature (i.e., drilling, face-milling, etc.). From within the CAM software, the NC-Code is manipulated to enable the identification of features during production, using feature markers. Instantiated as Siemens NX CAM extension, the novel design was tested on a 5-axis milling and drilling process on aluminium parts. The automated data set generation with feature correlation between different live-cycle phases was verified. As a result, the design supports feature optimization strategies for decision support systems - either as input for CAD/CAM, PLM, ERP and MES.

An AutomationML extension towards interoperability of 3D virtual commissioning software applications

ABSTRACT To achieve interoperability between different 3D virtual commissioning software, a generic virtual commissioning data model is required. AutomationML is a standard neutral format for interoperability in the engineering phase. However, the current AutomationML standard is not sufficient for full-scope 3D-based virtual commissioning data exchange, as attributes and modeling method of 3D virtual commissioning-related sensors, actuators and signal connections are not standardized in AutomationML. To fill this gap, the authors suggest extending AutomationML for interoperability in 3D virtual commissioning. In this paper, a case-driven iterative approach is introduced to evolve towards an AutomationML extension. This extension is gradually developed by taking the union of all virtual commissioning-related functions and attributes of 3D virtual commissioning software. During the iteration, naming rules are applied when a new attribute is added to the extension. With this approach, an initial AutomationML extension is created by implementing a first iteration. The interoperability performance of this extension is subsequently evaluated by conducting data exchange of a representative set of 3D emulation models between two 3D virtual commissioning software, namely Siemens NX and Visual Components, via self-developed ‘Import’ and ‘Export’ plug-ins. It shows that AutomationML extension-based data exchange converts 70% more attributes than that only based on AutomationML.

МЕТОД ПРОЕКТУВАННЯ ТА ПАРАМЕТРИЧНОГО МОДЕЛЮВАННЯ СИЛОВОЇ НЕРВЮРИ КРИЛА ЛІТАКА ТРАНСПОРТНОЇ КАТЕГОРІЇ

The creation of any structural element begins with the design of basic geometric parameters. In the article, the method of designing and determining the main elements of the structure of the main ribs of the wing with conditions of static strength were reviewed, and a method of three-dimensional parametric modeling was developed. The rib is one of the most important elements of the wing, which act significant flight loads, and the main ribs additionally act concentrated forces. The article analyzed the design features of the rib design of the wing of the transport category aircraft. An analysis of the current loads on the main rib was performed, shear and bending diagrams were determined. During realize high-lift devices, the aerodynamic flow of the wing changes significantly, which leads to a change in the stress-strain state of the wing. This relates not only to the increase in lift due to a change in the curvature of the wing and an increase in the wing area, but also due to a change in the position of the center of pressure relative to the chord of the wing. Therefore, to determine the loads, the aerodynamic characteristics, obtained by the numerical method in the ANSYS program, were used. In order to remain competitive, the aviation company needs to ensure the high quality of the manufactured equipment, its quick modernization and modification or change of the model series. The use of CAD/CAM/CAE/PLM systems at all stages of the life cycle of aviation parts, including the design and production stages, can significantly improve the quality of the created parts and reduce the cost of performing work related to design and production, while maintaining high rates of work. The method of three-dimensional parametric modeling of the main machined wing rib was developed using the Siemens NX computer integrated system, which allows to significantly reduce the stage of modeling typical elements of the aircraft airframe structure using the created three-dimensional parametric model of a typical structural element

An Optimization Method for Improving the Accuracy of Multiple Parametric Printed Parts in FDM

Dimensional accuracy is one of the main key features for achieving the desired fit in fused deposition modeling (FDM). Printer tolerance and build orientation are the main challenges faced during the prototyping phase and hence there is a need for a method to calibrate the printer and the material being used that can serve as a guide to designing the clearances of mating parts. This paper presents the design and validation of a tolerance prototype and the study, which, with some analysis and data representation, gives the optimal solution. Hence, this can be used to compensate for the variations in dimensions while printing. A tolerance prototype model consisting of squares and circles of various dimensions is developed in Siemens NX 11.0 that tests the printer in three different orientations i.e., x-axis, y-axis and z-axis. FDM printers Accucraft i250 (heat bed type) and Flashforge (non-heat bed type) are used to print the prototype. The dimensions are measured with calipers to arrive at the dimensional correction templates that are further used to design and validate movable components.

Exhaust Gas Pressure and Flow Velocity Analysis of the Conical Silencer High Performance Low Noise Exhaust Muffler

This study aims to determine the exhaust gas pressure and flow velocity of the conical silencer muffler compared to various types of muffler commonly used in the market. Conical silencer muffler developed to obtain high performance and low noise for internal combustion engine. Analysis of flow velocity and pressure used CFD method, the input fluid velocity parameter of 12000 mm/s with Siemens NX 10 software. Four exhaust mufflers have been designed in this study, conical silencer muffler, free flow muffler, a db killer installed in free flow muffler, and OEM muffler. The results of the analysis that have been carried out shown the conical silencer muffler has a max flow rate of 31200 mm/s with a pressure of 0.713 KPa, the OEM muffler has a flow rate of 47500 mm/s with a pressure of 4.250 KPa, the free flow muffler has a flow rate of 26500 mm/s with a pressure of 0.471 KPa, while the free flow muffler with db killer has a flow rate of 123000 mm/s with a pressure of 28.4 KPa. Based on these data, the performance of the free flow muffler was used as a benchmark for the performance of other mufflers. Conical silencer muffler has a flow difference of 4700 mm/s (18%) and a pressure difference of 0.24 KPa (51%) higher than free flow muffler, OEM muffler has a higher flow difference of 21000 mm/s (79%) and a pressure difference of 3.78 KPa (802%), free flow muffler with db killer has a higher flow difference of 96500 mm/s (364%) and a pressure difference of 27.93 KPa (5930%) compared to free flow muffler. Based on these data, it can be concluded the conical silencer muffler can generate performance near to the free flow muffler.

Optimization of Components with Topology Optimization for Direct Additive Manufacturing by DLMS.

This paper presents a novel design methodology that validates and utilizes the results of topology optimization as the final product shape. The proposed methodology aims to streamline the design process by eliminating the need for remodeling and minimizing printing errors through process simulation. It also eliminates the repeated export and import of data between software tools. The study includes a case study involving the steering column housing of a racing car, where Siemens NX Topology Optimization was used for optimization, and verification analysis was conducted using the NX Nastran solver. The final solution was fabricated using AlSi10Mg via direct metal laser sintering on a 3D printer and successfully validated under real conditions. In conclusion, this paper introduces a comprehensive design methodology for the direct utilization of topology optimization, which was validated through a case study, yielding positive results.

Integrated Aircraft Design System Based on Generative Modelling

This article presents the effects of work performed during a software project for generative models and spreadsheets, allowing the quick creation of conceptual models for aircraft. The presented software at the current stage is suitable for the creation of glider representation; however, a modular structure allows for developing and extrapolating the presented application to match the requirements of planes and UAV (unmanned aerial vehicle) design. The subject of this work is a response to the current trends and needs prevailing in the field of CAD (computer-aided design) and aviation. In the initial sections of this paper, theoretical issues related to the work being carried out are introduced, and the methodology for creating software for the construction and verification of the aircraft structure along with the need for interchange between databases of generative models is presented. In the following sections, the concepts and selected solutions for the user interface that supports the knowledge base are presented along with a set of procedures for its operation. Furthermore, a method for database integration with the methods used to determine design features for the developed generative models and the Siemens NX system is introduced. Problems encountered during software development, as well as solution examples for model applications, are specified. The results obtained and the models generated on their basis were tested with a strength analysis using Autodesk Inventor software and analysed in terms of meeting the initial assumptions. In the end, conclusions and observations were formulated resulting from the effects of the work performed during the project.

Case Study of Additively Manufactured Mountain Bike Stem.

This article is focused on a case study of the topology optimisation of a bike stem manufactured by selective laser melting (SLM) additive technology. Topology optimisation was used as a design tool to model a part with less material used for transferring specific loads than the conventional method. For topology optimisation, Siemens NX 12 software was used with loads defined from the ISO 4210-5 standard. Post-processing of the topology-optimised shape was performed in Altair Inspire software. For this case study, the aluminium alloy AlSi10Mg was selected. For qualitative evaluation, the mechanical properties of the chosen alloy were measured on the tensile specimens. The design of the new bike stem was evaluated by Ansys FEA software with static loadings defined by ISO 4210-5. The functionality of the additively manufactured bike stem was confirmed by actual experiments defined by ISO 4210-5. The resulting new design of the bike stem passed both static tests and is 7.9% lighter than that of the reference.

Precision Analysis of Chain Wheel Geometry Reconstruction Based on Contact and Optical Measurement Data

This study focuses on the detailed reconstruction of chain wheel geometry utilizing measurement data gathered from the MarSurfXC20 contact system and the iNEXIVE VMA 2520 optical system. Supplementary data were also gathered from a digital micrometer and a caliper to provide a comprehensive data set for the analyzed geometry. The geometric model of the chain wheel was then constructed using Siemens NX software. The reconstructed model was subsequently compared with the original design specifications to assess the fidelity of the reconstructed model. Results demonstrate a high degree of correlation between the model generated by reverse engineering and the original design model. Despite the satisfactory correlation, potential inaccuracies were identified, necessitating further research to mitigate these discrepancies and optimize the procedures for parameters beyond the established tolerance. The study affirms the feasibility of utilizing contact and optical measuring systems in the reverse engineering process of chain wheel geometry, although it underscores the need for additional refinement to improve the model's accuracy.

Parametric model of aircraft external geometry as a component of FAST-OAD aircraft preliminary design system.

Rapid evolutions in fields such as aerospace propulsion, materials engineering, geometry modelling tools or optimization tools provide the opportunity to search for novel configurations of future aircraft in an expanding domain. In order to effectively explore the space of variables of constantly expanding size, one needs tools that give the ability to automate this process. Such a tool is the Future Aircraft Sizing Tool for Overall Aircraft Design or FAST-OAD. FAST-OAD allows for rapid estimation of aircraft size, based on set, so-called Top Level Aircraft Requirements (TLARs) by using multi-disciplinary and multi-fidelity analysis and optimization.An essential component of such a system is a module capable of modelling the external geometry of the calculated case. This article describes an attempt to use a powerful commercial Computer Aided Design software, Siemens NX, to model the aircraft external geometry based on the results of the analysis performed by FAST-OAD. This approach, compared to previous works, brings some limitations but, on the other hand, gives the possibility to base the geometry on a mathematically consistent model and helps to better understand the set of parameters necessary to describe the geometry correctly.The main objective of this research is to provide a tool that allows the automatic generation of aircraft exterior geometry based on the output parameters received from the FAST-OAD package.An additional goal of this activity is to determine the parameter set necessary to properly define the external geometry, but at the same time not containing redundant, dependent geometric parameters. The minimum number of independent parameters necessary to completely describe the external geometry is sought.

Variable nozzle turbocharger: gas-dynamic calculation, 3D modeling, CFD analysis, characteristics

Introduction (problem statement and relevance). The environmental requirements for vehicle engines becoming more stringent require development and introduction of high-performance turbo chargers. Transition from external to internal varying, namely to the variable nozzles of the turbine, is caused by the necessity to reduce the transient process time during operation of the engine and the vehicle itself.The purpose of the study is development and confi rmation of the methodology (general strategy) for designing and modernization of radial-axial turbines with variable nozzles.Methodology and research methods. The study used the combination of calculation models for the engine itself with preliminary verifi cation based on the results of tests on the engine test bench (AVL BOOST, CRUISE M), gas-dynamic calculation of the turbine stage with determination of geometric parameters of the blade ring, housing (volute) and blade drive mechanism, their geometric modeling (Siemens NX) followed by 3D models export, CFD simulation of the stage fl ow including taking into account the transfer element (with impeller rotation) and generation of the stage curves (AVL FIRE).Scientific novelty and results. Combination (synthesis) of calculation models of different levels makes it possible to determine geometric parameters of the turbocharger turbine with variable nozzles providing high effi ciency (performance factor) of the turbine stage with a simultaneous shift of the maximum torque mode of the engine itself to the area of lower crankshaft rotation rate (along the full-load curve).Practical signifi cance of the paper consists in reduction of the time of design and subsequent refi nement (experimental) works during creation and modernization of turbines with variable nozzles of small-sized turbochargers. The obtained values of relative geometric parameters can be used at the design stage

Developing digital twin design for enhanced productivity of an automated anodizing industry and process prediction using hybrid deep neural network

Automation is beneficial when implemented in challenging environments requiring less human effort or reducing human effort. Employee safety is a concern to increase productivity, delivery and achieve the required quality. The present research investigates the possibility of installing an automation procedure in an anodizing industry called GOLDEN ANODIZER, which is situated in Coimbatore, India. During the preliminary analysis at the specified industry premises, there was a reduction in productivity, quality and customer delivery due to manual operations, including some health issues were identified. And hence the present investigation analyses the possibility of installation of an automation system for the anodizing process. For such reason, the digital twin of an automation system is first designed, developed and tested using Siemens NX software. The anodizing factors such as Anodizing medium temperature (K), Acid Concentration (wt%), applied voltage (V) and Responses Surface Finish (Ra), Film Thickness (tf) and Time Duration (T) were optimized for improved productivity and quality. Prediction results and RMSE analysis show that the proposed hybrid PSO-LFA algorithm has outperformed all modern algorithms. The proposed algorithm optimized the anodizing parameters and suggested 3650.7 s as a new cycle time. Also, the improved cycle time can boost the plant outcome by 182% and reduce the manpower by 46% through the proposed Automation system.