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Design and Implementation of Modern Design Platform for Mechanical Products Ding Hua?Duan Lei?Yang Zhaojian?Wang Xuewen?Wang Yiliang College of Mechanical Engineering of Taiyuan University of TechnologyTaiyuan, China yangzhaojian Abstract?Based on modern design theory of products, the paper sets up a web-based design model and develops modern design platform for mechanical products with the applications of .NET and component technology, Web database technology and CAD(Computer Aided Design) / CAE(Computer Aided Engineering) secondary development tools, aiming at solving the problems of distributed knowledge resources and low efficiency in the process of mechanical products design. The platform is characterized with the functions of remote design, online parametric mapping of performance curves and equipment installation layout, remote fault monitoring and diagnosis for equipments, and CAD/CAE collaborative design and analysis, which can shorten the cycle of product development, reduce the capital investment of enterprises, and strengthen the exchange of information sharing. The paper introduces the design and implementation methods and verifies the validity and reliability of the platform by specific examples. Keywords-modern design; design platform; remote design; fault monitoring and diagnosis; CAD / CAE collaborative analysis; .NET I. INTRODUCTION In essence,the competition between manufacturing sectors is that of the product design. In China, the development of manufacturing industry is mainly relaying on the introduction of foreign design. Therefore, it is impossible for China to improve the competitiveness of national manufacturing industry, if it can not take the lead in introducing the latest technology to products to make up for the inadequacy of the original products performance. Different from the relatively stable processing equipment, the design knowledge is a dynamic collection of knowledge, which means that the advanced knowledge in the past is the general knowledge at present and will become the knowledge to be updated in the future. If fact, this is the most important reason to construct and develop products design platform in the environment of distributed resources 1. At present, the online cooperation research of the worlds developed countries is going ahead with full stream, the guiding ideology of which is to strengthen the solidarity, cooperation and development of member units and to make full use of integration and their respective features in order to carry out research in related disciplines more effectively. In the field of online cooperation design, the focus of domestic and foreign R & D units is different, some of which focus on the technology research of remote interactive collaboration environment 2-4, while others focusing on the system development on some specific subject areas5-7. However, so far, little research on design platform for mechanical products has been carried out. Based on the theory of modern design, the paper establishes the model of modern design and develops modern design platform for mechanical products, which includes the platform framework to support the integration of distributed design resources, a series of application integration components environment, and six application systems to support product design. The modern design platform provides wide range of service innovation platforms and builds an innovation design environment of regional collaboration for mechanical products. II. SUMMARY OF MODERN DESIGN THEORY Modern design theory is the theoretical basis for the construction of product design platform, which studies design activities under distributed resources environment. 2009 Second International Conference on Intelligent Computation Technology and Automation978-0-7695-3804-4/09 $26.00 2009 IEEEDOI 10.1109/ICICTA.2009.5433152009 Second International Conference on Intelligent Computation Technology and Automation978-0-7695-3804-4/09 $26.00 2009 IEEEDOI 10.1109/ICICTA.2009.5433152009 Second International Conference on Intelligent Computation Technology and Automation978-0-7695-3804-4/09 $26.00 2009 IEEEDOI 10.1109/ICICTA.2009.5433152009 Second International Conference on Intelligent Computation Technology and Automation978-0-7695-3804-4/09 $26.00 2009 IEEEDOI 10.1109/ICICTA.2009.5433152009 Second International Conference on Intelligent Computation Technology and Automation978-0-7695-3804-4/09 $26.00 2009 IEEEDOI 10.1109/ICICTA.2009.5433152009 Second International Conference on Intelligent Computation Technology and Automation978-0-7695-3804-4/09 $26.00 2009 IEEEDOI 10.1109/ICICTA.2009.5433152009 Second International Conference on Intelligent Computation Technology and Automation978-0-7695-3804-4/09 $26.00 2009 IEEEDOI 10.1109/ICICTA.2009.543317Authorized licensed use limited to: CHINA UNIVERSITY OF MINING AND TECHNOLOGY. Downloaded on June 09,2010 at 03:22:09 UTC from IEEE Xplore. Restrictions apply. Modern design theory holds that design is the soul of manufacturing industry and is driven by performance demand and that design is knowledge-based and new knowledge-centric. Because knowledge acquisition is resource-dependent, competition is forcing design resources to change from vertical structure to horizontal structure, that is, distributed resources environment. The development of computer and network technology makes it possible that constructing a research and development platform of dynamic integration of distributed design resources. Product design platform is the specific supporting environment and implementation tool for modern design theory and method of product applied in enterprises1. III. PLATFORM DESIGN MODEL Online cooperation design model is constructed by open system architecture8, which includes the following three layers (Fig.1). The layer of support platform: the platform is supposed to adopt standard and general system software. The system software to support the diversification can reflect the compatibility of the platform. Resource pool includes basic database, material database, engineering knowledge, and other related data and knowledge. The layer of support tools: it provides system secondary development tools and tools for the integration of the platform and the other systems. Figure 1. The online cooperative design model for mechanical products The layer of general platform: it forms the main part of modern design platform for mechanical products. The layer is composed of a series of special function modules and the corresponding general platform can be realized through calling, coordinating, controlling, and integrating these special function modules. The general platform includes: general support system on mechanical design; innovation support platform on mining mechanical equipment; innovation support system on heavy-duty mechanical equipment; remote monitoring and fault diagnosis system; CAD/CAE collaborative design and analysis system and platform management system. IV. PLATFORM DESIGN A. Structure Design The platform adopts three-layer B/S structure, that is, Browser/Server/Database.The three-layer structure is clearly divided into three application parts (presentation part, business service part, data access part), which are called respectively interface layer, business service layer, and data layer. The three layers are logically independent and can be achieved independently. Interface layer is the front-end user interface, the function of which is to achieve interaction with user by user interface at client side, submit service requests to application servicer and display the data of application output. Business service layer, also called business logic layer or middle layer, is the core of the whole application program, which deals with all the service requests from client side, including numerical calculation, numerical analysis, and the integration of various CAx software. The function of the data layer is to process data definition, data query and updating and to maintain data security and integrity. With Windows 2000 Server+IIS5.0+.NET as its platform, SQL Server 2000 as its backstage database and Microsoft Visual Studio?MVS?2005 as its development tool, the system completes its construction and improvement by use of ASP.NET and component support technology. B. Function modules Design for platform function shown as Fig.2: General Platform General Support System on Mechanical Design Innovation Support System on Mining Innovation Support System on Heavy-duty Mechanical Equipment Remote Monitoring and Fault Diagnosis System CAD Collaborative Design System CAE Collaborative Design System Platform Management System Support Tool CAD Modeling Tool UG?PROE CAE Analysis tool ANSYS Graphic Mapping Tool AutoCAD Secondary Development Tool Interface Development Tool Coordination Standard Network System Hardware Platform Engineering Database Engineering Knowledge Base Modern Design Platform for Mechanical Products Support Platform Resource Pool316316316316316316318Authorized licensed use limited to: CHINA UNIVERSITY OF MINING AND TECHNOLOGY. Downloaded on June 09,2010 at 03:22:09 UTC from IEEE Xplore. Restrictions apply. Figure 2. Function modules of online technical support system for mechanical equipment V. APPLICATION SYSTEMS IN THE PLATFORM A. Innovation Support System on Mining Mechanical Equipment The system provides selection design for eight kinds of large-scale mining equipment including mine hoist, belt conveyor, scraper conveyor, mining electric locomotive, mine ventilator, mine pump, mine compressor, mining electric equipment. Based on automatic online equipment selection, the system saves a large number of working hours of users and designers with the cumbersome conventional assignment such as the process of optimization, the calculation of working point and drawing, which now can be handled accurately and rapidly by computer. Moreover, traditional selection method can not achieve the effect of optimization in that parameters and programs involved in the process of selection are excessive and that parameter calculation and program determination are quite complex and some factors are difficult to be quantified. The system makes the selection result more accurate through establishing mathematical model of selection. 1) Selection design module Selection of each equipment is divided into several functional modules, of which the online hoist selection subsystem, for example, consists of modules such as equipment selection, electric drive, sample expansion, selection method and auxiliary function. The selection process plays a key role in any selection of mechanical equipment. The selection operator inputs in the platform interface the key parameters, which are then sent to a Web Server after formatted. The Web Server implements the preliminary selection according to the preset selection algorithm, during which the Server sends data request to the database, which would then feedback the result of selection to the Server after receiving the request. In accordance with selection optimization method, the server would send data request again to the database. At last, the database returns the final selection result which then would be outputted to the platform interface. 2) Graphic Display Module a) The online mapping on curve diagram of equipment performance The online mapping on curve diagram of equipment performance refers to the process of mapping equipment performance curve automatically by computer according to experiment data. In consideration of no specified function expression on characteristic curve of equipment defined by the manufactures through experiment, the graphing method is needed to find the intersection point and the corresponding condition parameters. Because the process of selection is carried out by computer automatically, people are not allowed to intervene in the process of selection. The Public Database of Mechanical Design Innovation Support System on Mining mechanical Equipment General Support System on Mechanical Design Remote Monitoring and Fault Diagnosis System Model Transferred CAE call Finite Element Analysis Dynamic Analysis Kinematical Analysis Hoisting Equipment Design Drainage Equipment Design Ventilation Equipment Design Compressor Design Electric Locomotive Design Scraper Conveyor Design Modern Design Calculation Method Data Query Mechanical Dictionary Business Directory Data Upload Fault Diagnosis Fault Diagnosis Diagnostic Method Innovation Support System on Heavy-duty Mechanical Equipment Metallurgical Machinery Mining Machinery Hoisting and Conveying Heavy Metal Forming Heavy Casting and Forging Calculation of Load and Sensitivity Collaborative CAD / CAE Design and Analysis System Common Data Professional Standards Engineering Materials Design Technology Equipment Information Product Information Modern Design Platform for Mechanical Products 317317317317317317319Authorized licensed use limited to: CHINA UNIVERSITY OF MINING AND TECHNOLOGY. Downloaded on June 09,2010 at 03:22:09 UTC from IEEE Xplore. Restrictions apply. Figure 3. The online mapping page key issue is how to convert the human process to find intersection in mapping into computer process, the answer to which is the fitting method. Based on the calculation results of all the cases, the best curve fitting method is determined after the analysis and comparison of a variety of fitting methods. Then the equation of each curve would be obtained by contriving the optimal algorithm to generate function. At last, the equipment performance curve is drawn through programming language. The system adopts .NET component technology for designing Graphic Display Module and then makes the application program into executable file (.EXE) or dynamic link library (.DLL). ASP.NET adds a bin folder. When using components, there is no need for people to register them, which the system would load automatically after the *.dll file is copied directly to the bin folder. Fig.3 is a webpage that displays the online mapping of the mine drainage pump performance curve, in which there are the characteristic curve of pump and the relation curve on characteristic curve, lift, shaft power, and efficiency, cavitations height of pipeline and flow rate of pipeline. b) The parametric mapping of equipment installation layout The layout drawings of equipment installation are usually engineering drawings by the help of AutoCAD. In most cases, a range of products are accompanied with the same layout drawing of equipment installation, only different in size. In view of this situation, many object-oriented programming languages and applications can communicate with AutoCAD and manipulate many functions of AutoCAD by utilizing the technology of AutoCAD ActiveX Automation?CADAA?. Parametric drawing program design of equipment installation layout in the system is carried out mainly on the basis of parameters provided by the structure-known mechanical equipment installation layout of different types. In view of the limited size data of mechanical equipment, people need to determine mapping parameters by analyzing structural characteristics of mechanical equipment. Firstly, by analysis of the structural characteristics of parts, the basic size of parts and the correlation between basic size and installation size are determined. Then the corresponding basic size as mapping parameters is calculated through the given installation size. After that, mapping program can be designed in accordance with the graphic needs. B. Remote Fault Monitoring and Diagnosis System The remote fault diagnosis of equipment is a new technology which combines mechanical equipment fault diagnosis with network technology. The technology can be practiced by setting up state monitoring points on the key equipment of large-scale enterprises to collect the state data and establishing remote diagnosis centers in research units with strong technological force to monitor and diagnose the state of equipment performance. The operation processes of the system are as follows: firstly, the operation state information of mechanical equipment is collected by sensors installed on the key equipment of large-scale enterprises, which then would be stored in the equipment information database after signal preprocessing and A/D conversion. After that, the information would be uploaded to diagnosis center for fault diagnosis by e-mail or file upload and then the diagnosis center returns diagnostic result to user or the data file can be sent to relevant experts and partners for the collaborative diagnosis, the result of which would be returned to user. On the basis of its function, the system can be divided into three modules: Online local monitoring, Diagnosis expert and Remote fault diagnosis. C. CAD / CAE Collaborative Design-Analysis System At present, the remote CAD/CAE resources acquisition based on WEB is an active research and application area. 318318318318318318320Authorized licensed use limited to: CHINA UNIVERSITY OF MINING AND TECHNOLOGY. Downloaded on June 09,2010 at 03:22:09 UTC from IEEE Xplore. Restrictions apply. The system can accomplish the parametric modeling and the parametric finite element analysis of the main components of web-based mechanical equipment. The system realized by the secondary development tools of CAD/CAE software and .NET technology, can not only carry out task of online parametric modeling in accordance with the basic parameters input by user but also that of parametric finite element analysis of some key components of the selected equipment. The model and the analysis result are available for users to browse and download. In creating the system, the application of CAx software and integration technology is the focus of the study. The system adopts interface integration, which can be achieved by API interface function provided by tool layer and general platform layer, and encapsulate corresponding function module to realize CAx software call. Hence the sound componentization structure and openness. 1) CAD cooperative design system With UG adopted as the support software at the server side, and by using parametric design function of UG to make parametric modeling of parts, the system makes use of function provided by UG to upgrade parameters of the parts and then makes the parametric design program into an individual component to be encapsulated for users remote call. Thus, remote CAD design is achieved. Based on the above technology, remote CAD design system of web- based shearer parts is developed. Fig.4 are the user-side display pages for the remote design of gear. ?Figure 4. Web-based gear design model 2) CAE collaborative analysis system The system bottom CAE software adopts software ANSYS of large-scale general finite element analysis. The users operation in the environment of ANSYS is encapsulated by the system as the macro for users remote call in order to realize the remote CAE application. The remote CAE analysis system of web-based large-scale electric precipitator is developed according to the actual need of some plant. Fig.5 is the home page of the system, which currently is in a good condition. Workflow is as follows: CAE analysis center registers the task after receiving the task package of product analysis submitted by user and then guides the user to input or choose parameters needed in the process of analysis in a friendly graphical interface. From modeling to mesh generation and imposing of constraint and load, the executable command file is generated automatically by the system without users comprehending the generation process of command file. By way of complete function encapsulation, the system encapsulates all functions that would be used by user in the environment of ANSYS. At the user side, user fills in parameters in accordance with design steps. Then the system would automatically compile a batch command script file and submit the compiled file to solver, which would automatically execute the file to complete the finite element analysis. The post-processing also adopts batch command flow mode to extract all analysis results concerned to user in one time such as form, data, graphics, and animation, etc, all of which the CAE analysis service center would finally return to user. Figure 5. Remote parametric design and finite element analysis system 319319319319319319321Authorized licensed use limited to: CHINA UNIVERSITY OF MINING AND TECHNOLOGY. Downloaded on June 09,2010 at 03:22:09 UTC from IEEE Xplore. Restrictions apply. VI. DISCUSSIONS With the purpose of creating an innovative setting for mechanical product design under regional collaboration, and accelerating product innovation of manufacturing by use of knowledge service, the paper does research into cooperative design method on mechanical product under the network environment, aiming to construct an open, cooperative innovation design platform based on network by integrating the existing technological resources of machine-building industry. By making a breakthrough in key technologies of web-based CAD/CAE call, the online mapping of equipment characteristics curve and the online parametric mapping of equipment la
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