and computer-based manufacturing system that integrates manufacturing activities with models and simulation rather than objects and real operation. Need for VM • It is the advancement of lean manufacturing system where the money and time of operation of the engineers is saved by testing them in the virtual world before applying in the real time operation. • In this environment many oriented technology support the activities of the development process that can be used in a integrated way. • They support the product at every stage of its manufacturing process. Technologies of VM • It is new kind of manufacturing technology that mainly consists of Simulation technology Virtual reality technology Information technology Simulation lab • The initial purpose of VM was to achieve a better comprehension of the use of higher interactivity surfaces. • This lead to the development of the virtual prototype of the interlock of the CNC turning machine which followed by the creation of framework to allow a generation of concurrent and distributed environment. • The further development lead to the use of neutral format files to provide data interoperability in the VM environment • In this lab, the integration of the project and information occur. • The process and the design of the product is studied and the necessary changes are made in them before they are manufactured • It is used in various different fields to integrate the process and the object and predict the outcome. • Depending upon the target, various simulation methods are used to obtain the required output. Virtual reality technoloy • The development of 2D to 3D is done by virtual reality technology. • The design and drawings that were made in simulation lab is converted into 3D models and the factors that affect the job when used is real world is calculated. • Inorder to create a modular system, “database interface” has been created so that the virtual layout builder can work without regards to the internal structure of the information system. • The virtual reality technology has grown from 3D software to wearable glasses that provide information about the system. • It is used in different sectors where it helps the individual to scan the area and the difference from original can be visualized. • It is used in various departments in an industry from inventory management to factory floor planning. • The smart glasses that provide video, graphics and text guide the workers in the step by step manufacturing process. • It is used to simplify and significantly shorten the process. Information technology • They guide the information and the data that has to be processed along the system. • The data is being processed in Structured Query Language( SQL ) sequence throughout the process. • Though, it uses various programming techniques and languages to process the data, the main processing is done using SQL • The various stages in SQL include Parsing, Optimization, Row source generation and Execution. • Parsing: the statement is broken into different SQL structures and Parse call is given that prepare the database for its statement of execution. • During the parse call the database performs the following check Syntax check Semantic check Shared pool check • In Optimization, the system performs Hard Parse where multiple data files are executed and they are being checked. • Row source generator is a software that receives the optimal generation plan from the optimizer and produces an iterative execution plan that is usable by the rest of the database • During execution, the SQL engine executes each row source tree produced by the row source generator. Virtual fusion • The main disadvantage that is faced in virtual manufacturing is that the validation methods with the physical system lead to costly run-off process or inefficient manual over rides. • One of the approach to solve this is by introducing a virtual component into the physical environment. • The virtual fusion is done by integrating the virtual and physical components in a system into a single entity. • It forms a hybrid architecture for the part flow, process, full system validation and analysis. • Some of the advantages of virtual fusion environment include: 1. Less waste 2. Improved system responsiveness 3. Reliable updates • It is majorly followed in mass production and industries where cost effectiveness play an important role. PLC • In virtual environment, the most oftenly used system controller is Programmable Logic Controller (PLC) • The fusion environment consist of system controller, physical plant and a model of key components within the physical plant, and a virtual fusion filter that synchronizes and filters the data from the physical plant model. • The various process that is being followed in PLC include, 1. Identify the process 2. Key components of the process 3. Essence for each process 4. Effect of the essence • To achieve the aforementioned processes, various sensors and actuators are used which will be activated by the PLC based on the needs. Virtual fusion filter • The goal of the filter can be divided into two main tasks 1. Synchronize the input data from the physical and virtual environments 2. Filter the data values to ensure that the input signal to the system controller contains the essential characteristics to trigger the next process when the physical part is swapped with its virtual counterpart. • Data synchronization in the real time is necessary to ensure that correct signal is sent to the system controller at the correct time. • Mismatch in timing between the real and virtual world will result in incorrect behaviour. • Once the synchronization has been confirmed, the essence value from the virtual and physical system are compared to identify the discrepancies due to the introduction of virtual part. Modelling assumptions • The simulation and physical essence and effect parameters for the given model should match. • For a given input signal from the system controller, the simulation and physical testbed should execute the same process. • A work part’s process sequence through the system should be independent of whether the part is physical or virtual. • A virtual part must provide the necessary essential characteristics that trigger all the subsequent process. • A virtual machine with a virtual process must result in the necessary effects on the work plant. • Part handling devices are tracked separately from the work part. • Virtual parts are introduced in the virtual environment prior to the physical system. Major obstacles in development of VM • The operational speed of the system: The VM system is required to handle large amount of work on complex mathematical computation, graphical image processing, data exchange and remote communications. These include construction of 3D solid model, 3D animation, virtual reality(VR), graphical image processing, manufacturing resource planning etc. The external interface and the speed of the I/O of the computer have to be enhanced. • Manufacturing know-how, modelling and representation: The successful development of VM depends on present knowledge and capabilities of applying modern mathematical tools to describe and to present the knowledge in a systematic manner. For example, the present understanding on the selection of optimal cutting conditions for metal removal process is still far from perfect. • Artificial intelligence (AI) for knowledge acquisition: Better learning and knowledge acquisition capabilities of the RM facility to facilitate the monitoring of the operational performance of the RM system as well as to make better and more accurate predictions and decisions. • Unify the data standards: though there are standards build by ISO organisation, the data standards used by the production facilities and software of different manufacturers might be different. Conclusion • It appears that nowadays we manufacture for both manufacturability and manufacturing efficiency. • Though there is lot of work to do, all pieces are in place for virtual manufacturing to become a standard tool for the design to manufacturing process. References • Virtual manufacturing as a way for the factory of future: Mariella Consoni Florenzano Souza, Marcco Sacco, Arthur Jose Vieira Porto • Virtual fusion: integrating virtual components into a physical manufacturing system: Nicholas M Putman, Francisco Maturana, Kira Barton, Dawan M. Tilbury • Philippe Dépincé, Damien Chablat, Peer-Oliver Woelk, Virtual Manufacturing: Tools for improving design and production, Technical Workshop on Virtual Manufacturing, 2003. Thank you!