Human simulation in BIW spot

welding process using

Process simulate

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 Overview
 In Process Simulate it is possible to have a human model in the
simulation & Creating human simulations with weld gun accessibility in
Process Simulate is very demanding in OEMs
 Human simulation allows users to verify the design of a workstation,
ensuring the product parts can be reached, assembled and maintained.
 Human simulation provides powerful capabilities to analyze and optimize
the ergonomics of the human operation, thus ensuring an ergonomically
safe process according to industry standards.
 Using the human simulation tools, the user can perform realistic
simulation of the human tasks and optimize process cycle times
according to industry standard ergonomics libraries.

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 Features of Process Simulate

 Static and dynamic collision detection

 Sequencing of operations
 Resource modeling (3D and kinematics)
 Human tasks simulation
 Reach envelopes
 Vision window
 Postures
 Auto grasp wizard
 Ergonomics analysis
 Gun search wizard
 Weld gun validation

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 Benefits of Process Simulate

 Reduce cost of change with early detection and communication of product design issues
 Reduce number of physical prototypes with upfront virtual validation
 Optimize cycle times through simulation
 Ensure ergonomically safe processes
 Reduce cost by re-using standard tools and facilities

Benefits over DELMIA for Human simulation

 Simulating several manufacturing scenarios with less time consumption since the
simulation is user friendly
 Applying kinematics is easy & more parameters can be included for validation
 Sequence of operation can be easily modified & controlled

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 Methodology

 To carryout human simulation in Process simulate we need to study ergo

standard of particular OEM
 Ergo standard gives the values of operator constraints like reachability,
allowable postures, clearance & load
 Standard values are the parameter for human simulation in process simulate &
these values are assigned while doing simulation to get desired results
 Concerns are documented for the cases violating these parameters while doing
human simulation

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 Neutral Posture
Important parameters needs to
check in ergo standard & to be used  Neck straight
 Back upright
as input for human simulation are  Arms to the side
shown below  Legs straight
 Feet evenly balanced on the floor
Poor Postures

Bend > 20 Twist > 45 Lean > 20 Arching Back > 20

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 Poor Postures
Flexed > 20 Extended > 20 Stretched > 20
Reach distance exceeds 800mm

Tilted > 15 Rotated > 30

800mm

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 Poor Postures

Arms out to front > 90 Arms out to side > 60 Extension > 20 Arms In Flexion > 135

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 Results of human simulation will be
verified with below conditions. If the
Operator working region is beyond the
ergo region shown below then it should
be reported with suitable proposal

Load <5kg Load >5kg<8kg Load >8kg<12kg

1300mm
1200mm
1000mm

800mm 800mm 800mm

300mm 600mm 300mm 500mm 300mm 500mm

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