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Custom Analyses & Virtual Modeling (FE Method)

Goes beyond our standard portfolio of analysis services and includes relevant solutions that perfectly match the requirements of your individual application.

Virtual modeling (also known as "finite element analysis") is part of our custom service portfolio To date, renowned companies successfully rely on this service offering to achieve substantial improvements in cycle times, energy conservation, reliability and facility lifespan. We empower customers to fully utilize the hidden potential of positioning technology to achieve tangible results. For additional information about this service offering or supplementary case studies, please contact us at support@psi-technics.com.

Virtual Modeling / Finite Element Method (FEM)

Using Virtual Modeling / Finite Element Method (FEM) to optimize and troubleshoot facilities in factory logistics and automated processes (e. g., industrial vehicles and conveyor systems such as hoists, shuttle cars, freight elevators, material lifts, crane systems, stacker cranes, bridge cranes or overhead cranes) – Identifying installation weak spots ahead of time to cut long-term costs.

PSI Technics offers you a "glimpse into the future" of your installation - enabling you to predict and avoid costly downtimes for new and existing installations.

Advanced Planning: PSI Technics' use of sophisticated Virtual Models / Finite Element Methods helps detect potential weaknesses that can affect future performance. Using virtual modeling, PSI Technics offers you a "glimpse into the future" of your installation. This service enables you to predict and avoid problems that can lead to costly downtimes in new and existing installations, in addition to cutting costs in the long run.

For existing applications, PSI Technics creates computer models to pinpoint stress and strain, weak spots and potential changes for improvement.

For new applications, PSI Technics simulates the expected system behavior and performance prior to the actual installation to predict and analytically detect potential interferences. This approach allows you to identify needed improvements early in the planning stage when comparing designs of different providers.

A Case Study from the Automotive Industry: Virtual Modeling Reveals Huge Optimization Potentials at Volkswagen

PSI Technics is designing the new positioning standard in cooperation with Volkswagen AG in Wolfsburg, Germany.

The Volkswagen AG Conveyor Technology Planning department (PWG-P/F) commissioned PSI Technics to analyze and evaluate a vertical material lift in a vehicle body warehouse.

The Volkswagen AG Conveyor Technology Planning department (PWG-P/F) commissioned PSI Technics to analyze and evaluate a vertical material lift in a vehicle body warehouse. The successful cooperation was aimed at developing a new positioning standard for similar vertical lifting systems.

Virtual modeling – an analysis of machine behavior via computer modeling – was used to simulate all relevant system components and to digitally recreate a variety of different loading conditions. Volkswagen's goal was to reveal optimization potential with regard to improving cycle times, system stability and reduced wear.

Virtual modeling provides reliable data and extensive insights into machine behavior.

By using virtual modeling, different drive and closed-loop configurations could be compared and evaluated with regard to their cost-benefit ratio prior to retrofitting the XSB51 vertical material lift. Based on Volkswagen AG's positive experiences with PSI Technics' ARATEC Positioning Solution System at their Wolfsburg factory, the ARATEC was also used for the virtual modeling pilot project.

Revealing and realizing optimization potential.

A motion analysis was performed to determine the system's current motion profile, which provided a basis for identifying optimization potential. All existing loading conditions and motion sequences were simulated in a virtual model using finite element methods (FEM), multi-body models and controller modeling. FEM is an accepted method of obtaining detailed analysis data. The results were verified against the actual operation of the system and illustrated the benefits of using an intelligent positioning controller versus the more common PLC- or drive-based open-loop control generally designed by OEMs and system integrators. In general, a stress reduction of 10% that can be achieved based on the analysis results can increase a system's lifespan by 50%.

The retrofitted vertical lift fulfilled and exceeded all of Volkswagen's expectations regarding cycle times, stability, reduced wear and power consumption. As calculated during virtual modeling the system's mechanical stress was reduced by more than 15%. At the same time, power consumption decreased and cycle times were reduced by 30%.

Evaluation of the mechanical stresses of a system by means of a dynamic simulation.

At PSI Technics, virtual process modeling goes beyond outlining a desired machine behavior. We offer you an actual representation of the behavior of your specific machines, providing detailed insight into both physical and technical aspects of your installation using real data that far exceeds rough approximations or guesswork.

 

YOUR ADVANTAGES:

• Optimized process costs
• Energy savings
• Increased availability
• Shorter cycle times that match your specific process
• Reduced facility wear
• Reduced operating and maintenance costs
• Improved process quality and sustainability of your processes
• Consistent use of lightweight components to reduce installation weight

 

Three-phase optimization process.

PSI Technics' virtual process modeling is a comprehensive service offering aimed at optimizing existing factory logistics installations. Our experienced staff uses extensive analysis tools to reveal the optimization potential in your facility. We can assist you with designing and commissioning new installations to help minimize the risk of positioning errors that lead to excessive costs.

After the analysis is complete, we are providing you with a sound basis for improving your installation - giving you a complete picture of tangible optimization benefits that lie ahead.

Our application engineers would be happy to provide recommendations for your specific operating environment. Please call +49 (0) 2630 91590-0 or use the contact form to submit your questions or requests or send an e-mail to support@psi-technics.com.

 

Many renowned customers rely on solutions from PSI Technics, including:

• ABL Technic
• AK Steel
• Aleris
• Automation Machine Design
• Corus
• Daimler
• Hanson Pipe & Precast
• Hong Kong Air Cargo Terminals Ltd.
• Konecranes
• Logan Aluminum
• Novelis
• Ovako
• Robert Bosch
• Rotalec Group, Inc.
• Salzgitter Stahlhandel
• Sapa Alluminio Ornago S.p.A.
• Shanghai General Motors
• SKF
• Stollwerck
• TRW Automotive

For more information our application experts are standing by to answer your calls or written requests. Please call +49 (0) 2630 91590-0, use the contact form to submit your queries or send an e-mail to support@psi-technics.com.