Software for design and simulation, visualization and evaluation

We use MATLAB/Simulink software, including the relevant toolboxes (machine learning and deep learning, image processing, optimization), to carry out complex numerical calculations and model technical systems. We also use Python to create graphical user interfaces (GUI), program machine learning models and AI applications.

We use LabVIEW software to visualize measurement data and create user interfaces for machines or test benches.

We use the PlantSimulation software for discrete-event material flow simulations. We use Sim 3D software to create animations and simulations of production and logistics systems. Movements and material flows are mapped realistically and physical properties such as gravity, friction and inertia are taken into account.

The use of material flow simulations offers great advantages in the planning and re-planning of production, storage and logistics systems and increases planning reliability.

We use the EMA WorkDesigner ergonomics evaluation software to map work processes in production in a simulation model. We use the software to model people at work, for example in assembly or production. The program then calculates the Ergonomic Assesment Workplace Score (EAWS). This number indicates whether the modulated activity is an ergonomically critical workload. We can then optimize the workflows and process steps to create a more ergonomic workflow and optimize ergonomics at the workplace.

We use the finite element method (FEM) to simulate forming processes. We simulate the material flow of forging, cross wedge rolling and ring rolling processes using Forge NxT software, among others. We simulate the new type of hybrid forging, innovative inhomogeneous heating strategies and wear reduction in die forging with Simufact. Ansys Workbench software is used to calculate mechanical loads or carry out structural-mechanical modeling as part of product development.

We usually use the CAD program Creo Parametric for design in our research projects and consulting projects in the field of product development. We use it to design forming tools, for example for burrless precision forging, multidirectional forging, cross wedge rolling and various prototypes as part of product development projects.

We also use Creo Simulate for load analyses and to analyze our design data. After design, we use it to simulate tool deformation under load, for example. This is particularly useful for complicated tool systems.

We use the modelling language GAMS (General Algebraic Modeling System) to formulate complex mathematical optimization problems.

In the associated software environment, sequence, assignment or selection problems can be described mathematically in the form of target functions and restrictions. The formulated optimization problem can then be optimally solved using a solver (e.g. CPLEX) after entering the required input data.

One possible application is the optimal arrangement of production and storage areas in factory layout planning, for example to minimize the material flow length.

To create the 3D print data, we use the latest slicing software such as:

• Simplify3D
• Ultimaker Cura
• SuperSlicer
• PrusaSlicer

In addition, we also develop our own scripts to adapt the machine code to enable interaction between 3D printers and other machines - for example, the automated insertion of RFID tags in additively manufactured components or the automatic removal of finished components from the printer.

IPH uses the following photogrammetry software to process the drone images into point clouds and then into CAD models suitable for planning:

• Agisoft Metashape
• Pix4D

IPH engineers have developed their own software tool based on the research results from the Instant Factory Maps project.

The photogrammetry software is used, among other things, to map the actual state of factory layouts.

The analysis and optimization of products and processes often requires the use of statistical methods. These can only be managed effectively with the support of suitable software. Examples of this are the analysis of process capability or the planning and evaluation of tests.

We use the Minitab statistics software, which was specially developed for statistical analyses in quality management and offers a wide range of statistical methods and graphical tools.