Showing posts with label SolidWorks. Show all posts
Showing posts with label SolidWorks. Show all posts

Friday, 25 July 2014

75 Years of Batman

By
 

Batman75_logo_1COLOR_blk_580_53337eb4cb4440.11378405
If you’re not a comic book or super hero fan, today might have seemed just like any other day.  However, for those die hard fans of vigilantes, super heroes, protectors of the innocent; today marks a significant day in history; 75 years of Batman.
That’s right, Bruce Wayne’s alter ego, The Caped Crusader, The Dark Knight, The Batman, has been using his technician know-how and martial arts prowess since 1939.  And you may be wondering, why are you reading about this on a SOLIDWORKS Blog Post?

Let’s start with an easier question, one I think all engineers can relate to.  Often within circles of geeky friends, the question inevitably rises, ‘who is your favorite super hero’.  Personally, my immediate response is always, ‘either Batman or Ironman’.  This is usually followed by odd looks from the person asking the question.  Certainly, any other super hero has much greater powers than these two heroes?  But do they?  The interesting thing about Batman (and Ironman) is besides being extremely wealthy, they both are incredible engineers and industrialists.  Think about that for a moment.  Neither of these heroes have any supernatural abilities, just a desire to solve problems and use engineering as a solution.  Once I explain myself, I usually like to followup and mention that both Wayne Enterprises (and Stark Industries) most likely use SOLIDWORKS as a result!

With that, I thought today it would be fun to look at few of my favorite gadgets that Batman uses in his crime fighting efforts.  In doing so I spent some time looking over the last 75 years of tools, gadgets, and iconic vehicles used by Batman, and some of the complex engineering Wayne Enterprises incorporated into the designs.

Batarang: This device is one of the most iconic devices employed by the Caped Crusader.  The Batarang has had many different forms from a simple yet effective boomerang, to remote controlled and GPS guided versions.  Though the basics of the design are simple, the shape of the Batarang might make it less than ideal as a traditional boomerang.  If you look at traditional Australian boomerangs, they follow the design of an airfoil, ultimately allowing for flight.  However, the Batarang traditionally has a somewhat sharp leading edge for subduing foes.  Once you start to consider some of the more modern variations of this device, which incorporate electronics for remote and GPS controlled guidance, this story changes.  Today, aircraft such as the B2 Stealth Bomber and the F-117 Stealth Fighter would be unflyable by traditional human piloting skills. However, with the aid of fly-by-wire and computer controlled assistance, the computer makes 1,000′s of small adjustments a minute, constantly keeping the aircraft stable.  So, it might be safe to assume that the Batarang has found a way to package all of these electronics into a very small form factor.  I am going to assume that they used SOLIDWORKS Electrical and CircuitWorks to accomplish such a feat!


Grappling Gun: This practical device makes appearance throughout history as well, providing Batman with vertical ascension faster than any would be villain could catch him.  The Grappling Gun is one of my all time favorite devices.  In fact, an alternative design even makes an appearance in today’s Technical Blog post where I show how to use gear mates to build the gear-train in the device.
But as for the design of this device, it’s fairly straight forward, and many variants are actually employed today, albeit not in such a small form factor.  The biggest challenges with this device is incorporating a motor capable of lifting not just Batman himself, but quite often rescuing Vicki Vale from danger.  The torque requirements for this small motor would have to be pretty extreme, and in this case, I’m certain that they would have used SOLIDWORKS Simulation tools to calculate the loads and stresses to size and design this motor.


Utility BeltUtility Belt: The all purpose tool used by Batman over the years.  Not so much a single tool itself, but a very compact storage device for my of Batman’s other gadgets, most notably a fan favorite being the infamous Shark Repellent from the 1966 Batman Movie!  This device is actually quite a practical device used by nearly every law enforcement agency around the world, although, most don’t carry around Shark Repellent.  Utility belts come in a variety of sizes and purposes, such as mentioned, law enforcement, construction workers, hiking enthusiasts and many more.  Most today employ attachment mechanisms to allow for complete customization, and I would guess that the ‘hidden’ compartments within the Batman Utility belt are equally customizable.  The challenge faced with this gadget is obviously packaging everything into such a small space.  The perfect solution for this was most likely SOLIDWORKS design software, and heavy usage of Configurations for the many different varieties seen throughout the years.


TumblerTumbler: There are nearly as many vehicles parked in the Batcave as there are movies about Batman.  However, few get people as excited as the Tumbler which made it’s appearance in The Dark Knight.  This vehicle could perform maneuvers reminiscent of a fighter jet, while being a complete land vehicle.  The concept behind this has even had documentaries and behind the scenes series dedicated to it.  So when determining if this vehicle could exists, I think the answer is, it almost does.  SOLIDWORKS customer and Crowd Source Design project Local Motors developed the Rally Fighter years ago, which I would have to say comes pretty close.

RebreatherRe-breather:  This device featured in many of the older Batman films is actually quite a practice device employed today.  As an aid to scuba divers, a re-breather, or a scrubber as they’re sometimes referred to, absorb exhaled carbon dioxide and is ‘recycled’.  This gas then has any remaining oxygen extracted providing prolonged submersion over that of a typical SCUBA device.  A good example of this is the Seaquest Air Source from Aqua Lung another SOLIDWORKS Customer.

But again, Batman with his engineering know-how, as managed to minimized the overall design of this device to be completely portable.  To ensure he there is no lack of oxygen when pursuing villains underwater like in this iconic fight scene, you can be confident that he used SOLIDWORKS Flow Simulation to ensure proper airflow and circulation through the device.

BadHood
Eyes and Ears: Batman has always had the need to communicate with others.  Whether this be with Boy Wonder Robin, his butler Alfred, Commissioner Gordon, or in recent years Lucius Fox at Wayne Enterprises.  The method of his communication is integrated discretely into the hood that Batman wears to conceal his identity.  Likewise, the hood also provides an array of optical enhancement capabilities that allow The Dark Knight to see in…well the dark of night. This incorporates an array of night vision, infrared and optical tracking.
Like many of the other gadgets discussed here, most of these capabilities can be found today, though in much larger and sometimes unwieldy variants.  What’s makes Batman’s versions so unique, is it’s ability to track information from his surroundings and provide feedback based on these results. Batman can then even relay this information on to the Batcave’s super computer tended by one of his crime fighting assistants where the information can be further processed.  This is ultimately a big buzz word today in the world of Engineering; The Internet of Things. Companies today are incorporating more ‘connected’ aspects into their designs.  Take Nest for example, a SOLIDWORKS customer.

They have developed a series of home devices that are are perpetually aware of their surroundings, constantly evaluating their environment and making efficient decisions.  What makes Internet of Things devices so unique is their ability to both collect data from their surroundings, take that information and make decisions and provide useful feedback to the end user.  In the case of Nest their thermostat monitors movement around the area, decisions the user makes about temperature, and ‘learns’ when people are home, when to turn the temperature down, and up, to save money on utility bills.

Batman’s device on the other hand has been used to gather audio and visual information and provide him with useful decision making feedback.  For a design such as this, you would expect a wide range of SOLIDWORKS products to be used in its design.  From SOLIDWORKS design tools to get the fit, form and function, tools like CircuitWorks and SOLIDWORKS Electrical to develop the complicated electronics and finally tools like SOLIDWORKS Simulation to ensure the design is rugged enough to take a ‘POW’ to the head.

We’ve only covered a handful of creative devices used by Batman and Boy Wonder over the years, and I’m sure many of you have your own favorites as well.  Unfortunately there’s not enough time to cover all of them, but each and everyone of Batman’s tools could be considered an engineering marvel in its own right. So my question to you is, what is your favorite Batman gadget?  Post your responses below!

If you happen to miss the link above, there’s another, more technical post I’ve created over here on the SOLIDWORKS Technical Blog. In this post I show how Batman, or rather ‘CADMAN’ in this case, might design the iconic Grapple Gun.

You can read more posts from  on the SOLIDWORKS Blog and SOLIDWORKS Tech Blog

Wednesday, 2 October 2013

Layout Based Assembly Design


Do you evaluate your mechanism assemblies before investing 3D modelling time?

Having participated in several design projects requiring the development of a mechanism, I’m sure I’m not alone in investing a fair amount of time in a mechanism assembly which, according to my trusty pen and notepad will function beautifully, to find that the reality is that its fundamentally flawed.  So, how can SolidWorks help in this stage between notebook scribbles and a fully solid model?

Layout Based Assembly Design allows us to create & evaluate our mechanism assemblies as 2D sketches.  The car jack seen below for example has been created as a typical SolidWorks assembly, with several individual parts mated together to provide mechanism movement.



When fully retracting the jack, a fairly obvious design flaw with the top link becomes evident, meaning the jack doesn’t retract low enough. 

Of course, we could make some changes in this assembly to overcome this flaw, however given that I’ve already spent time creating the assembly and now, I’m  looking to spend more making changes, it may have been more efficient to conceptualise my mechanism as a Layout Based Assembly Design, then create the 3D geometry.


 
We begin our Layout Based Assembly Design using the ‘create layout’ button, once we’ve done so, we’re ready to sketch in our first component.
 
When using Layout Based Assembly Design, sketch blocks represent individual parts so we’ll turn our sketch entities into a single block using the ‘Make Block’ button.
To represent the rest of our components, we could either create them or if we already have them (as I do here) we can use the ‘Insert Block’ button.
 
Once we’ve inserted our subsequent blocks, sketch relations can be used to associate the blocks together.  In this case, I’ll be using a concentric sketch relation
 
Now with all my sketch blocks in place and sketch relations added, I can move the mechanism and begin to evaluate it.  The issue we identified from the original assembly now becomes evident.  The difference here is, as I’ve not had to create 3D geometry or even mate the components together I’ve identified this issue in a matter of minutes.
 
Rectifying the flaw is as easy as deleting the offending block and replacing it with a new one. Evaluation tools such as measure are supported in a Layout Based Assembly Design, so we can be sure we’ve improved the design.
 

 
Once satisfied with our mechanism assembly we can convert the blocks to 3D geometry easily by right clicking on the block in the feature manager tree and selecting ‘Make Part from Block’
Notice at this stage the block is converted to a part file, which when right clicked has the option to either ‘open part’ or ‘edit in context’ from the toolbar at the top.
 
 
The end result of converting my sketch blocks to 3D geometry can be seen below.


 
 


Tuesday, 4 June 2013

Could Top Down Assembly Modelling save you time?

Having recently joined the SolidWorks technical team at TMS CADCentre a lot of my time has been dedicated to expanding my SolidWorks knowledge by participating in SolidWorks training courses.  Although I had used SolidWorks extensively in my own design work and considered myself as somewhat of a seasoned user I was amazed at some of the functionality covered in the training courses that I simply was not aware of.
Top down modelling from Assembly Modelling is a prime example of this and will be the focus of this article.  By ‘Top Down’ we refer to creating parts in the context of the assembly as we go, opposed to the more commonly used ‘bottom up’ method wherein all the parts are created separately.
The intention with the crank shaft model seen below is to add a pulley.  The pulley and associated parts could be created separately and added (bottom up technique) but as I need to reference other parts in the assembly it makes sense to use the Top Down in context technique.

Before beginning you can set any subsequent parts created in the assembly to save as external part files under system options/assemblies.  If you do so, you will be prompted to define a save location upon new part creation.


To start adding your new part go to insert components and when prompted select a reference planer face.

The assembly is now ready for the creation of a new part.  As the geometry I require to create the pulley already exists I don’t need to bother re-creating it and can instead just do a simple convert entities command and a basic extrude.  The outer diameter is taken from the pulley at the opposite side of the crankshaft and the inner diameter defined by the pulley end shaft.


The new part appears in block colour for clarity until clicking the confirmation icon in the top right corner.  Note how the new part is now inserted into the tree and appears in the defined save location if you chose to ‘Save new components to external files’.


And that’s it! I’ve quickly and easily added a new part to my assembly without even having to create a sketch by using in context top down modelling.  Using the same quick process I’ll also add another pulley to simulate how this crankshaft could connect to the camshaft.
Notice I’m not constrained to referencing a face when creating my new part – I can use a plane, which is what I’ll do here.  The camshaft pulley is created using some simple geometry and a boss extrude.  Mating this pulley in place is not essential as it’s likely I would go on to construct the camshaft which the pulley would be fixed to.

Lastly, to complete my in context modelled pulleys I’ll use a belt to link them using the Belt/Chain tool.  Notice how the belt/chain tool inserts only a representative sketch line.

A top tip with the belt tool is to select ‘Create belt part’ under properties.  This creates the belt as a separate part, meaning it can then be opened and edited.  This is useful here as it means we can extrude it and have a better representation of a belt than a sketch line.

I hope you find this functionality as useful as I do when it comes to simplifying and quickening the process of adding parts to an assembly.  Now go try adding some in-context parts to that old assembly you have!

Wednesday, 18 April 2012

Simulating The Repair Of Sports Injuries

We're all used to hearing about footballers and other professional athletes damaging their cruciate ligament or suffering some other tendon injury.  I remember being told once that they can repair this by cutting away more of the damaged tendon and it seemed like a crazy statement.  How can removing material make something stronger?
Time to do a little bit of medical Simulation!
I fired up SolidWorks and modelled a simple strip with two small tears on each side.  Keeping things symmetrical helped with the setup.  





Close up of the tear

A quick simulation was set up

And here's the results


Maximum stress here was just over 1GPa, almost double the yield limit of the material.
Clearly we are failing here so now for the repair!

All I did here was increase the angle of the cut from 10 to 170 degrees.  This removes 13% of the original bar.
So what did this do to the stress?  Let's take a look:

Wow!  The maximum stress has fallen by 800MPa, a 79% drop in peak stresses.  We can live to run another day!
But why does this happen?  How can removing material increase the strength of the part?
It's all to do with how the stress can spread through the part.  With the narrow/sharp tear the stresses can only act at the root because there are no stresses at the top of the tear openings, but by smoothing out the damage, stress can spread across the entire width of the part allowing more material to take up the strain.
Once again I was able to use SolidWorks Simulation to illustrate what seems to be a paradox, and get the truth.