3d Modeling And Use of Animation in Industrial Facilities

Prof.Dr. Kamuran GÜÇLÜ,

Prof.Dr., Kamuran.guclu@gedik.edu.tr,

Asc.Dr. Kayhan KAPLAN,

Asc.Dr., kayhankaplan@hotmail.com,

Seda Muratoğlu,

sdmuratoglu@gmail.com

Gedik University Faculty of Architecture and Fine Arts. Istanbul/Turkey

By the development of technology, the usage of three dimensional (3D) images which are created by computers are increasing in all areas. 3D technology which is used in Industrial facilities for many years, reached the final point with animations and simulations. This study was carried out in Gedik Casting Welding factory in Istanbul (Turkey). All factory with an area of 25,000 m², is modeled in three-dimensional by a computer realistically. Also manufacture and production process in the factory animated in real-time. Results of this study are used for different purposes. First, the animation of production process revealed the advantages and disadvantages of the factory in terms of efficiency and planning. This study will be an important guide for establishing these types of facilities in the factory. On the other hand these high-quality images and animations can be used in both national and international advertisement of the factory. Thus, the opportunity to feel being in factory and evaluation will be provided without visiting the factory.

Introduction

In parallel with the development of Information Technology, new ones are being added to the graphic processes realized by three-dimensional cards (Alpha blending, Environment mapping, Fogging, Shading, Gouraud shading, Lens flaring, Texture mapping, Mip mapping). While the computer games are shown as the propulsive force in the development of the three dimensional technology in the personal computers today, in the near future, three dimensional applications will be a part of the operating system and the business applications will be three dimensional as well (Kaplan et al., 2009).

Three-dimensional (3D) visualization of simulation results is an important and useful technique for engineering simulation (Rohrer, 2000). It allows users to examine the complex processes of production plants in real-time and from different aspects. 3D visualization represents physical working environments with 3D graphics objects, and presents abstract simulation models by means of computer animation. It produces the visual presentation of what is to happen in the real world, thus providing users with a facility to study and analyze the production and logistics behaviors of industrial manufacturing operations (Zhong and Yuan, 2011). Through 3D visualization, users can obtain information not only from reports and statistical results, but also from the visual scenarios of the entire operational cycle within production plants, including supply chains, inventory, resource utilization, flow of materials, and the overall operation.

1. Field of Study

This study was carried out in Gedik Casting and Valve Factory; Istanbul-Turkey. Gedik Casting Factory is located in Hendek Organized Industrial Zone where is 160 km far from Istanbul City Center. Factory has 25.000 m2 covered area and 25.000 m2 open area (figure 1). Iron casting, Spheriodal Graphite Cast Iron, Steel and Stainless Steel, Bronze and Sand Casting products were manufactured in this factory.

Fig. 1. Gedik Casting Factory and Location

This factory is established 4 main modules: Sand Preparation System, Sinto Casting Line, Melting Furnace, Cleaning and Grinding.

These modules also work with Core room, Dust Collection Systems, Furnace Systems. Manufacture capacity of the factory is 25.000 tones per year.

Factory Features and modeled departments:

• Horizontal flaskless molding line with capacity of 250 mould/hour.

• Steel casting automatic molding up to 400 kg with resin-cored molding.

• Cooling and sorting conveyor system for effective casting handling.

• Two fully automated independence sand plants.

• Steel Casting: single piece: 10 - 1.000 kg.

• With the size of the mold with a molding machine 500x600x250/250mm.

• FBOX III Unrated weighs 1kg-50kg cast iron (figure 2).

Fig. 2. Fbox: photorealistic modeled

• Large parts of the molding is possible of except that FTL.

• Ductile iron can be cast in one piece up to 2000 kg.

• 4 medium frequency induction furnaces.

• Machining workshop capabilities.

• Automatic continues grinding and trimming system.

• Fully equipped metallurgical laboratories and NDT.

• MFOuUllyLDeqINuiGppLeIdNEmSetallurgical laboratories and NDT.

• 2 FBOX-III flaskless molding lines with the dimensions of 500X600x250 [mm].

• 1 box-shaped molding line with the dimensions of 1000X800X300[mm].

• 1 FTL (steel casting) alphaset resin sand molding line.

• Core: The cores are made by Shell and Cold Box Core Machines.

Fig. 3. Fbox line modeled

2. Method

Research was commenced primarily with the modeling of Gedik Casting Factory. This long-run research required bringing together different methods since it was based on a study that had scientific, social, and aesthetical features. With this objective in my mind, a path in the form of Data Collection, Analysis, Modeling, Overlying, and Rendering was followed. Modeled in the Factory of Gedik Casting is shown in Figure 2.

Fig. 4. Flow chart of the study

3. Process Modeling and Animation

In the research, the structures that would be primarily modeled were selected and their source information was gathered.

Location of the factory was modeled 3D according to existing CAD Project. The usage of open areas and passage implementation is visualized with flora (figure 5,6). All fields and machines in the factory were modeled realistically.

Fig. 5. Gedik Casting general model

Fig 6. Gedik Casting outdoor model

To present animation more realistic, kinematic characters added to scene. All levels in the production animated separately. Modeled characters, were animated according to their task in the factory. (Figure 5,6).

Fig. 7. Factory interior model 1

Fig. 8. Factory interior model 2

Conclusion

The research is important as it covers different fields of science like archaeology, landscape planning, provincial planning, and computer-supported animation. It is an original project thanks specifically to the utilization of different scientific methods and the convergence of the software programs used for different areas like remote detection, solid modeling, and animation the research, the structures that would be primarily.

Results of this study are used for different purposes. First, the animation of production process revealed the advantages and disadvantages of the factory in terms of efficiency and planning.

This study will be an important guide for establishing these types of facilities in the factory. On the other hand these high-quality images and animations can be used in both national and international advertisement of the factory (figure 9). Thus, the opportunity to feel being in factory and evaluation will be provided without visiting the factory.

Fig. 9. Process animation

References

1. Kaplan, K., Pamir, H., & Parlar, T. (2009). Antik Kent ve Çevrelerinin Görselleştirilmesi, Modellenmesi, ve Animasyonu ile Gerçek Zamanlı Render Motorlarının Kullanımı: Antakya Kenti Örneği. Ankara TUBITAK Proje No: 107278

2. Rohrer, M. W. (2000). Seeing is believing: The importance of visualization in manufacturing simulation, Proceedings of the 2000 Winter Simulation Conference, 1211-1216.

3. Zhong, Y., Yuan, X., (2004). 3D visualization of discrete event simulation and its applications in virtual manufacturing. International Journal of CAD/CAM. 4 (1): pp. 19-32.