Real-time capable collision calculations for virtual commissioning in production technology through parallelization (EKoVIP)

• Applicant: Professor Dr.-Ing. Alexander Verl
• Subject Area: Production Systems, Operations Management, Quality Management and Factory Planning
• Term: since 2026
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 576083193

In this project, a parallelized collision calculation for virtual commissioning is being developed. This is executed on a graphics processing unit (GPU) and integrated into a real-time co-simulation. In the interaction of machines, tools and workpieces, virtual commissioning is an important method for testing the production process in the context of the control. Precise collision calculation is an important factor, especially in production technology. Physical collision calculation is particularly challenging when it comes to parts with high variations and complex geometries that require high precision in large quantities. Co-simulation architectures already exist in the field of virtual commissioning, which could be supplemented by a parallelized collision calculation. As an initial step in the proposed project, the data and time synchronization of a GPU will be investigated. The aim of this investigation is to integrate an additional GPU solver into the existing co-simulation architecture. Particular attention is paid to the challenges of synchronizing data flows and time steps of the GPU solver in order to ensure efficient and timely synchronous communication between the various simulation components so that there are no clock delays. A central aspect of this investigation is the real-time cycle of the GPU, which ensures that the calculations are carried out within a defined time frame. In the further course of the project, a collision algorithm will be developed that includes both collision detection and collision resolution on the GPU. This will be based on existing approaches. This algorithm will then be integrated into the co-simulation environment so that it works together with the various components of the simulation in the same way as the other solvers. Finally, the functionality and performance of the overall concept are validated using an example scenario. In this scenario, an unloading and separation process is simulated in which a large number of piece goods are taken into account.

• DFG Programme: Research Grants
• Co-Investigator: Dr.-Ing. Armin Lechler