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Create the Simulation
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Analyze the movements Enhance the Simulation
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Tool Validation
Module 3
R15AP2
Overview
In creating a simulation of an assembly process, the manufacturing enterprise gains valuable information regarding the optimization of the process. Best trajectories to avoid clash conditions and part assembly sequencing are among the first, most critical information to be obtained. Now that the structure is set and the data ready, the movements of the simulation can be added. For the examples shown here, entire subassemblies are moved and conflicts will necessarily occur.
Objectives
Topics in this module are:
Create move activities Use Dynamic clash to identify conflict conditions Edit and Delete move activities Add advanced part motion Run, Compile and Replay the simulation
3 hours
Toolbars
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D Add Advanced Part Motion Refine Moves with Compass Manipulation Editor Change Compass Location Use Smart Target
E Run, Compile & Replay 3 hours Run the Simulation Compile the Simulation Replay the Simulation
DELMIA Corp. 2003
Inst.
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Create Basic Moves Hide Unused Resources View with Explode Create Movements
Inst.
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Creating movement is the basis of the simulation. Movements generate the shots and tracks that the simulation will replay for analysis and visualization.
Because it is a virtual world, a basic move can be constructed without reference to other elements in the world. This can be refined with other tools.
Moves can only be created with reference to a process activity. They can be inserted before, after, or as a child of the process activity. This restriction guarantees that the process plan accurately reflects the intended movements of the parts for the assembly or disassembly sequence. This creates a valuable asset in Design for Assembly discussions. It also forms the preliminary information for the generation of work instructions for the shop floor production effort.
To Hide unused resources select the resource to be hidden, right click and select Hide/Show. The resource will remain in the PPR tree but be invisible in the world Repeating the process will return the visualization to the world
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Select NO.
The product will return to normal.
DELMIA Corp. 2005
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Locate the Create a Move Activity on the Simulation Activity Creation toolbar.
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The Preview window should contain the representation of the part that was identified in the Process node of the PPR tree.
If the product data has not been linked to the process activity by Assigning the Product the preview screen will be blank
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For basic moves, click OK in the Edit Shuttle box
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When the Edit Shuttle dialog box is closed, the compass attaches to the geometry that will be moved, and the Track box open.
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Grab an axis of the compass and move the mouse. The part will move as far as is desired on that axis.
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When the move has been recorded, a line will appear showing the trajectory
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Skip to end
Stop play
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The Initial State should have been saved when the working environment was created. If it was, then it is a good idea to restore the initial state before running the simulation.
Click OK on the Restore Initial Condition for all Products and Resources. This returns the world to the condition before any movements were introduced.
Select the starting point of the simulation element by highlighting it in the PPR tree. Selecting the Process node (or nothing) will run the entire simulation. Inst.
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Controls the visualization update rate. Continually adjusts the simulation step size to real time.
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When the simulation is finished or you wish to stop, click the X to close the box or toggle the Process Simulation icon to off.
Inst.
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Scope: This exercise will give you practice in creating basic simulation moves. It will begin with an established environment containing a process plan and the 3.5 HP engine as the product. Although most resources are hidden, the workbenches remain as a reference point. In the interests of time, no attempt has been made to develop a complete simulation study involving all of the components of the engine. Conditions: V5 and DPM Assembly Process Simulation workbench must be open. Access to the files in R15 DPM Assembly / PROJECT DATA
In this exercise you will: Hide unused resources View the product parts with Explode Create basic move activities
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Do It Yourself (1/3)
Starting point
Ending point
Load: R15 DPM Assembly / Project Data / Process / Disassembly3 Hide Unused Resources
Use the Hide/ Show selection. Right click on each item in the PPR tree to hide the CHAIR, TOOLCART, AND WRENCH
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Do It Yourself (2/3)
Use Explode to look at all of the parts in the Engine
Examine the PPR tree for the process plan. If there is not a process activity and product data linked to every part, then there will be conflicts when move activities are created.
Use this process: 1. Highlight the Product node. 2. Select Explode from the Analysis tools toolbar. 3. Examine the parts. 4. Close the view. DO NOT alter the positions.
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Do It Yourself (3/3)
Create Basic Move Activities that will remove the following subassemblies from the engine:
1. 2. 3. 4. 5. 6. 7. 8. 9. Cover Air Filter Highlight the Process Activity where the move will be created. Create a move activity and designate its position as child. Check that the preview window has the correct geometry then Close the Edit shuttle box. Grab the compass on an axis that will move the part away from the engine. Record the move. Repeat grabbing and moving the part until you can position it on the workbench. Record each shot. Use the player toolbar to reset and view the moves. When satisfied, close the track box to finish the move activity for that part.
Add Dynamic Clash Detection Activate Dynamic Clash Create Moves using Dynamic Clash
Inst.
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RECALL: A basic move activity can be created without consideration of other elements in the world. Dynamic Clash is a function that will identify clash conditions as a move is being performed. Critical information regarding the direction, axis orientation, and path that the part must travel to locate properly without conflicting with any of the surrounding geometry is obtained .
Activating Dynamic Clash when creating movements will assist in determining the viability of the intended movement by providing feedback when a clash condition is present. This information allows modification of the move before it is recorded and becomes part of the simulation. Using this functionality when creating moves in a simulation greatly reduces the need for editing later. Dynamic Clash can also provide early indicators of deficiencies in the process plan by demonstrating unsolvable clash conditions, thereby allowing modification of the process at an early stage of effort. While Dynamic Clash offers a great deal of visual input, it does not analyze or generate reports. This functionality will be addressed later in this course.
DELMIA Corp. 2005
More about Collision Detection can be found in the OnLine documentation R15AP2
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Using the Pull down arrow, pull the Clash toolbar out of the Simulation Analysis toolbar.
Clash Detection (off) No clash information is provided. All movement is stopped when a clash is encountered. Clash Detection (on)
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Attempt to move the part and notice that the places where the moving part will contact other parts become highlighted in red. The red highlighted contact area will disappear when the conflict no longer exists.
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Working with Dynamic Clash Activated reduces the operating performance of the software. It is best to turn Dynamic Clash on only when required to visualize potential clash conditions, and then turn if off again.
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Edit and Delete Moves Edit a Move Activity Delete a Move Activity
Inst.
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The ability to modify movements greatly enhances the speed and utility of doing simulation studies. It is not uncharacteristic for a completed simulation study to be modified and reused in a slightly different context in order to have multiple scenarios to compare and evaluate. It is also not uncharacteristic for a simulation under construction to require modification based on information that becomes apparent with the use of Dynamic Clash or other downstream analyses. Whether using Hub or file based systems, this iterative interaction with the process plan is crucial to the development of a viable study.
EXAMPLE: Dynamic Clash may reveal that the process activity calls for the movement of a sub-assembly which cannot be accomplished with the sub-assembly intact. In this case, the process plan requires modification to include process activities at the component level. Once accomplished, move activities can then be generated for individual parts, or part groups, in a sequence that will prevent clashing.
Moves can be modified or deleted at any point during or after construction of the simulation.
More about Editing and Deleting Move Activities can be found in the On- Line documentation
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A complete move activity can be deleted in its entirety simply by highlighting it in the PPR tree and then using the Remove from PPR tree icon A shot ( or multiple shots ) within a move activity can also be deleted so that the move activity itself remains but is modified for some new influence in the environment, e.g. the addition of a resource like a tool, human, or robot.
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Select the move activity that needs to be modified. Double click to open the activity. This will activate the player, recorder, and manipulation toolbars.
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Notice that the compass is attached to the part, as at the beginning of the move activity.
Click on the end point of the shot you wish to delete. The compass will move to that point
Example: to delete this move
Click here
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Record the modification and close the track. The move activity will be updated to the new condition.
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A shot ( or multiple shots ) within a move activity can also be edited so that the move activity itself remains but is modified for some new influence in the environment, e.g. the addition of a resource like a tool, human, or robot.
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Select the move activity that needs to be modified. Double click to open the activity. This will activate the player, recorder, and manipulation toolbars.
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Notice that the compass is attached to the part, as at the beginning of the move activity.
Click on the end point of the shot you wish to delete. The compass with the part will move to that point.
Inst.
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The trajectory will reorient to the new shot location. This can be done as many times as desired until recorded.
Each edit or delete must be recorded; however, any number of edits or deletes can be made until the new move activity is satisfactory. 6 When the new move activity has been modified to satisfaction, close the track dialog box with OK.
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Scope: This practice exercise is to familiarize you with the use of Dynamic Clash as a valuable tool for the creation of viable move activities. The feedback information from Dynamic Clash will cause re-evaluation and editing of movements that were intended or recorded and improve the reliability of new move creation. Conditions: V5 and DPM Assembly Process Simulation workbench must be open. Access to the files in R15 DPM Assembly / PROJECT DATA In this exercise you will:
Turn on Dynamic Clash Edit existing movements Create additional move activities Examine collision conditions
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Do It Yourself (1/3)
Starting point
Ending point
Turn on Dynamic Clash and use the information to re-evaluate the existing move activities. Use Delete and Edit functions to modify existing move activities. Create move activities for the next set of parts that avoid collisions wherever possible.
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Do It Yourself (2/3)
1. Turn on Dynamic clash detection
2. Play the move activities of the Cover and Air Filter parts that were disassembled in the previous exercise. Determine if there are clashes in those moves. Use the Delete and Edit functions on the Recorder toolbar to modify the moves to avoid clashes where possible. Improve time if possible.
3. Create Move Activities that will remove the following subassemblies from the engine. Avoid clashes where possible. Edit or Delete moves to obtain the optimal path and time.
Question for consideration If the grid size set in the environment is in smaller increments, will it influence whether or not a clash occurs?
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Do It Yourself (3/3)
4. Discuss with your instructor which subassemblies have insolvable clash conditions and what would have to be done to resolve them. You do not need to be concerned about the location of the parts on the workbench
5. If time permits, modify the process plan and product data links to resolve one clash condition at the part level. Add a component level activity Manage the process sequence in the Pert Chart Link the product geometry Create a move activity for that part
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Add Advanced Part Motion Refine Moves with Compass Manipulation Editor Change Compass Location Use Smart Target
Inst.
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The top part of the dialog box will show the current coordinates of the part involved in the move activity relative to the world origin. Set the new coordinates and click Apply.
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If multiple moves are required, the absolute position can be set as the first or last shot of a move activity.
The bottom part of the box permits the designation of the linear distance and/or the rotational angle for each compass move.
In this example any move activity that is initiated will only be able to move in 500 mm increments and any rotations will occur only every 45 degrees. The constraint was applied to every direction.
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5 Input the coordinates of the absolute location. Click apply. 6 Record the new shot.
DELMIA Corp. 2005
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Move the part using the compass and note the movement reflecting the designated increments. Record each shot.
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DELMIA Corp. 2005
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When creating basic move activities, the part is manipulated with the parts origin relative to the world origin. If there is another influence in the manipulation of the part, like a human hand, or automated pick and place, it will be more effective to see the move from the vantage point of the physical contact. Moving the compass to the location where the part will be handled will allow the simulation to represent more realistic visualization of the process, even without the resources being present.
Identified point of contact for handling.
Moved compass.
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Detach the compass by clicking on the Attach/ Detach icon. The icon will change to a released hand and the compass will turn white. Place the cursor over the compass until the crossed arrows appear then move the compass to the desired new location and release. 5 Notice that an open hand and a dot indicate the original position of the compass. Any movements created will now be in reference to this location on the part.
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The part can be inverted by symmetry which creates a mirror image but changes the data The part can be flipped
The Dynamic Smart Target function will not display a dialog box because it permits free selection of a series of constraints to align. These constraints must be selected between the part to be moved and the final location of the part. All of the same features can be selected; lines, planes, axis, points, etc. Once selected, moving the part to proximity of the target will cause the part to snap into place.
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Move the cursor over the part geometry until you find a plane, axis, line or point that you wish to align, then click to select.
The cursor will designate: A Plane A line A point A cylinder A circle A V4 Axis
DELMIA Corp. 2005
In this example, the axis of the hole in the crankshaft cover was aligned with the axis of the crankshaft.
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Move the cursor to the destination location and identify a plane, axis, line or point that is to be aligned with the first selection. Click to set. The part will jump to the alignment designated.
A possible next target would be to align the top line of the part to the matching line on the block
Smart Target remains active until toggled off. This permits reuse of targeting until complete.
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Record the move. Using Dynamic Smart Target allows the selection of multiple points to reference between the part and the target location rather than just one at a time.
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Run, Compile and Replay Run the Simulation Compile the Simulation Replay the Simulation
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More about Running, Compiling and Replaying simulations can be found in the On-Line documentation
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Click OK on the Restore Initial Condition for all products and resources. This returns the world to the condition it was in prior to any movements being introduced.
Locate the Process Simulation icon on the Simulation toolbar. Select the starting point of the simulation element by highlighting it in the PPR tree. Selecting the Process node (or nothing) will run the entire simulation.
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Turning this on will display a box that identifies each activity as it happens.
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Play the simulation. When the simulation is finished or you wish to stop, click the X to close the box or toggle the Process Simulation icon to off.
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2 The Compile Simulation dialog box appears. 3 4 5 6 Click OK. 7 If the Applicative Data option was set
through Tools/Options then the name of the replay will be seen in the PPR tree under the Applications node.
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Name this iteration of the simulation some unique name. Set the step size larger to run faster if desired. If Retain Initial State is activated all elements present are retained. If not then only the products and resources assigned to activities are retained.
The Replay toolbar appears. It works like the other player toolbars.
The Replay options will allow you to change replays and the speed selection will allow you control the speed of the replay.
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Scope: In this exercise you will finish the disassembly of the engine while practicing the use of Advanced Movement techniques. When you have completed the disassembly you will compile the simulation an run the replay Conditions: V5 and DPM Assembly Process Simulation workbench must be open. Access to the files in R15 DPM Assembly / PROJECT DATA
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Do It Yourself (1/5)
Starting point
Ending point
Use the advanced movement techniques to disassemble the rest of the engine, then compile the simulation for replay.
Do It Yourself (2/5)
1. Remove the Head Assembly to this Absolute location.
2 Remove the Exhaust valve, Intake valve, and Cam in these incremental units.
Question for consideration. Is it possible to locate these parts on the workbench in these increments?
3. Detach the compass from the part origin and relocate it at the end of the Crankshaft.
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Do It Yourself (3/5)
4. Remove the Crankshaft and put it on the workbench but DO NOT record the movements.
5. Use Smart Target to snap the axis of the Crankshaft to the hole in the block. Select Smart Target. Select the axis of the Crankshaft. Select the axis of the hole in the block. Record the move.
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Do It Yourself (4/5)
6. Continue using Smart Target to snap the plane of the Crankshaft to the plane of the hole opening in the block. Start position the crankshaft axis is aligned with the hole axis. Select the plane of the crankshaft. Select the plane of the hole opening. Record the move.
Start position
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8. Your screen should have the Crankshaft correctly placed in the hole of the block.
Summary
This module is the heart of creating a basic simulation. There is much more that can be done; however, the process can now be viewed and initial conclusions can be drawn.
Coming Up
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