V5 Robotics Training Guide

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copyright law. The copyright in this document is owned by DELMIA Corporation, Auburn Hills, Michigan, USA.

Any user of DELMIA Corporation software is authorized to view and print this document subject to the following conditions:

1. The document may be used for information purposes only by the user.

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Any product, process, or technology described or exhibited in the document may be subject to other intellectual property rights reserved by DELMIA Corporation and are not licensed hereunder.

DELMIA Corp.

900 N. Squirrel Road, Suite 100 Auburn Hills, MI 48326

(248) 267-9696

IGRIP , Virtual NC , ENVISION , UltraArc , UltraGRIP , UltraSpot , UltraPaint , DELMIA V5 , Process Engineer ,and QUEST , are registered trademarks of DELMIA Corporation.

Microsoft, Windows, and Windows NT are either trademarks or registered trademarks of Microsoft Corporation in the United States and/or other countries. NT is a trademark of Northern Telecom Limited. UNIX is a registered trademark in the United States and other countries, licensed exclusively through X/Open Company, Ltd.

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Step 1 Delmia Working Contents PPR

Ø Getting familiar with the DELMIA V5 software user interface

Step 2 Delmia V5 Software Settings

Ø Viewing all of the user interface menus and functions

Step 3 IGRIP Workbench and Toolbars

Ø Reviewing the Workbench and Toolbars

2 Process Preparation

Step 4 Starting a Project

Ø Reviewing the creation of our project

Step 5 Resources Product and Moving

Ø Reviewing the Resources and Product for our project

3 The Project

Step 6 Open the Project and Inserting Robots

Ø Getting familiar with the Project and Insert the robots

Step 7 Creating a Area / Floor for the project

Ø Using the AEC Workbench

Step 8 Placing and Assigning Robots

Ø Moving the geometries around the project

Step 9 Mounting a Weld Gun

Ø Using the mounting function to attach the weld gun to the robot

Step 10 Hide and Show Attachments

Ø Displaying/ Not Displaying the Attachment information

4 The Robotic Functionalities

Step 11 Creating the Process Plan

Ø Getting familiar with the Project and creating the process

Step 12 Fastener Assignment

Ø Assigning welds to a process activity

Step 13 Assigning the Robot Resources to the Process

Ø Assigning the resources to the process for the flow

Step 14 Jogging a Robot

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2 Step 17 Editing the Height of the Robot Riser

Ø Using the part design workbench to edit the height of the riser

Step 18 Create and view a Weld Study Analysis

Ø Use the Weld Study Analysis for verification of welds to the robot

Step 19 Robot Controller Profiles

Ø Defining the Robot controller profiles

Step 20 Auto Placing Robots

Ø Using the Auto Place for the best position for the robots

Step 21 Robot Envelope

Ø Creating a Robot envelope

Step 22 Reach function for the Placement of Robots

Ø Reviewing the Robots location and Reach.

Step 23 Reviewing the Teach Dialog box and Edit Weld Points

Ø Reviewing the project through simulation in the Teach a robot

Step 24 Tag Transformation for Weld Positions

Ø Using the Tag Transformation to move one of the welds

Step 25 Creating VIA Points in the Robot Path

Ø Creating via points within a path.

Step 26 Using the Add Tag Icon

Ø Edit the path, and add a tag

Step 27 Using Trace TCP in the Teach Dialog box

Ø Using the Trace function to view the path

5 The Weld Gun Functionalities

Step 28 Weldgun Actions

Ø Reviewing the Weldgun actions

Step 29 Dress Operations

Ø Using the Dress Operations to copy the data to other weld points

Step 30 Using the Call Task

Ø Creating multiple programs, and calling them into one

Step 31 Robot Task Simulation

Ø Run the Robot Task

Step 32 Crash Analysis

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Step 33 Adding a Icon to a Toolbar, Creating a Section

Ø Reviewing the project through a section

Step 34 Modifications to the Path

Ø Modify a path for the robot

Step 35 Automatic Configuration of Singularity, Set Turn Numbers

Ø Editing the path for configurations automatically

Step 36 Multiple Resource Simulation

Ø Running multiple simulations at once

Step 37 Using the Pert Chart for Parallel Running

Ø Editing the Pert Chart

Step 38 The Process Simulation

Ø Running the process Simulation

Step 39 Adding Welds Tags to the Path

Ø Reviewing the projects paths

Step 40 Automatic Task Collision for Zones

Ø Using the Automatic Task collision for I / O zones and Interference Zones

7 Data Information

Step 41 I / O Map and Monitoring

Ø Monitoring the I / O configurations in the project

Step 42 Exporting I/O Information

Ø Exporting the data from the project

Step 43 Data Readouts and Documentation

Ø Exporting the data from the Project

Step 44 Listing Activities, or Products Resources

Ø Listing our objects in our Project

8 Advanced functions

Step 45 Clamping Functions

Ø Using the Clamping functions to open close the clamps in the simulation

Step 46 Offline Programming

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4 Step 47 Setting up the Auxiliary Device

Ø Using the data for the Auxiliary device to run

Step 48 Mounting a End Effector to a Robot

Ø Using the mounting function to attach the end effector to the robot

Step 49 Teaching a Robot on the Rail

Ø Teaching with the Rail

Step 50 Pick and Drop Actions

Ø Pick and drop the part

10 Remote Tool Center Point Procedures

Step 51 Creating a Remote TCP

Ø Start setting up the project for a remote tool center point for the robot

Step 52 Creating a New Tag Group

Ø Create a tag group to associate the tags

Step 53 Creating Tags in the Group

Ø Create a tags in our group

Step 54 Creating a Robot Path

Ø Create a path for the robot to follow

Step 55 Creating a Pick and Drop

Ø Utilize the pick and place to grab the part for the ped welder

Step 56 Perform a SetTool for the fixed TCP

Ø Create a tag group to associate the tags

11 Exporting Data

Step 57 Creating Movies and Pictures

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This procedure describes the V5 software approach using the Process, the Products, and the Resources. The Resource Centric Approach is also discussed.

In this approach, the user will have the ability to:

• The user Physical Activities that will have Resource Assigned, and the Robots, also will have Active Tasks to be simulated.

• If the user changes their mind, the Resource Assignment has to be modified, and the Active task designated, No Process redesign is required! Time saving, allows for “what if” scenarios.

V5 IGRIP Facilitated Project: RH Body Side Assembly with Tooling and Robotics

Title Working Contexts

Process

Product

Resources

This is where we create our project’s process flow. This tells the story of what activities we are going to do in this project.

Ø We assign (link) from our ProductList and our ResourceList

This is where we import all of our Products. They would mostly be e.g. car parts (steel, plastic), motors.

Ø They are then linked to the activity function in the Process.

This is where we import all of our Resources. This could be chairs, tables, the floor, manikins, tooling, conveyors, and fixtures.

Ø Anything that is going to happen with this Resource is stored under its name in the ResourceList. We then link the

“whatever” action to the activity in our Process. This way we can have multiple “whatever’s” and try the multiple ways in our Process, with a click of the mouse….

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1 Working Contexts PPR.doc 2 of 3 Copyright DELMIA Corp. 2004

Process

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Files are saved using these extensions.

Process/ Product/

Resource (PPR) tree

The PPR tree is a 2D view of the process. It appears in the same view as the Inventory Space window. It lists all the parts, products and resources required to make a specific product, plus specific applications data. It also lists, in hierarchical form, the actions required to perform the process that produces the product.

In V5, PPR trees are stored in process documents and have a .CATProcess

extension.

process A process is a series of actions or activities that alter parts. The end result of a process is the creation of a product or a part of a product.

product Products consist of parts, which may or may not be grouped into assemblies. They appear in product structure documents; in V5, these documents have a .CATProductextension.

The difference between a product and a resource consists in how they are used with in a process. The end-result of the process should result in the creation of the product or products listed in the PPR tree.

product structure document

The product structure document is a key component in V5. It provides users with a way to organize product creation in a hierarchical format. Each product

structure document can contain parts, which make up assemblies, which, in turn, make up products.

Product structure documents have a .CATProductextension

Resource Resources consist of parts, which may or may not be grouped into assemblies. They appear in product structure documents; these documents have a

.CATProductextension.

The primary difference between a product and a resource consists in how they are used within a process. The resources required during the process should be listed in the resource branch of the PPR tree.

Many resources appear in V5 catalogs. Resources imported from catalogs cannot be broken down into discrete parts (e.g., selecting the mounting plate of a robot selects the entire robot, not just the mounting plate.)

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2 DPM - IGRIP settings.doc _{Copyright DELMIA Corp. 2004} 1 of 22

This procedure describes how to launch an IGRIP session and become familiar with the IGRIP workbench toolbars.

The Training Manuals are divided into modules and steps. Depending on the class, each module represents the configuration and each step in the module guides you through a procedure. A project will be created from start to finish.

Settings

This reviews the setting required for our project.

1. Launch the software. To do this, click the icon on the desktop, or select Start / Programs / DELMIA, DELMIA V5.

2. In the menu bar, select Tools / Options.

3. Select General / General tab. In the save field, deactivate Automatic Save. V5 IGRIP Facilitated Project: RH Body Side Assembly with Tooling and Robotics

IGRIP –

Software Settings

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4. In the Document tab click on Other folders (make sure it says Yes under the Active column). Click the Configure button.

When creating a process, users may choose to obtain part geometry from another file. The original storage location of these files probably differs from the current location of files. When V5 attempts to read these files, it cannot find them because pointers inside of the data still point to the original location. Configure this location to link to the directories where the project is saved.

5. In the Other Folders window, search for the project and add the directory with the Add Tree button. Click on OK to complete this setting.

The project is then added to the linked document list. For this project, your teacher will detail the path.

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2 DPM - IGRIP settings.doc _{Copyright DELMIA Corp. 2004} 3 of 22 6. In the Environment Tools toolbar, the Toggle

Manipulation Handle Mode command can be toggled On/Off. When toggled on, a green box appears around the selected object. This box makes the object easier to grab and move.

7. Under the General / Display / Navigation tab, deactivate the Preselect in geometry view option.

Objects can now be chosen from the PPR tree only. If this option is active, objects in the 3D view are automatically selected by passing the mouse over them. Selections, in this made may be made that are not wanted.

8. Deactivate the Display manipulation bounding box option.

9. In the Navigation field, activate the Gravitational effects during navigation option. Select Z.

This option is especially useful for a project with a floor; you can rotate around and the floor stays level with the viewpoint.

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10.In the General / Display / Performances tab note the settings for the 3D Accuracy, the 2D Accuracy, and the Level of detail fields. The values are at the lowest setting (as shown below) to give a more exact view of the geometry with this setting. A circle is displayed as round not as an octagon.

11.Scroll down in the Performance tab to the Miscellaneous field, and activate Save lineic elements in cache. This allows you to see wire frame geometry.

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12.The General / Display / Visualization tab displays the color settings for the software. For this project, change the background to white. Click on the down arrow or click on the pull down menu to see the available colors.

13.In the General / Parameters and Measure / Units tab, change the length of the units to inches.

The default color for a clash (collision) is

orange. If the robots are orange, the clash is difficult to see. Change the clash color in the Selected elements field

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14.Use the General / Parameters and Measure / Report Generation tab to set the location and report content options.

The default values are acceptable.

15.To hide constraints, in the General / Parameters and Measure the Symbols Tab click on Filter button. The Constraint Filter dialog box appears. In the Filter field, select Hide All then click on OK.

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16.In the Infrastructure / Product Structure / Cache Management tab / Cache Activation field, activate the Work with the cache system option.

17.In the Infrastructure / DELMIA Infrastructure / Simulation tab, adjust the simulation settings to match the options shown. Set the step size to 0.3 to make the simulation run faster.

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18.Select the Infrastructure / DELMIA Infrastructure / Robot Analysis tab. These settings determine what system behavior when tool center point (TCP) limitations are exceeded during a simulation. Additional options control TCP trace display in the 3D view.

The table below provides an explanation of the TCP trace parameters that you can set. The options take effect immediately and apply to all applications containing simulation commands. Parameter Value

Show point Provides the color and symbol for each point within a TCP trace. Show line Provides the color, type of line, and line thickness for each TCP trace Show axis Provides the color, line type, and thickness for the axis of each TCP trace.

Delete path A simulation's path is deleted when a new simulation is run. Otherwise, each path_{remains visible until the session ends.}

Show legends

Text appears when a point/line/axis is (pre)selected by the user. The text contains information related to the current point. The text can contain any of the following data (if selected): • Name • Time • X axis • Y axis • Z axis • Yaw

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19.Select the Digital Process for Manufacturing / Tree tab. In the Hierarchy tree field, select all the items as shown.

20.Select the Digital Process for Manufacturing / DPM – Fastening Process Planner / Commands tab. In the Fastener Assignment field, Activate duplication assignment.

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21.Click on the DPM – Fastening Process Planner / Fastener Visualization tab. To see the coordinates, activate the Show the fastener(manuf)/tag option to see the coordinates.

22.Select the IGRIP / Robot Task Display tab. The Options dialog box appears:

Select the desired values, or accept the defaults.

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23.Click on OK. Use the tasks contextual menu to activate the task display. The task display is not updated automatically.

24.Use Update All Tasks in the Sequence toolbar to refresh the visualization.

Option Role

Cartesian Target These options are for tag, weld, and Cartesian targets. Show X, Y, Z Values/Show

Y, P, R Values Checking these boxes causes these values to be displayed when themouse is moved over the target. Joint Target These options are for joint and home targets.

Show Joint Values/Show

Auxiliary Axes Joint Values Checking these boxes causes these values to be displayed when themouse is moved over the target. Line Connects the operations.

Set/Wait Line Shows the IO connections.

Show Actions Displays as icons the actions in the viewer

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25.Select the IGRIP / Teach Dialog Settings tab. No changes need to be made for this project, however, the following changes are possible:

• Select items from the “Data included in the table box” field and move it to the “Available Data” area using the left arrows. Data item order is changed with the up and down arrows. When the teach command table option is activated in the software, this is the order and selection that is used.

• The options list order determines the order in which the data fields appear in the teach table.

• Activate the Show Task visualization option to automatically display the task visually when teaching a task.

26.Set up the system for Offline Programming. To do this:

a. Remove any Java version earlier than version 1.4

b. To determine the Java version installed on your computer: i. open a command prompt

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2 DPM - IGRIP settings.doc _{Copyright DELMIA Corp. 2004} 13 of 22 c. Download the latest version of Java fromwww.java.Sun.com

d. Create the directory, c:\jdk extract the java files to this directory. e. Set your environment variables for CLASSPATH and Path to c:\jdk\bin f. Go to the Tools / Options / Offloading Programming tab. In the Java

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27. In the AEC Plant / General tab, change the Grid step value to 0.5 in. This value affects the manipulation handle (used for easily moving a geometry); the manipulation handle snaps to the value set.

28.Change the Depth Effect value. To do this, in the main menu, Select View / Depth Effect. In the Near Limit field, activate the Fixed option and set the value to 100.

In the Far Limit field, activate the Fixed option, and set the value to 500000.

Now you can zoom in on an item in the 3D view, and the clipping planes modify to only display the center of the field of visions center.

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29.To change the size of the PPR tree, click on the line connecting the directories, and in the View toolbar click on the zoom in or out.

Click on the line again to get back to the 3D view. To display, or hide the PPR tree, select the F3 key on the keyboard.

To deactivate the zoom capability, go to the Tools / Options / General / Display / Tree Manipulation tab and uncheck the Tree zoom after clicking on any branch option.

30.To find an object in the PPR tree, right-click on the object in the 3D view and choose Center Graph from the contextual menu.

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31.In the main menu bar, select View / Toolbars to view the list of toolbars.

32.Another way to view the toolbars is to drag them from their docking position. To do this, drag the move handle of the toolbar to the center of the geometry window.

33.Some of the toolbars have toolbars imbedded in them. Use the black arrow to expand the toolbar, and then select the move handle and drag it.

Keyboard Shortcuts

Use this keyboard key (or combination)... To...

Escape Exit the current dialog box (when there is one) F1 Get contextual online help

Shift + F1 Get help on toolbar icons

Shift + F2 Toggle the specification tree overview on and off F3 Toggle specification tree display on and off Alt + F8 Run macros

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Shift + F3 Activate the graph is the model is active and inversely Home Display the top of the graph

End Display the bottom of the graph Page Up Relocate the graph one page up Page Down Relocate the graph one page down Ctrl + Page Up Zoom In the graph

Ctrl + Page Down Zoom Out the graph

Up arrow Relocate the graph 1/10th (one tenth) of a page to the top Down arrow Relocate the graph 1/10th (one tenth) of a page to the bottom Left arrow Relocate the graph 1/10th (one tenth) of a page to the left Right arrow Relocate the graph 1/10th (one tenth) of a page to the right Ctrl + Tab Swap active document windows

Alt + Enter Run the Properties... command Ctrl + C Run the Copy command Ctrl + F Run the Search... command Ctrl + G Run the Selection Sets... command Ctrl + N Run the New... command

Ctrl + O Run the Open... command Ctrl + P Run the Print... command Ctrl + S Run the Save... command Ctrl + V Run the Paste command Ctrl + X Run the Cut command Ctrl + Y Run the Redo command Ctrl + Z Run the Undo command

Another useful shortcut

Clicking an icon lets you run the command associated with that icon only once. However, double-clicking an icon lets you use the associated command as many times as you want without having to click on the icon several times.

Call outs are used throughout the project to give tips and expand explanations.

Expanded explanations, examples, information, or facts…

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Open, and review a Workbench. Compass Minimize / enlarge / close / Window 3D view Window size buttons Current workbench

Some toolbars are hidden. Place the mouse over the arrows and drag the toolbar into the 3D view

Text window for command or function Command prompt

or other information Toolbar Software version / File name Workbench main menu bar PPR tree Expand / collapse Click on line to adjust PPR tree

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Other Basic Techniques

• Sometimes when rotating or panning, the geometry disappears from view. To regain view, right-click the geometry in the PPR tree and select Reframe On from the contextual window. The geometry

reappears and the view zooms to that geometry.

• Press and hold the Middle Mouse Button to move the model in the 3D view.

• Press and hold the Middle Mouse Button and the Left Mouse Button to rotate the model in the 3D view.

• Press and hold the Middle Mouse Button, press then release the Left Mouse Button, then drag the mouse vertically to zoom the model in the 3D view.

• Click on any line in the PPR tree, then use the mouse buttons as described above to adjust the size and location of the PPR tree.

The 3D Compass

Use a graphic manipulator referred to as the 3D compass to perform a number of

manipulations on objects created and managed by certain applications (for example, Product Structure, Assembly, FreeStyle Shaper, DMU Navigator, etc.).

The 3D compass is also used to manipulate viewpoint representations ("cameras"), which capture viewpoints.

The 3D compass is always active. Show and hide the compass by toggling the View / Compass command. Note that hiding the compass does not deactivate it.

The compass is displayed by default in the top right corner of the document.

The letters X, Y and Z represent the axes. The Z-axis is the default orientation. The point close to the Z-axis is the free rotation handle used for freely rotating the compass and the

document's objects at the same time.

The red square is the compass manipulation handle you use to drag the compass and place on objects to be manipulated. You can also rotate objects around this point.

The base of the compass, the XY plane, is the privileged plane. This concept is not useful when simply using the Select command. It is only useful when using application commands that use manipulators, which require working planes.

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Reviewing the Compass Functions

Right-click on an object to display its contextual menu. From this menu, select Snap

Automatically to Selected Object. In the 3D view or in the PPR tree, select an object. The compass immediately snaps to that object.

1. To reset the compass to its default position, from the main menu select View / Reset Compass.

2. To move the compass, place the mouse pointer over the red box, and click the left mouse button or LMB. The pointer changes to a grasping hand. Drag the mouse and compass toward an object in the 3D view. The compass snaps to that object.

3. In the contextual menu, select Edit. The parameter for

Compass Manipulation appears. The current coordinates of the compass manipulation handle (red square), with respect to the center of the world, are

displayed in the axis fields for the Position option.

• Coordinates

Set the coordinate values to move and rotate objects.

• Increments

Set the incremental values for translation and rotation.

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Conventions used in the online documentation

Certain conventions are used in CATIA, ENOVIA and DELMIA documentation to help you recognize and understand important concepts and specifications. The following text conventions may be used:

The titles of CATIA documents appear in this manner throughout the text. File -> New identifies the commands to be used.

The use of the mouse differs according to the type of action you need to perform.

Use this mouse button whenever you read:

Select (menus, commands, geometry in graphics area, ...)

Click (icons, dialog box buttons, tabs, selection of a location in the document window, ...) Double-click

Shift-click Ctrl-click

Check (check boxes) Drag

Drag and drop (icons onto objects, objects onto objects) Drag

Move

Right-click (to select contextual menu)

Graphic conventions used in the Online Documents are denoted as follows:

indicates the estimated time to accomplish a task.

indicates a target of a task.

indicates the prerequisites.

indicates the scenario of a task.

indicates tips

indicates a warning.

indicates information.

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indicates methodological information.

indicates reference information.

indicates the end of a task.

indicates functionalities that are new or enhanced with this Release.

Enhancements can also be identified by a blue-colored background in the left-hand margin.

When DELMIA software is launched, by default, it opens the workbench last used in the previous session.

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3 workbench toolbars.doc 1 of 10 Copyright DELMIA Corp. 2004

This procedure describes how to launch an IGRIP session and get familiar with the IGRIP workbench toolbars.

The workbenches and the toolbars are described. Docking and undocking is practiced.

Robot Task Definition

This workbench provides tools for 3D modeling at the workcell level. Robot Task Definition provides all the tools required to perform robotic feasibility studies and programming in an environment where product data and manufacturing resources can be integrated into a single 3D model. This model performs the basis for the development of robotic processes. Robot Task Definition allows you to test for robot reach and access in a complex manufacturing workcell. It provides tools for the development of robot programs and facilities to test those programs while checking for interferences. The output of Robot Task Definition is a workcell model that is ready for the next step: development of a complete manufacturing simulation with synchronization of all resources.

These models can consist of a combination of multiCAD product models, legacy DELMIA D5 devices, and general CATIA V5 and V4 resource models. Robot Task Definition interacts with V5 Plant Layout so that users can either re-use the plant model or modify it.

Robot tasks and tag definitions for robot motion are integral to Robot Task Definition. Users can create tags and add them to tasks or can create tags in free space for clearance moves. Robot Task Definition provides interactive jogging and robot teaching capabilities to develop and test robot tasks. These tasks can be simulated, one at a time.

In addition to the basic setup commands, Robot Task Definition contains analysis tools. These tools add the following capabilities:

basic measuring of distances and angles collision and band width analysis.

It is expected that tool designers and simulation engineers will make excellent use of this product. V5 IGRIP Facilitated Project: RH Body Side Assembly with Tooling and Robotics

IGRIP –

Workbenches and

Toolbars

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Workcell Sequencing

This workbench is a powerful 3D simulation tool used to simulate robotic manufacturing

processes. It builds upon the workcell model developed in Robot Task Definition, Human Task Simulation, or DPM Assembly Process Simulation. With Workcell Sequencing, the user can coordinate and review the functioning of multiple resources as they work in tandem.

The interface is intended to enable task synchronization among any programmable resources such as robots or human models. The tools are synchronized using IO technology. Workcell Sequencing allows it to link the resource programs to the process planning, and so creates a bridge between the resource-centric programming and the high-level manufacturing process description.

Design and manufacturing engineers can use Workcell Sequencing to see simulations of robotic movement. The simulation reproduces both simple and complex robotic manufacturing processes exactly as they are defined.

1. Start an IGRIP V5 robotics session. To do this, click on Start / IGRIP Robot Offline Programming.

To view the toolbars horizontally, drag them by their move handle, redock them in the top toolbar docking area, and drag them into the 3D view. Some of the toolbars have toolbars imbedded in them. Use the black arrow to expand the toolbar, and then select the move handle and drag it.

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Workbenches and Toolbars

Robot Offline Programming

______________________________ _________________________________ ___________________________________ _________________________________ __________________________________

Select

Off-Line

Programming

Calibration

PPR Tools

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________________________________ _________________________________

Simulation

Activity Management

Team PDM

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________________________________ __________________________________ _______________________________ __________________________________

Environment Tools

View

Standard

Simulation Analysis

Tools

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________________________________ ____________________________________

________________________________ __________________________________

The V5 General command toolbars appear in every workbench from this point on only toolbars specific to Workcell Sequencing, Robot Task Definition, and Device Building are covered.

Analysis

Knowledge

Layout Tools

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Workcell Sequencing __________________________ ________________________ ____________________________ ________________________ ____________________________ ________________________ ____________________________

OLP

PPR Tools

IO Import/Export

Resource

IO Management

RRS Connect

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________________________ __________________________

Robot Task Definition

__________________________

______________________ ___________________________

Interference Zone

Device Motion

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_________________________ __________________________

________________________ __________________________

_________________________

Activity Management

Sequence

Robot Management

Robot Controller

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Device Building

________________________

_____________________ __________________________

_____________________ ________________________

Workbench

Device Building

Frames of Interest

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4 Starting a Project.doc _{Copyright DELMIA Corp. 2004} 1 of 2 This describes how to start a project from the beginning. The products and resources consist of parts that may or may not be grouped into assemblies. The part data is stored in product structure documents that have a .CATProduct extension.

The difference between a product and a resource depends on how you wish to use them in your process. The end result of the process should be the creation of a finished product consisting of the products listed in the PPR tree. The resources used in the process to create the final product should be listed in the resource branch of the PPR tree.

This procedure has:

In addition to loading resources using the Resource Context command (as described in this procedure), The robot catalog, can also be used.

This procedure reviews the different ways a project can be started.

1. By default, the software opens to the workbench used in the last session. To open the IGRIP – Robot Task Definition workbench select Start / IGRIP. The workbench opens with a new process document.

Loading products Loading resources V5 IGRIP Facilitated Project: RH Body Side Assembly with Tooling and Robotics

Starting the Project

Another example is if the software is open, and we want to start a new project. Close, or save the existing window (X) then we have a blue screen, (no workbench selected) for this example; close the Process window, (X).

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2. To start a new process document, select File/ New and the New dialog box appears. Scroll down, select Process, and click on the OK.

3. The PPR tree displays the Process consisting of: 1. ProcessList

2. ProductList 3. ResourcesList

4. Notice the displayed toolbars bordering the 3D view, and the Process Name, Process 2. There are two processes open. Click on the Close button for Process2.

The workbench icon always appears in this corner (unless moved) Move the mouse over the icon to display the workbench name.

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5 Resources Product and moving.doc 1 of 6 Copyright DELMIA Corp. 2004

Products and resources consist of parts (which may or may not be grouped into assemblies) and appear in product structure documents. Files that contain products or resources have a .CATProduct extension.

Products and resources differ in how they are used in a process. Products that are used to create the end-result of a process should be listed under the ProductList section of the PPR tree. Resources required during the process itself should be listed in the ResourceList branch of the PPR tree. The PPR tree serves as a tool to organize the digital manufacturing

environment.

The PPR paradigm allows the user to describe a scenario (i.e., the Process) for manufacturing, processing and transforming a series of items (which are embedded in the ProductList) with a number of resources (which are embedded inside the ResourceList), The relationships

between the activities (or operations), products and resources are both accessible and editable inside the PPR Environment.

Process documents are always using a PPR environment.

The actors and the transformed items of a process must be imported into the PPR environment (as the sections which follow describe). However, a process can be created without these elements and then completed later as those elements are brought into the environment at a later stage in the process design project.

In this procedure, a product (RH Body Side Outer) and resources (tooling, tooling bases, robot risers) are inserted into the process.

1. In the main menu bar select Insert / Insert Product. V5 IGRIP Facilitated Project: RH Body Side Assembly with Tooling and Robotics

Products and

Resources

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2. The Import Window dialog box appears. Select the Product folder from the 3 Geometry folder, and Open.

3. Tooling is added next from the main menu. Select Insert / Insert Resource.

The Product appears in the PPR tree and the 3D view.

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4. The Import window appears. Go up one directory, select the Resource directory, and then select the Station.CATProduct. Click the Open button.

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6. Using the View toolbar select the different Icons to change the 3D view.

7. Open the Quick view and View mode toolbars and try different commands. Also use the mouse to zoom in, out, and rotate.

8. Insert a resource. From the Resources direcrory, select the Fixture Base.CATProduct.

9. The bounding outline, and the compass is used to move the fixture base into position. Click on the Fixture Base Stn1. Notice that the text in the PPR tree is highlighted orange (default color), and, in the 3D view, the base is highlighted.

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10.Move the mouse over to one of the edges of the base. The side that you selected it moves in that direction.

11.The base can be rotated with the compass. To do this, right-click on the compass and, from the contextual menu, Select Snap Automatically to Selected object.

12.In the 3D view, click on the Base. Grab the circular line on the compass and move the mouse to rotate the base.

13.To be exact, right-click again on the compass, and select Edit from the contextual window. The Parameters for compass manipulation dialog box appears.

14.Type in –90 in the Along X / Angle field and click on the Apply button.

15.Grab the compass, as shown below, and move the base close to the station fixture.

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16.Try to place the base under the station’s risers. Later the snap function is introduced for more exact placement.

17.Close this file. A different file with a complete setup will be used in the next step.

View the base from different positions to ensure that it is placed correctly…

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6 Open Project insert robots.doc 1 of 6 Copyright DELMIA Corp. 2004

The Robot Task Definition workbench, allows you to test for robot reach and access in a complex manufacturing workcell. It provides tools for the development of robot programs and facilities to test those programs while checking for interferences. The output of Robot Task Definition is a workcell model that is ready for the next step: development of a complete manufacturing simulation with synchronization of all resources

In this procedure, a project is opened and robots and other resources are inserted.

1. In the main menu select File / Open, and select the 3Geometry / Process / Robotics.CATProcess. Click the Open button.

2. In the main menu, select Insert / Insert Resource. In the Resources directory, select the robot riser, Riser M.CATProduct, and Open. The riser appears.

Opening a Project &

Inserting Robots

(Removing from PPR Tree)

Some of the data has already been set up. You will step through the inserting process..

This way everyone has the geometry in the same coordinates..

Same page

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3. In the PPR Tree, Click on the Riser M; it highlights. Move the mouse over one of the lines on the edge and click and hold the mouse. The pointer becomes a hand. Move the mouse to drag the riser. Position this riser on the side of the tooling, as shown.

4. Release the mouse button, and click anywhere in the 3D view to deselect Riser M. When not selected, the riser is no longer the default color orange.

5. Follow the same procedure to insert the resource, Riser S, and place accordingly.

6. Snap the compass to Riser M. To do this, right-click on the compass and choose Snap automatically to selected object from the contextual menu, Right-click again on the compass and select Edit. Click on Riser M from the PPR Tree. Place these numbers in the Parameters for Compass Manipulation dialog box, Apply and OK.

Careful:

If you select the riser M from the 3D view window, depending on what part you clicked on, that is the only part that will move….

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7. Repeat the procedure for Riser S by clicking on the name in the PPR Tree.

8. Save as, this file in the Process directory, as Robotics1.CATProcess.

9. Reset the settings on the Compass. To do this, right-click on the compass and choose Snap automatically to selected object from the contextual menu, this deactivates this function.

10.In the Activity Management toolbar, click on the Catalog Browser.

(Or in the main menu, click Insert / Catalog Browser.) 11.Select the Open file Icon.

This sample catalog comes with the software, and like a Department catalog, we can shop for Robots, Tooling, etc. New Catalogs can be created and customized as desired…

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12.Check with the instructor for the path to the robot catalogs. (This location falls where they loaded the software in the computer).

Note the position to place each robot in the project that we are

stepping through. The layout picture is at the end of this step.

13.Select the ABB.catalog, and click the Open button. The Catalog Browser now shows all of the robots in the catalog. Switch the view to Details.

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14.The Robot IRB_6400_24_150 is used in the project. Using the Filter command, search for all of the robots that start with IRB_6400. Select the options shown in the filter, click on Apply, and the results appear in the catalog browser. Click on OK in the Filter box to close this window. Click on the IRB_6400_24_150 text in the Catalog Browser.

15.The Robot now is attached to the pointer in the 3D view. Move the mouse and place the first robot around (encompass) the station. Notice that the world position values are shown, (if set in the options), or they appear in the command prompt field. The number changes as the robot changes position in the world.

16.When the robot is correctly positioned in the world, click the left mouse button, and another robot appears.

17.Move the mouse over the Riser M, and notice that the crosshairs change to a box and line. Position the robot as shown, and click on top of the Riser M.

18.Another robot appears. Position this robot on Riser S, and the final robot on the seventh axis rail, or gantry. Disregard the next robot, and Close the catalog Browser. This cancels the command.

19. Go into the Catalog for Fanuc robots and insert the S-420iS robot. The project should look similar to the example shown.

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Note the position of each robot and its number in relation to the product. The Positions

are important when setting up the interactions between the robots.

20.For viewing ease, keep the rotation of the mouse relative to the floor. To do this, select the Tools / Options / Display / Navigation tab. In the navigation field, activate the

Gravitational effects during navigation option and the Z (axis) option.

Incorrect insertion in the PPR tree

21.In the PPR tools toolbar, click on the Remove from PPR icon, and then, in the PPR tree, click on the item that you want to remove.

IRB 6400 24 150.1 IRB 6400_24 150.2

IRB_6400 24_150.3 S-420iS.1

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7 creating a floor area.doc 1 of 4 Copyright DELMIA Corp. 2004

In this step, an area or floor is created.

In the Plant Layout workbench a floor, is created, saved, and imported into the project.

1. In the main menu, select Start / AEC Plant / Plant Layout.

2. In the Plant Layout toolbar, select the Area command.

The Area Creation dialog box appears. V5 IGRIP Facilitated Project: RH Body Side Assembly with Tooling and Robotics

Creating a Area

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3. Change the X and Y lengths to 800in. To do this, Click inside the white text fields and type in the numbers. In the 3D view, select in the window the origin of the area. Select 0,0,0. (If you move the mouse around, in the geometry window, you will see the coordinates change).

4. In the View toolbar, select the Fit All In command. The entire floor is displayed in the 3D view.

5. Change the name of Product 12. In the PPR tree, right-click on Product 12 (you might have a different name). In the contextual menu, select Properties. In the Product tab of the Properties dialog box, change the text in the Part Number field to Plant Floor. Click on the Apply and OK buttons.

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7 creating a floor area.doc 3 of 4 Copyright DELMIA Corp. 2004

6. The plant floor is created. Right-click on the name Area 1 in the PPR Tree, and under Properties, deactivate the Show area name option. Then click on the button Apply, and Ok.

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7. Save the floor. In the main menu, select File/ Save as. Select 3 Geometry / Resources and click the Save button.

8. Close this document (X in corner), and return to the current project. To insert the floor, select Insert / Insert Resources, and select the Plant Floor.CATProduct file.

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8 placing and assigning robots.doc 1 of 5 Copyright DELMIA Corp. 2004

In this procedure, the snap function is used to move robots and other components.

Robots, and the Robot Riser, are moved and positioned in the project. (Check the last page

in this step to see how the finished project looks)

1. Select Robot IRB_6400_24_150.1, and move the mouse over the green line shown in the image. Click and hold the left mouse button down (changes mouse to a hand) and drag the robot up. As the robot moves, the position values change.

Select various lines, in the bounding outline around the robot, and use the move functions. When completed, make sure that the robot is up in the air. Click in a blank area in the 3D view to deactivate this function.

2. In the Layout Tools toolbar, Click on the Snap icon.

3. The Snap Options dialog box appears. Accept the defaults. In the far left corner, under the bottom toolbar, the system prompts you to select an object to be moved. Select the Robot IRB_6400_24_150.1 from the PPR Tree.

Placing and Assigning

the Resource: Robots

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4. The selected robot turns orange, the Define Reference Plane (From) dialog box appears and a green compass is displayed on the robot showing the current

orientation.

5. As you move the mouse pointer, a small white rectangle is displayed to show the selectable planes. A line normal to the rectangle shows the direction in which the snap will be performed.

6. Move the white rectangle and line to the desired plane and orientation as shown in this image and click the left mouse button. The green compass moves to this location and orientation.

Note: This step does not need to be done if the green compass is initially in the desired location and orientation.

7. Click OK in the Define Reference Plane (From). The reference plane is set and the command prompt asks you to select an object to be snapped to.

8. In the 3D view, click in the center of the top plane of Robot Riser M. Orientate the rectangle and line as shown in the image. Right-click the compass and click OK in the dialog box.

9. The Snap Options Dialog appears. In the Select field, click Face. Click the OK button to align the two faces selected.

For this snap function, we will be using the Snap Option, Define Plane..

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Snap the rest of the robots, to the desired locations, if required.

10. Next, the robots are rotated so they face the fixtures. Right-click on the compass to get the contextual menu, and select Snap Automatically to Selected Object. Click on the Robot S-420iS in the PPR tree. Notice that the compass positions itself to the center of the Robot.

11.Right-click on the compass again, and select the Edit function. The Parameters for compass manipulation dialog box appears. In the Along Z, Angle, type in 90, and click on the Apply button. The robot rotates to face the tooling.

12.Another way to use this dialog box is to place 90 degrees in the Rotation increment values. With the values set this way, the compass will rotate in 90-degree increments.

Yes, it gets easier…

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13.When you are rotating the IRB_6400_24_150.1 robot, make sure that you select the Robot first, then the Riser M, (hold down the CTRL button) that way it rotates both using the Riser M’s compass. This places the robot and riser in front of the tooling.

14.Select the other robot IRB_6400_24_150.2, and rotate. The IRB_6400_24_150.3 make sure to select the Riser S, then the Robot. This rotates them around the Robots compass. 15.For the ease of programming (creating the robot path), select the S-420iS robot and make

sure that it is placed at these coordinates.

16.In the Layout Tools Toolbar, select the Attach icon. You are prompted to select the Parent first select the Riser Top as shown,

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17.The Child Selection dialog box appears, select OK. The Parent – Child relationship

appears.

18.In the Environment Tools toolbar, select Hide

Attachment and click on the text to hide right-click on the text, and select Hide/Show from the contextual menu.

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This procedure shows how to mount a weld gun to the Robot.

In this procedure, two weld guns will be inserted and mounted on each of the robots.

1. From the main menu, select Insert / Resource and select the Weld Gun1.CATProduct and the Weld Gun2.CATProduct in the Resources directory, under 3 geometries.

Mounting a Weld Gun

The weld guns are on top of one another…

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9 Mounting a Weld Gun.doc 2 of 3 Copyright DELMIA Corp. 2004

2. Select the Set Tool Icon from the Robot Management Toolbar.

3. The Robot Dressup dialog box appears. Select the Robot IRB_6400_24_150.1 and Device Name under Weld Gun 1, Click on the Rocker2#2.1 under the Weld Gun 1. The system recognizes the device name not the product name, click on Apply.

4. The end effector’s orientation is incorrect on the robot. Manipulate the compass to turn the end effector as shown (next picture).

Do not select ok yet… we

need some adjustments!!

Yes, if drawn with correct orientation it should line up, and you can click on the OK with no adjustments…but..

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5. When completed, click on OK.

6. The Parent / Child relationship is displayed in the 3D view.

7. Follow the same procedure to mount the other weld gun. Use the Set Tool command to mount the weld gun to robot S420iS.

8. Right-click on the Child / Parent Relationship, and select the Hide/ Show command. (To hide the text and line). This will make it easier to see all the geometry; the text and lines will not interfere.

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This procedure shows how to use the Hide/Show function using the Text that shows the Parent/Child Relationship.

In this procedure, commands in the Environment Tools toolbar are used to show and hide text. The Swap visible space function is reviewed. This is another way to hide all at once (Double Click on the Icon, and this keeps it active for more selections).

1. To make the parent / child relationship visible, in the Environment Tools toolbar, select the Show Attachment icon, and click on one of the robots in the PPR tree.

2. Click on the icon again, and select the other robot, so that both relationships are shown. 3. Double-click the Hide Attachments icon (icon

stays orange). Click on the text, to hide it. Hide both relationships, and then click on the icon to deactivate.

.

4. To view the data in the No Show area, click on the Swap visible space icon in the View toolbar.

5. This 3D view has a green background indicating that this is the No Show area. A component hidden in the product structure appears in low highlights in the PPR tree.

Hide/Show

Attachments

Where does it hide it? The text is placed in the swap visible space3D view.

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6. Click on the Swap Visible Space icon to bring you back to the main 3D view.

7. If there is a lot of data and the view is confusing, use the Hide / Show command to place some of the data in the No Show area. This area is for viewing only; and the main 3D view is the active view where functions are available.

8. Try the Hide / Show command with some of the geometry. Pick the geometry from the PPR tree or from the 3D view to see different results. Also, notice the icon in the PPR tree when executing the Hide / Show command.

9. When completed, make sure all the geometry is visible, excluding the Parent / Child relationships.

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This procedure describes how to create a process plan in DPM Fastening Process Planner. There are two ways to create a Process: using customized activities, and using the standard default activities. Later, a Process Flow chart will be automatically created.

In this exercise, a process plan will be created for the RH Body Side Assembly. The standard commands in the Activities toolbar will be used.

Using the Resource Centric approach in the next step, the tasks will be assigned to activities. Physical activities are imported into the process from a user activity library. Dress-up activities such as viewpoint, visibility, and text message activities are created under the process node.

1. Open to the DPM Fastener Process Planner workbench. From the main menu, select Start / Digital Process for Manufacturing / DPM Fastening Process Planner.

2. In the Activities toolbar, scroll the mouse over each icon to see the activity names.

3. Select the Insert Station Activity icon and click in the PPR tree, the word Process. V5 IGRIP Facilitated Project: RH Body Side Assembly with Tooling and Robotics

Creating the Process

Plan

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4. The Create Activity dialog box appears. Click on the More >> button to see the Station Activity Attributes. Change the Name to Station 1 and click on OK. Create another activity and name it, Station 2.

When you insert a station activity in the PPR tree, it will always be a successor to another station activity or a child of the main process. Stations activities children are other activities; it cannot be a child of, say a clamping activity.

5. Using the commands in the Activities toolbar to create the Stations (as shown). Make sure that you select the previous activity when inserting the new one. This will create your process that flows from activity to activity correctly.

6. If you do not have the proper process…

Follow the steps below to correct your process.

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1. In the Data Views toolbar, select the Open PERT Chart and click on the word Process in the PPR tree.

The PERT Chart Window appears showing the Activities. Select an activity box with the left mouse button and drag it to the desired location. The position of any activity in the PERT chart can be modified after changing an activity's position, it will automatically snap to the center of the nearest grid square when the mouse button is released.

2. To see the Text in the Activity boxes, from the main menu, select Window / Tile Horizontally.

3. With a split view, when a activity is selected it highlights in both windows.

The names of the activities in the Pert Chart are easier to see….

Click on the + sign to view the activities under the stations process…

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Linking or Sequencing activities in the PERT chart

The chart may be created with the links in place or it may not have the links in place. This procedure also explains how to modify existing links. The PERT chart appears below the PPR tree. Each box represents an activity. Each box can be manipulated and moved within the chart.

4. To delete the links, move the mouse over the line, and right click for the contextual menu. Select Delete. If needed, delete the links and create new ones so they match the process flow.

5. To create a link between two activities, click

on the Link icon. Click in the box that you want to start the link, and then the box to link to. If no other links need to be created, click on the link command to deactivate it.

Final Process

6. Close the Pert chart when completed.

To zoom in or out, click in the window (to make it active), and select the mouse functions for zooming…

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This procedure describes how to assign and view welds in a process welding activity, thereby managing and validating these Weld points well in advance of production.

In this exercise, the DPM Fastener Process Planner workbench will be used to assign the welds.

1. In the PPR tree, under Station 1, select SpotWelding 1.

2. In the Fastener Management toolbar, select the Assign fasteners from Product to an Activity command. In the PPR tree Products list, select Assembly Joints under the RH Body Side Assembly.1.

Fastener Assignment

If there is no welds showing under the fasteners available for assignment, make sure in the Tools / Options / Digital Process for Manuf / DPM – Fastening Process Planner / Commands / Activate Part Loading Constraints is deactivated.

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3. The Fastener Assignment dialog box appears. This displays the total number of welds and what activity the welds are assigned. At this point, no welds are assigned. Notice that there is a pull down window for in the List of Products with Fasteners and for the List of activities. Hold the Ctrl key down and select the Welds 1,3,5. Use the arrow to assign them to the selected activity.

Welds are assigned and no longer available unless Allow Duplicate Weld Assignment is toggled on. (This is in the tools / options / Digital Process for Manufacturing / Commands) This would be toggled on if a parallel process were also being created. Welds can also be

assigned depending on what parts have been loaded prior to the welding activity selected in the Process. Apply Part loading Constraints must be toggled on for this to take effect. We will not be using that function.

4. With the Fastener Assignment dialog box still open, select Station 1 >Spot Welding .2 from the List of activities or the PPR tree.

5. Select welds 07, 09, 11, and 13 and click on the arrow to move the welds and assign them to selected activity. At this time select the accountability tab and confirm that the odd welds have been allocated.

6. Notice that, while assigning welds the weld names appear in the 3D view when they are selected, they change color. Close the Fastener Assignment dialog box when finished.

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Weld Information or Weld ID

7. To continue to view the weld names, position the geometry conveniently in the 3D view. Select the Show Weld ID in 3D window button. Expand the ProductList in the PPR tree and select the RH Body Side Assembly. A weld ID dialogue box comes up. Verify that the All sub-products option is checked, and the Switch is yes, (double click on the product name if it is not) This activates them on, and off using the Apply button. Click on the Apply button a few times to see them turn on and off, then when they are off, Close.

8. The Assigned Weld information in the PPR tree.

9. Collapse the RH Body Side Assembly node in the Productlist.

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This procedure describes how to assign products and resources to activities within the process. There are four methods that can be used to assign products and resources to activities:

Using the Assign a Product/Resource command (Activity Management Workbench)

This method allows you to define a relation from a list of relation types at the time of the assignment

Using the Assign an Item and Assign a Resource commands (Activity Management Workbench)

This method allows you to quickly assign a product or resource to an activity, without querying for the relation type

Using the drag-and-drop method from within the PPR tree

Using the drag-and-drop method from the 3D viewer to the PPR tree

The purpose of a process and its associated activities is to transform items, which are

represented by a specific set of data. This data may refer to products, welds, other fasteners, or points to inspect. Therefore, the more generic term "item" is used throughout the

application.

Because more than one resource is often needed for a particular activity, multiple resources may be assigned to an activity.

In this procedure the robots will be assigned to the welding, loading, and unloading activities. This creates a process that can be simulated.

Lets Talk and Review the different choices…

Assigning the Robot

Resources to the

Process

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Assigning a Product

To perform the procedures described:

• The products and resources to assign must have been previously imported to the process (i.e., they are currently displayed in the ProductList and ResourcesList).

• The activities that make up the process have been created.

• The PPR tree for the process must be visible.

To view assigned resources on the PPR tree, the appropriate filter (Resources) must be enabled.

We will review some of the icons:

Assigning a Product

Method 1: Using the Activity Management Toolbar.

1. Click on the Assign an item icon.

2. Select the product to be assigned from the ProductList of the PPR tree.

3. Select the activity in the PPR tree that the product is to be assigned to. The selected product will then be shown in the Items folder of the selected activity. This is a way to assign a product so that it has no relation to saving to the PPR Hub.

4. Click on the Assign a product/resource icon. 5. Select the product to be assigned from the

ProductList of the PPR tree.

6. Select the activity in the PPR tree that the product is to be assigned to. The selected product will then be shown in the Items folder of the selected activity.

7. Select the type of relation for the process/product and click OK. The product will then be shown in the Items folder of the selected activity: (Use the 1stoption, they are explained below)