Process Simulate on eMS Basic Robotic

Simulation
Student Guide
September 2011
WKP115S – version 10.0

Publication Number
MTXW115S-S-100
Getting Started

This software and related documentation are proprietary to Siemens Product

Lifecycle Management Software Inc.
© 2011 Siemens Product Lifecycle Management Software Inc. All Rights
Reserved.
All trademarks belong to their respective holders.

2 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100

Contents

Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Basic Robotic Simulation Course Overview . . . . . . . . . . . . . . . . . . . 19

WKP115S Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
WKP115S Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Learning tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Basic Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Training Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Introduction to the Training Manual Structure . . . . . . . . . . . . . . . . . 1-3
Methodology and Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Basic Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
What is Process Simulate? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Typical Process Simulate Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
The Theory of Tecnomatix eBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
The Four Basic eMS Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Using Process Designer to Figure Out How to Manufacture a
Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Hierarchical Trees and Libraries of Nodes . . . . . . . . . . . . . . . . . . . . 1-13
Generic eMS Process Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Generic Process Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Accessing Data in Process Simulate . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Supported Workflows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Method 1: Starting and Exiting Process Simulate Directly . . . . . . . . 1-19
Method 2: Starting and Exiting Process Simulate from Process
Designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Activity: Starting Process Simulate . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Basic Options Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Data Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Activity: Setting and Viewing Basic Options . . . . . . . . . . . . . . . . . . 1-24
Check In and Check Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Check In and Check Out Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Checking Nodes In and Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Check Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Check In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Cancel Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Get Check In and Check Out Status . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Creating High-Level Resource and Operation Trees . . . . . . . . . . . . . . . 1-33

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Creating Objects Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

Activity: Create the High-Level Operation Tree (1) . . . . . . . . . . . . . 1-35
Activity: Create the High-Level Resource Tree (2) . . . . . . . . . . . . . 1-36
Activity: Associate the Trees Together . . . . . . . . . . . . . . . . . . . . . . . 1-37
Using the Navigation Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Navigation Tree Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
Navigating with the Mouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
Navigating with the Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
Right Click Expanding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
Right Click Collapsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44
Examining Object Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
Basic Object Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46
Activity: Examine the Object Types that are Available . . . . . . . . . . 1-47
The Concept of Prototype and Instance . . . . . . . . . . . . . . . . . . . . . . . . . 1-48
Library Nodes (of Parts, Operations and Resources) . . . . . . . . . . . . 1-49
Prototype / Instance Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50
Seeing the Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51
Viewing Object Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52
Activity: Examine the Part Library . . . . . . . . . . . . . . . . . . . . . . . . . 1-53
Activity: Examine the Resource Library . . . . . . . . . . . . . . . . . . . . . 1-54
Creating a Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55
Introduction to Studies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56
Activity: Setting the Working Folder . . . . . . . . . . . . . . . . . . . . . . . . 1-58
Activity: Creating a New Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-59
Process Simulate Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60
Process Simulate Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61
Process Simulate Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62
Status and Title Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63
Viewer Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-64
Process Simulate Viewer Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-65
Viewer Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-66
Operation Tree Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-68
Object Tree Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69
Object Tree Viewer Nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-70
Activity: Browsing the Process Simulate Scene . . . . . . . . . . . . . . . . 1-71
Window Layout Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72
Window Layout Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-73
Docked and Floating Viewers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-74
On Demand Window Viewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-76
Save/Restore Window Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-77
Activity: Docking and Floating Windows . . . . . . . . . . . . . . . . . . . . . 1-79
Activity: Saving a Window Layout . . . . . . . . . . . . . . . . . . . . . . . . . 1-80
Activity: Using a Window Layout . . . . . . . . . . . . . . . . . . . . . . . . . . 1-81
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-82

Process Simulate on eMS Environment . . . . . . . . . . . . . . . . . . . . . . 2-1

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Working with Viewers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Graphic Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Object Tree Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Right Click Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Working with Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Automotive Activity: Getting an Overview of the Objects in the Object
Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Airplane Activity: Getting an Overview of the Objects in the Object
Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Structure Activity: Getting an Overview of the Objects in the Object
Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Activity: Object Tree Basics and Groups . . . . . . . . . . . . . . . . . . . . . 2-12
Activity: Using the Right Click Popup Menu . . . . . . . . . . . . . . . . . . 2-13
Graphic Viewer Setup and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Graphic Viewer Control Overview . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Finding the View Control Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Graphics Background Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Mouse Movement Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Rotation Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
View Control with the Mouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
View Control with the Space Mice . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Basic Viewing Command Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Activity: Graphic Viewer Control . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Customizing the User Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Accessing and Using the Customize Window . . . . . . . . . . . . . . . . . . 2-31
Resetting and Saving Customizations . . . . . . . . . . . . . . . . . . . . . . . 2-34
Entity Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Selection Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Pick Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Toggling Detailed or United Representation . . . . . . . . . . . . . . . . . . 2-38
Viewing and selecting PMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Activity: Selecting Objects in the Graphic Viewer . . . . . . . . . . . . . . 2-42
Activity: Additional Methods of Multiple Entity Selection . . . . . . . . 2-43
Activity: Using Toggle Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Introduction to Selection Filters (Optional) . . . . . . . . . . . . . . . . . . . . . . 2-45
Selection Filter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Activity: Blanking all the Frames using Selection Filters
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Introduction to Display By Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Display by Type Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Available Types for Display by Type . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Activity: Blanking all the Frames using Display By Type . . . . . . . . 2-51
Measurement and Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Linear Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

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Activity: Relationship Between Measuring and Units . . . . . . . . . . . 2-57

Graphical Visualization and Performance . . . . . . . . . . . . . . . . . . . . . . . 2-58
Graphical Visualization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Dynamic Clipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
Performance Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Performance Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
Activity: Changing Visualization Performance . . . . . . . . . . . . . . . . . 2-65
Activity: Changing Graphical Visualization . . . . . . . . . . . . . . . . . . . 2-66
Additional Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Window Manipulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Toolbar Manipulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
Searching for Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Expand to selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Collapse to Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
Display or Hide the Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Accessing Online Help and Release Notes . . . . . . . . . . . . . . . . . . . . . . . 2-74
Quick Help Topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
Online Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Release Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80

Placement Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Introduction to Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
The Placement Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Introduction to Fast Placement and Restore Design Relative Position . . . 3-4
Fast Placement Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Activity: Using Fast Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Changing Pick Behavior and Creating Frames . . . . . . . . . . . . . . . . . . . . 3-7
Setting Pick Intent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Setting Pick Level Refresher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Basic Techniques for Creating Frames . . . . . . . . . . . . . . . . . . . . . . 3-10
Advanced Techniques for Creating Frames . . . . . . . . . . . . . . . . . . . 3-11
Activity: Creating a Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Introduction to Placement Manipulator . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Reference Frame Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Placement Manipulator Basic Options . . . . . . . . . . . . . . . . . . . . . . . 3-16
Placement Manipulator Advanced Options . . . . . . . . . . . . . . . . . . . 3-18
Activity: Shifting and Rotating Instances On-screen . . . . . . . . . . . . 3-19
Activity: Relationship Between Placement Manipulator Measuring and
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Activity: Incremental Shifting of Objects from a Reference Frame . . 3-21
Introduction to Relocate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Relocate Command Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Basic Relocate Command Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Advanced Relocate Command Usage . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Activity: Relocating an Object Relative to Two New Frames . . . . . . 3-27

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Activity: Relocating an Object Relative to Two Existing Frames . . . 3-28

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Quick Introduction to Kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Fundamentals of Kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Kinematics Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
General Kinematics Usage Commands (part 1) . . . . . . . . . . . . . . . . . 4-5
Activity: Jogging the Joints of a Simple object . . . . . . . . . . . . . . . . . . 4-6
Creating Device Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
General Kinematics Usage Commands (part 2) . . . . . . . . . . . . . . . . . 4-8
Activity: Defining Kinematic Poses . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Activity: Creating a Simulative Operation from Poses . . . . . . . . . . . 4-10
Inverse Kinematics Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Principles of Inverse Kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Relocate Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Direct Kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Inverse Kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Level of Kinematic Inverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Using Inverse Kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Kinematics Usage Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Activity: Examining the Kinematic Tree of a Robot . . . . . . . . . . . . . 4-19
Activity: Making the Robot Move . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Process Simulate Analysis Tools and Study Data . . . . . . . . . . . . . . 5-1

Save Scenario . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Scenario Data Storage in the Database . . . . . . . . . . . . . . . . . . . . . . . 5-4
Scenario Data Administrative Note . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Creating and Using Snapshots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Snapshot Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Activity: Creating Snapshots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Using the Markup Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Markup Editor Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Markup Editor Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Activity: Creating Markups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Adding Text in the Graphic Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Graphic Viewer Text Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Activity: Setting the Note Options . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Activity: Creating Notes in the Graphic Viewer . . . . . . . . . . . . . . . . 5-20
Activity: Creating Dimensions in the Graphic Viewer . . . . . . . . . . . 5-21
Storing Pictures of the Scenario . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Activity: Outputting the Graphic Viewer to a File or Printer . . . . . . 5-23
Introduction to Collision Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Collision Detection Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Collision Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

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Defining a Collision Set (List Pair) . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Rules of Thumb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Selection Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Activity: Collision Viewer and Fast Collision Sets . . . . . . . . . . . . . . 5-31
Activity: Defining Collision Sets (List Pairs) . . . . . . . . . . . . . . . . . . 5-32
More on Collision Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Collision Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Configuring Level of Detection Granularity . . . . . . . . . . . . . . . . . . . 5-37
Near Miss Value Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Collision Report Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Activity: Collision Setup and Collision Viewer . . . . . . . . . . . . . . . . . 5-42
Activity: Filtering Collision Results . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Factors that Affect Collision Detection . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Collision Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Discussion: Factors that Affect Collision Detection (Not an
Activity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Cutting Sections with Section Planes . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Basic Section Cutting Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Section Plane Alignment Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Optional Activity: Creating and Moving a Section Plane . . . . . . . . . 5-53
Optional Activity: More on Cutting Sections . . . . . . . . . . . . . . . . . . 5-54
Cutting Sections with Section Volumes . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
More Section Cutting Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Optional Activity: Creating and Moving a Section Volume . . . . . . . . 5-57
Recording Process Simulate Simulations to an .AVI File . . . . . . . . . . . . 5-58
Activity: Outputting a Simulation to an AVI File . . . . . . . . . . . . . . . 5-60
Movie Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
Introduction to Movie Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
Activity: Using Movie Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

Other Selected Basic Topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Process Designer Commands in Process Simulate . . . . . . . . . . . . . . . . . . 6-2
List of Project Management Commands in Process Simulate . . . . . . . 6-3
List of eMServer Tools in Process Simulate . . . . . . . . . . . . . . . . . . . . 6-4
List of Other Process Designer Commands in Process Simulate . . . . . 6-5
Activity: Using Some Project Management Commands . . . . . . . . . . . 6-6
Using Process Simulate Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Process Simulate Disconnected Introduction . . . . . . . . . . . . . . . . . . . 6-8
Disconnected System Root . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Saving a .PSZ file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Process Simulate Disconnected Usage . . . . . . . . . . . . . . . . . . . . . . . 6-11
Updating back the eMS Database . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Activity: Starting and Exiting Process Simulate Disconnected . . . . . 6-13
Activity: Updating Process Simulate Disconnected from the eMS
Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

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Activity: Updating the eMS Database from Process Simulate

Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Modeling and Kinematics Overview . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Overview of Process Simulate Basics . . . . . ................. . . . . . 7-2
Starting Out this activity . . . . . . . . . . . ................. . . . . . 7-3
Process Simulate Basics Review . . . . . . ................. . . . . . 7-4
Modeling Basics . . . . . . . . . . . . . . . . . . ................. . . . . . 7-5
Other Basics . . . . . . . . . . . . . . . . . . . . . ................. . . . . . 7-6
Activity: Starting Process Simulate and Setting the Working
Folder . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . . 7-7
Activity: Opening Your Study . . . . . . . . ................. . . . . . 7-8
Process Simulate Basic Modeling Tools . . . . ................. . . . . . 7-9
Modeling and Kinematics Functionality ................. . . . . 7-10
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . ................. . . . . 7-12

Modeling Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Modeling Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Modeling Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Modeling Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Solid Modeling Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Other Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Solid Creating with Primitives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Solid Creation Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Activity: Modeling a Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Using Wireframe to Create Solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Wireframe Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Activity: Revolving 2D Entities to Make a Solid . . . . . . . . . . . . . . . . 8-13
Activity: Extruding 2D Entities to Make a Solid . . . . . . . . . . . . . . . 8-14
Modeling Gun Shanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Tools Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Activity: Sweeping 2D Entities to Make a Solid . . . . . . . . . . . . . . . 8-17
Modeling a More Complex Object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Tools Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Using the Working Frame to Build . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Ways of Creating and Placing Objects in Modeling . . . . . . . . . . . . . . 8-21
Activity: Modeling a Simple Robot for Kinematics . . . . . . . . . . . . . . 8-22
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

Kinematics Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Kinematics Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Ways to Get Kinematic Objects into Process Simulate . . . . . . . . . . . . 9-3
Kinematics Background Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Basic Kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

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Attributes of a Kinematic Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

Methodology to Define a Kinematic Device . . . . . . . . . . . . . . . . . . . . 9-8
Instructor Demo: Simple Kinematics . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Activity: Simple Kinematics (Part 1) . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Activity: Simple Kinematics (Part 2) . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Activity: Simple Kinematics (Part 3) . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Kinematics Basics Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Activity: Add Joints to a Simple object . . . . . . . . . . . . . . . . . . . . . . 9-15
Leading Joint and Follow Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Lead and Follow Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Description of Joint Dependencies . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Kinematic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Activity: Leading Joints and Follow Factors (Gun) . . . . . . . . . . . . . . 9-20
Introduction to Kinematic Cranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Crank Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
First Draw the Kinematic Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Cranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Links and Joints of Cranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Instructor Demo: Kinematic Looping . . . . . . . . . . . . . . . . . . . . . . . 9-26
Activity: Kinematic Looping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Kinematic Branching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Branching Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
Gun Example of Kinematic Branching . . . . . . . . . . . . . . . . . . . . . . 9-30
Activity: Gun Kinematic Definition (Part 1) . . . . . . . . . . . . . . . . . . . 9-31
Activity: Gun Kinematics (Part 2) . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
Defining Speed and Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Speed and Acceleration Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Activity: Speed and Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
Defining Poses on the Gun Prototype . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
Pose Definition Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
Activity: Defining OPEN, SEMIOPEN, and CLOSE Poses . . . . . . . . 9-38
Defining an object as a Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
Tool Definition Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Tool Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
How Do I Define a Gun for Searching? . . . . . . . . . . . . . . . . . . . . . . . 9-42
Activity: Create the TCP and MNT Frames . . . . . . . . . . . . . . . . . . . 9-43
Activity: Defining an Object as a Spot Weld Gun . . . . . . . . . . . . . . . 9-44
Activity: Defining an Object as a Gripper . . . . . . . . . . . . . . . . . . . . 9-45
Assigning Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
Attribute Assignment Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47
Adding Kinematics to a Simple Robot . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
Simple Robot Kinematics Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
Activity: Adding Kinematics to a Robot Model . . . . . . . . . . . . . . . . . 9-50
Activity: Using Direct Kinematics to Move the Robot . . . . . . . . . . . . 9-51
Inverse Kinematics Device Creation and Usage . . . . . . . . . . . . . . . . . . 9-52
Inverse Kinematics Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-53

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Inverse Kinematics Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-54

Activity: Adding a Toolframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-56
Activity: Using Inverse Kinematics to Move the Robot . . . . . . . . . . . 9-57
Activity: More Inverse Kinematics (Optional Extra Credit) . . . . . . . 9-58
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-59

Other Selected Modeling & Kinematics Topics . . . . . . . . . . . . . . . 10-1

Rails, Gantries, and Positioners (External Axis Definition) . . . . . . . . . . 10-2
External Axis Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Activity: Sample Rail Creation Overview . . . . . . . . . . . . . . . . . . . . 10-4
More Kinematic Branching and Cranks . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Complete Kinematic Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Working with the Main Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Attributes of Cranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Example of a Parallel Pantograph (a.k.a. four bar linkage) . . . . . . . 10-9
Example of a Non-Parallel Pantograph (a.k.a. four bar linkage) . . . 10-11
Example of a Prismatic Screw (a.k.a. slider linkage) . . . . . . . . . . . 10-12
RRRP Slider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
PRRR Slider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
PRRR Offset Slider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
RPRR Offset Slider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
RRRP Offset Slider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Instructor Demo: Other Slider Cranks including RPRR Offset
Cranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
More on Kinematic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Function Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Process Simulate Function Definitions . . . . . . . . . . . . . . . . . . . . . 10-27
Implementation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
Instructor Demo: Implementing Joint Logic with Functions (Optional
Activity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
Instructor Demo: Kinematics Following a Surface (Optional
Activity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
The Train Joint - Function Example . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Train Joint Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Defining the Train Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Instructor Demo: Examine the Train Joint . . . . . . . . . . . . . . . . . . 10-39
The Cam Joint - Function Example . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
Cam Joint Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
Defining the Cam Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
Instructor Demo: Examine the Cam Joint . . . . . . . . . . . . . . . . . . . 10-46
Compound Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
Compound Equipment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48
Equipment Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
Creating Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51
Reconciling Navigation Tree Instances . . . . . . . . . . . . . . . . . . . . . 10-52
Kinematic Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53

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Activity: Setting up Compound Equipment . . . . . . . . . . . . . . . . . . 10-56

More Topics (Not Covered in Class) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
Advanced Kinematic Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60

General Robotics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Process Simulate Assembler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Creating a Study (Again) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Activity: Creating a New Study (Again) . . . . . . . . . . . . . . . . . . . . . . 11-4
Robotics Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Robotics Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Robotics Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
Activity: Training Data Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9

Spot Welding Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

Spot Welding Primer (Optional Topic) . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Spot Welding Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Designing a Spot-Welding Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Design Targets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Process Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
Basic Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
The Process: From Least Constraints to Most Constraints . . . . . . . . 12-9
Strategic Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
Weld Representation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11
Manufacturing Feature Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12
Viewing Manufacturing Features . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
Sources for Manufacturing Features . . . . . . . . . . . . . . . . . . . . . . . 12-14
Sources for Basic Manufacturing Feature Orientation . . . . . . . . . . 12-15
Activity: Viewing Spot Mfg Features in Process Simulate . . . . . . . 12-16
Projecting Spot Mfg Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
Weld Location Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18
Projecting Weld Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20
Activity: Projecting Spot Weld Mfg Features . . . . . . . . . . . . . . . . . 12-23
Creating and Editing a Weld Path . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-24
Verifying the Weld Location Orientation . . . . . . . . . . . . . . . . . . . . 12-25
Activity: Adjusting a Weld Path . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26
Multi Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-27
Steps for Creating Multi Sections . . . . . . . . . . . . . . . . . . . . . . . . . 12-28
Activity: Gun Shank Validation . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29
Weld Distribution Center (WDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30
WDC Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-31
WDC Primary Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32
WDC Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34

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Activity: Using Weld Distribution Center (with Automatic Approach

Angle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-35
Process Methodology, revisited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-36
Robotic Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-37
The Process: From Least Constraints to Most Constraints . . . . . . . 12-38
Overview of Gripper Creation (Optional) . . . . . . . . . . . . . . . . . . . . . . . 12-39
Discussion of Steps to Add Poses to an Object . . . . . . . . . . . . . . . . 12-40
Define an Object As a Gripper (Discussion Only) . . . . . . . . . . . . . . 12-41
Scenario Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-42
Setting up the Scenario (study) . . . . . . . . . . . . . . . . . . . . . . . . . . 12-43
Mount Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-44
Activity: Putting the Gripper on the Robot (for Ped. Welding) . . . . 12-45
Material Handling (Pick and Place) Operations . . . . . . . . . . . . . . . . . 12-46
Pick and Place Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-47
Activity: Get/Put the Part in the Fixture . . . . . . . . . . . . . . . . . . . . 12-48
Creating a Rough Mounted Workpiece (Pedestal Welding) Path . . . . . . 12-49
Introduction to Pedestal Welding . . . . . . . . . . . . . . . . . . . . . . . . . . 12-50
External TCP Usage Differences . . . . . . . . . . . . . . . . . . . . . . . . . . 12-51
Setting up a Mounted Workpiece Path . . . . . . . . . . . . . . . . . . . . . . 12-52
Reach Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-53
Jumping to a Location Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-54
Activity: Creating a Rough Mounted Workpiece Path . . . . . . . . . . 12-55
Orienting Workpiece Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-56
Steps to Orienting the Locations . . . . . . . . . . . . . . . . . . . . . . . . . . 12-57
Pie Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-58
Activity: Orient the Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-59
Introduction to Weld Gun Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-60
Geometric Gun Search Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-61
Activity: Weld Gun Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-63
Servo Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-64
Servo Gun Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-65
Servo Gun Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-66
Define an Object As a Servo Gun (Discussion Only) . . . . . . . . . . . . 12-67
Instructor Demo: Simulating Robots with Servo Guns . . . . . . . . . . 12-68
Activity: Working with Servo Guns . . . . . . . . . . . . . . . . . . . . . . . . 12-69
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-70

Material Handling Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

Overview of Gripper Creation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Discussion of Steps to Add Poses to an Object . . . . . . . . . . . . . . . . . 13-3
Define an Object As a Gripper (Discussion Only) . . . . . . . . . . . . . . . 13-4
Material Handling Scenario Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Setting up the Material Handling Scenario (study) . . . . . . . . . . . . . 13-6
Instructor Demo: Material Handling Example . . . . . . . . . . . . . . . . . 13-7
Activity: Pick and Place (Material Handling) Setup . . . . . . . . . . . . . 13-8
Material Handling (Pick and Place) Operations . . . . . . . . . . . . . . . . . . 13-9

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Pick and Place Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10

Activity: Create the Basic (PNP) Process . . . . . . . . . . . . . . . . . . . . 13-11
Activity: Stacking Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
Activity: Doing the Second Pass (Optional Activity) . . . . . . . . . . . . 13-13
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14

Continuous Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

Overview of Continuous Robotic Applications . . . . . . . . . . . . . . . . . . . . 14-2

Arc Weld Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
Painting Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8
More Continuous Robotic Applications . . . . . . . . . . . . . . . . . . . . . 14-12
Continuous MFG Representation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
Manufacturing Feature Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
Viewing Manufacturing Features . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
Sources for Manufacturing Features . . . . . . . . . . . . . . . . . . . . . . . 14-16
Sources for Basic Manufacturing Feature Orientation . . . . . . . . . . 14-17
Projecting Continuous Mfg Features . . . . . . . . . . . . . . . . . . . . . . . . . . 14-18
Continuous Location Constraints . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
Projecting Continuous Mfg Features . . . . . . . . . . . . . . . . . . . . . . . 14-20
Continuous MFGs and Continuous Feature Operations . . . . . . . . . . . . 14-23
Basic Usage of Continuous Mfg Features and Operations . . . . . . . 14-24
Activity: Using Continuous Feature Operations . . . . . . . . . . . . . . . 14-25
More Continuous Mfg Feature Applications (Arc weld, Paint, and
Debur) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-26
Additional General Continuous Mfg Feature Tools . . . . . . . . . . . . . 14-27
Additional Arc weld Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
Additional Paint Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-29
Additional Operation Menu Tools . . . . . . . . . . . . . . . . . . . . . . . . . 14-31
Activity: Creating Arc MFGs for the Whitehouse part . . . . . . . . . . 14-32
Activity: Creating Debur MFGs for the Whitehouse part . . . . . . . . 14-33
Activity: Creating Paint MFGs for the Whitehouse part . . . . . . . . . 14-34
Activity: Creating Arc Seams for the Whitehouse part (using Project Arc
Seam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
Activity: Creating Paint Paths for the Whitehouse part (using Project
Cont. Mfg Features) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-36
Activity: Creating Deburring Paths for the Whitehouse part (using Project
Cont. Mfg Features) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-37
Activity: Modifying Arc weld Operations and Seams . . . . . . . . . . . 14-38
Activity: Modifying Debur Operations and Seams . . . . . . . . . . . . . 14-39
Activity: Modifying Paint Operations and Seams . . . . . . . . . . . . . . 14-40
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-41

Final Steps for Robotic Path Development . . . . . . . . . . . . . . . . . . 15-1

Test Robot’s Reachability to the Locations . . . . . . . . . . . . . . . . . . . . . . . 15-3

Robotic Reach Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4

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Reach Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5

Robot Smart Place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
Smart Place Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8
Robot Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9
Jumping and Moving to a Location . . . . . . . . . . . . . . . . . . . . . . . . 15-10
TCP Tracker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
Activity: Testing Reachability (Method 2) . . . . . . . . . . . . . . . . . . . 15-12
Activity: See Robot Reaching Locations . . . . . . . . . . . . . . . . . . . . . 15-13
Dynamic and Static Collision Detection . . . . . . . . . . . . . . . . . . . . . . . 15-14
Collision Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15
Collision Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16
Dynamic Collision Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18
Introduction to Path Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-19
Path Modification Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-20
Activity: Adding Start / End Vias and Approach / Retract Locations in the
Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-21
Via Location Creation Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-22
Location Creation Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-23
Activity: Creating Collisions Lists . . . . . . . . . . . . . . . . . . . . . . . . . 15-24
Activity: Using Add Location By Pick . . . . . . . . . . . . . . . . . . . . . . 15-25
Location Modification Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-26
Location Modification Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-27
Automatic Approach Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-28
Modifying Locations Using the Path Editor . . . . . . . . . . . . . . . . . 15-29
Path Segment Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-30
Activity: Simulating a Segment of a Path . . . . . . . . . . . . . . . . . . . 15-31
Activity: Using Manipulate Location and Rotate Weld Locations . . 15-32
Activity: Using the Automatic Approach Angle window . . . . . . . . . 15-33
Activity: Modify Locations According to Robot Reach (Pie Chart) . . 15-34
Path Modification Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-35
Process Simulate Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-36
Path Modification Tools Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-37
Automatic Path Planner (APP) for Robot Paths . . . . . . . . . . . . . . . 15-39
Automatic Path Planner (APP) Robot Settings . . . . . . . . . . . . . . . . 15-41
Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-42
Modifying Paths Using Operation Properties . . . . . . . . . . . . . . . . . 15-45
Activity: Using Copy Location Orientation . . . . . . . . . . . . . . . . . . 15-46
Activity: Using Interpolate Locations Orientation . . . . . . . . . . . . . 15-47
Activity: Mini Putting It All Together . . . . . . . . . . . . . . . . . . . . . . 15-48
Activity: Using Reverse Operation . . . . . . . . . . . . . . . . . . . . . . . . 15-49
Activity: Reordering Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-50
Activity: Using Automatic Path Planner for Robot Paths . . . . . . . . 15-51
Activity: Using Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-52
Additional Path Creation Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-53
Duplicate Weld Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-54
Instructor Demo: Using Duplicate Weld Operation . . . . . . . . . . . . 15-55

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Editing Location Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-56

Basic Location Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-57
Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-58
Custom columns in the Paths Editor . . . . . . . . . . . . . . . . . . . . . . . 15-59
Activity: Editing Location Attributes . . . . . . . . . . . . . . . . . . . . . . 15-60
Signal (I/O) Definition & Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . 15-61
Steps for Driving Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-62
Activity: Driving Devices and Waiting Until a Device is Driven to
Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-63
Multiple Robot Simulation & Work Balance . . . . . . . . . . . . . . . . . . . . 15-64
Steps for Sending Signals to Robots . . . . . . . . . . . . . . . . . . . . . . . . 15-65
Activity: Adding a Second Robot . . . . . . . . . . . . . . . . . . . . . . . . . . 15-66
Activity: Two Robot Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-67
Activity: Setting Up Robot Signals using the Teach Pendant . . . . . 15-68
Working with Hard and Soft Limits . . . . . . . . . . . . . . . . . . . . . . . . . . 15-69
Hard limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-70
Soft limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-71
Activity: Avoiding Collisions with Stationary Objects . . . . . . . . . . 15-72
Robotic Swept Volumes and Interference Zones . . . . . . . . . . . . . . . . . 15-73
Swept Volume Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-74
Process Simulate Swept Volumes . . . . . . . . . . . . . . . . . . . . . . . . . 15-75
Process Simulate Interference Volumes . . . . . . . . . . . . . . . . . . . . . 15-76
Process Simulate Inference Zones . . . . . . . . . . . . . . . . . . . . . . . . . 15-77
Activity: Using Swept Volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-78
Activity: Using Inference Zones . . . . . . . . . . . . . . . . . . . . . . . . . . 15-79
Adding Events to a Sequence of Simulative Operations . . . . . . . . . . . . 15-80
Introduction to Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-81
Additional Event Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-83
Event Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-84
The Attach Command versus the Attach Event . . . . . . . . . . . . . . . 15-85
Instructor Demo: Adding an Attach Event . . . . . . . . . . . . . . . . . . . 15-87
Activity: Adding a View Point Event . . . . . . . . . . . . . . . . . . . . . . . 15-88
Activity: Add a Pause Event . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-89
Activity: Coloring Events by Type . . . . . . . . . . . . . . . . . . . . . . . . . 15-90
7th Axis and More (External Axis Usage) . . . . . . . . . . . . . . . . . . . . . . 15-91
External Axis Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-92
External Axes Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-93
Instructor Demo: Working with a 7th Axis . . . . . . . . . . . . . . . . . . 15-94
Activity: Working with a 7th Axis . . . . . . . . . . . . . . . . . . . . . . . . . 15-95
Creating Sequences of Simulative Operations . . . . . . . . . . . . . . . . . . . 15-96
Process Simulate on eMS Sequence of Operations Organization . . . 15-97
Types of Simulative Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-98
Creating Compound Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-99
Creating and Linking Compound Operations . . . . . . . . . . . . . . . . 15-100
Creating a Robotic Sequence (Method 1 and 2) . . . . . . . . . . . . . . . . . 15-101
Creating a Robotic Sequence (Method 1) . . . . . . . . . . . . . . . . . . . 15-102

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Creating a Robotic Sequence (Method 2) . . . . . . . . . . . . . . . . . . . 15-103

Comparing Methods of Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-104
PLPs and Rough Volumes (Not Covered in Class) . . . . . . . . . . . . . . . 15-105
Working with PLPs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-106
Creating Rough Volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-107
Other Robotics Features (Not Covered in this Course) . . . . . . . . . . . 15-108
Creating Weld Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-109
Multi-Assign Weld Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-110
Automatic Weld Point Assign . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-111
Update Weld Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-113
Unified Collision Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-114
Flip Location on Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-116
Selected Intermediate and Advanced Robotics topics (More Topics Not
Covered in the Basic Robotics Course) . . . . . . . . . . . . . . . . . . . 15-118
Putting It All Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-119
The Basic Process Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-120
The Detailed Process Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 15-121
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-123

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

Process Simulate on eMS Basic Robotic Simulation Student Guide 17

Basic Robotic Simulation Course
Overview

Course description
The Process Simulate on eMS Basic Robotics Simulation course provides
step-by-step instruction on how to use Process Simulate to create robotic
simulations.

Course objectives
Learn about:
• Basic Environment
o Study creation

o Creating sequences of simulative operations

o Collision detection

o Section cutting

o Video and picture output

• Defining kinematic devices

• Defining and simulating robotic spot welding

o Pneumatic and servo gun definition and usage

o Ped. welding and Gun on robot path development

• Defining and simulating robotic continuous applications

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Basic Robotic Simulation Course Overview

o Arc welding and grinding path development

• Defining and simulating robotic material handling

o Gripper definition and usage

o Pick and place path development

• And More
o Multi-robot simulation (i.e. interference zones)

o Swept volumes, 7th axis, etc...

20 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100

 Basic Robotic Simulation Course Overview

WKP115S Prerequisites

• Students should be skilled in the use of a mouse in windows-based

systems.

• Previous experience with a 3D system is recommended.

• A basic knowledge of robotics is suggested.

WKP115S Audience
This course is intended for individuals who want to become knowledgeable on
the creation of basic robotic simulations using Process Simulate on eMS.

Learning tracks
Learning tracks for the Tecnomatix application are found on the Siemens
PLM Software training website: http://training.ugs.com/tracks/index.shtml

Related Courses
• WKP101S – Process Simulate on eMS Part Flow Simulation

• WKP106S – Process Simulate on eMS Human Simulation

• WKP115S – Process Simulate on eMS Basic Robotic Simulation

• WKP215S – Process Simulate on eMS Intermediate Robotic Simulation

• WKP315S – Process Simulate on eMS Advanced Robotic Simulation

Process Simulate on eMS Basic Robotic Simulation Student Guide 21

Lesson

1 Basic Concepts

Purpose
To provide an introduction to Process Simulate.

Objectives
After you complete this chapter, you should be familiar with:
• The basic concepts of Process Simulate and Process Designer will be
discussed.

• The Navigation Tree viewer will be used to build and view basic product,
operation, and resource trees.

• Window Management, study objects, and basic options will be discussed.

• The concept of prototype and instances.

• The concepts of System Root, projects, libraries, and objects will be

introduced.

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Basic Concepts

Training Introduction
This topic describes the basic training manual structure.
It contains the following subtopics:
• Introduction to the Training Manual Structure

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 Basic Concepts

Introduction to the Training Manual Structure

The training manual is designed for a classroom containing two to ten eMS
clients, an eMS server (a.k.a. eMServer) workstation, and an Oracle Server
machine.
The students will be assigned as follows:
User Name Workstation Type eMS User Id
instructor client administrator
student client user1
student client user2
student client user3
student client user4
student client user5
etc... etc... etc...
student client user7
student client user8
student client user9

The course starts out using simple, basic data. Later, there are three
data that can be used: Automotive, Airplane, or Structural. In cases
where there is a data choice, the Activity will include the name of the
choice:
Activity Name Prefix Description
Refers to an automotive assembly
Automotive
process
Refers to an airplane maintenance
Airplane
process
Refers to a large structure
Structure (skyscraper or ship) general
assembly process

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Basic Concepts

Methodology and Workflow

This Student Guide begins by giving an overview of the overall goal of this
class, depicted in Topic 1.
It contains the following subtopics:
• Basic Definitions

• What is Process Simulate?

• Typical Process Simulate Usage

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 Basic Concepts

Basic Definitions

eBOP is an electronic bill of process. It is made up of four primary objects:

Product, Operations, Resources, and Manufacturing Features.
Product – refers to the object that will be produced from the manufacturing
process described in the eBOP.
Operations – refers to the sequence of steps that will be performed to produce
the product.
Resources – refers to the objects such as machines, tools, and workers–within
a manufacturing plant–that will perform the operations to produce the
product.
Manufacturing Features – Manufacturing features are used to represent
special relationships between several parts. Two examples of manufacturing
features are weld spots and datums.
Also in this training, eMS database refers to the Oracle database used by
Process Designer, Process Simulate, Web-Based BOP Manager, and BOP Web
Reporting. eMS data is data within the eMS database.

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Basic Concepts

What is Process Simulate?

Tecnomatix offers a suite of engineering study tools known collectively as

Process Simulate. This suite includes Process Simulate Human, Process
Simulate Robotics, Process Simulate Assembler (Flow Paths), and more ....
Process Simulate is a dynamic environment that facilitates concept
verification, as well as assembly and serviceability studies, by enabling an
engineer to conveniently:
• Verify the feasibility of a product assembly.

• Develop practical a path for assembly and the disassembly of parts.

• Perform robotic reach checks to desired locations.

• Develop and download robotic processes and paths (including logic)

• Perform human reach checks and ergonomic studies to desired situations.

• Develop human simulations

• Check collisions and clearances dynamically for tools, robot arms and
the human hand.

• Perform serviceability studies of the assembly.

• Determine how to service a specified part of the assembly.

• Etc ...

The Process Simulate interface looks very similar to the interface for
Microsoft Word or other Windows applications. The same File, Edit, View,
and Help options are displayed on the menu bar.

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 Basic Concepts

Typical Process Simulate Usage

This training manual is divided into the following sections and follows the
displayed workflow.

Step 1 Opening a New Study:

Product, operation, and resource trees, which represent a desired smaller
area of the complete project, are loaded into the simulation environment.
Step 2 Creating and Modifying Simulative Operations:
Paths are developed for the assembly parts in order to determine if the
assembly can be effectively assembled and disassembled. You can use the
commands in the Path menu and/or Placement toolbox to create a path for
each part in the assembly.
Step 3 Sequencing Simulative Operations:
A sequence combines separate operations into an entire assembly process.
This process defines individual operations for the currently displayed
assembly, combines them into a sequence of operations, and simulates a
selected sequence. The purpose of these commands is to demonstrate and
verify the feasibility of a complete assembly procedure in the dynamic
simulated environment, and to produce a detailed assembly report.

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Basic Concepts

Step 4 Analyzing Simulative Operations :

Collision list pairs and set clearances are created using the Collision viewer,
and are checked during the movement of the parts along their paths.
The simulative operation is then simulated. These commands affect motion
along the path, either continuously from the beginning to the end, or as single
steps between locations. When desired, the simulation can be halted and then
restarted in either the forward or the reverse direction. The simulation may
begin at any location or at any time. The simulation can be stopped when one
of the collision or clearance conditions is violated.
The path can be edited at problematic locations to obtain a more optimized
path. The last step in this process is the verification of all locations where
an assembly part violates a predefined clearance along the path, and the
determination of where minimum clearances are reached along the path.
Step 5 Outputting Deliverables :
Process Simulate provides various outputs for the engineer. The following
outputs constitute documentation of fault conditions, which can be used as a
means of communication with the designers:
• A report of the collision and clearance violations along the path.

• A report of the path or paths that were developed for the assembly parts.

• A movie of the simulation, in .AVI format.

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 Basic Concepts

The Theory of Tecnomatix eBOP

The eBOP data is stored in the eMS database. There are several primary
tools used to access that data:
• Process Designer – Primary process design content creation tool

• Process Simulate – Simulation environment containing several

Tecnomatix engineering tools.

• Machining Line Planner – Content creation tool for NC machining

planning.

• Plant Simulation – Analyze plant throughput, etc...

• Web-Based BOP Manager – Web browsing tools

In order to better understand Process Simulate, it helps to know a little

about Process Designer, and the way the data is structured within the eMS
database.
It contains the following subtopics:
• The Four Basic eMS Objects

• Using Process Designer to Figure Out How to Manufacture a Product

• Hierarchical Trees and Libraries of Nodes

• Generic eMS Process Overview

• Generic Process Introduction

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Basic Concepts

The Four Basic eMS Objects

The eMS users (Process Designer, Process Simulate, and Wed-Based BOP
Manager) coordinate four basic groups of objects: parts, operations, resources,
and manufacturing features.

1. Parts are the pieces that make up the manufactured product.

• The part tree lists all of the parts of the final product as a hierarchical
model that depicts how the parts relate to one another in the
completed product.

2. Operations are the actions performed in order to manufacture

the product.
• The operation tree lists all of the operations and describes the order
in which they will be performed.

3. Resources are the factory facilities that perform the operations

on the parts; these include assembly lines, stations, zones, work-cells,
tools, and fixtures.
• The resource tree lists the workers, tools, and fixtures. It also
describes the order and placement of the resources as well.

4. Manufacturing features Manufacturing features are used to

represent special relationships between several parts. Two examples of a
manufacturing feature are weld spots and PLP (datums). This object type
is generally used by Automotive Body-In-White users.

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Using Process Designer to Figure Out How to Manufacture a Product

1. First, we decide on a part that we would like to manufacture.
• Parts are represented by an orange triangle in eMS.

2. Manufacturing features are associated to parts.

• Manufacturing features (MFG) are represented by a green icon in
Process Designer.

3. Now we need to figure out how to manufacture this part. For example,
does it require spot welding, stamping, painting, assembly, etc... These
are the operations that must be performed in order to create this part.
• Operations are represented by magenta squares in Process Designer.

4. Manufacturing features (i.e. weld spots) are assigned to the operations.

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Basic Concepts

5. Now to perform these operations, we will need specific resources. For

example, we may need robots, workers, spot welding guns, dump units,
workcells, factories, etc...
• Resources are represented by blue circles in Process Designer.

6. The relationships between the basic objects (operations, resources, parts,

and manufacturing features) and the objects themselves define the eBOP.
This is what is contained in the eMS database.

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Hierarchical Trees and Libraries of Nodes

There are two main ways that nodes are stored in the eMS database: as
a hierarchical tree and as libraries. Each of the four basic types of objects
is a little different in how they are stored in the eMS database. See the
descriptions that follow.
Product Representation:
• Part Library is a flat tree that contains the master of each unique part
from the hierarchical product tree.

• Product Tree is a hierarchical tree typically organized by regions of the

final product (i.e. underbody, motor compartment, etc…) by the product
design group. Two types of product trees:
o EBOM – (Engineering Bill of Materials) Product data organized by
areas of the vehicle. This is the typical tree used by the product design
group and stored in a CAD system.

o MBOM – (Manufacturing Bill of Materials) Product tree organized

by how the product will arrive at the plant for assembly. This tree
contains assemblies of incoming parts into the stations along the line.

• In Process Assembly Tree (or IPA Tree) is a hierarchical tree similar in

structure to the operation tree. It contains the list of parts that have been
allocated as incoming parts into a station in the assembly line.

Resource Representation:
• Resource Library is a flat tree that contains the master of each unique
resource from the hierarchical resource tree. More resources may exist
in the resource library than are used in the resource tree. This library
shows the standard list of common resources (i.e. robots and workers) and
resources specific to a project (i.e. tooling). Sub-libraries can be created to
better organize the resources.

• Resource Tree (a.k.a. BOR: bill of resources) is a hierarchical tree

typically organized by regions of the manufacturing plant (i.e. plant, line,
zone, station, etc…). Each station contains a list of resources used there.

Operation Representation:
• Operation Library (optional) is a flat tree that contains the template copy
for commonly used operational sequences.

• Operation Tree (a.k.a. EBOP: electronic bill of process) is a hierarchical

tree typically organized by regions of the manufacturing plant (i.e.
plant, line, zone, station, etc…). Each station contains the sequence of
operations that will be performed there.

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Basic Concepts

Manufacturing Feature (MFG) Representation:

• Mfg Feature Library is a flat tree that contains the master of each unique
weld spot or datum. Sub-libraries can be created to better organize
the Mfg features by regions of the final product (i.e. underbody, motor
compartment, etc…).

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 Basic Concepts

Generic eMS Process Overview

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Basic Concepts

Generic Process Introduction

Here are the steps that would be followed in a generic project using Process
Designer and Process Simulate:
Detailed Steps
1. Data Administrator creates new Collaborative Context (containing the
desired Structure Contexts).*

2. Data Administrator creates a new Application Interface and matching

eMS project.*

3. Users synchronize Context data into this project.**

4. Create Plant/Line/Zone operation and resource tree skeletons.**

5. Create Station inside the Zones.**

6. Layout the station Resource contents (or at step 9).**

7. Assign Template Operations to Stations.**

8. Setup PERT chart for Zone/Stations. **

9. Assign Resources to Stations (or at step 6). **

10. Request/Perform a detailed Scenario (study) (Robcad, Plant Simulation,

Process Simulate, Process Simulate Assembler, Process Simulate Human,
Process Simulate Robotics, Process Simulate Commissioning, etc…).

11. View data using Wed-Based BOP Manager and BOP Web Reporting.**

12. Users Publish to Teamcenter and Process changes*

* These topics are covered in the EMS135D course and are only needed if
linking the eMS database to the Teamcenter database.
** We will not cover these topics in this training class. It will take several
classes to cover all these steps.

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 Basic Concepts

Accessing Data in Process Simulate

This Topic describes ways to start Process Simulate on eMS.
It contains the following subtopics:
• Supported Workflows

• Method 1: Starting and Exiting Process Simulate Directly

• Method 2: Starting and Exiting Process Simulate from Process Designer

• Activity: Starting Process Simulate

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Basic Concepts

Supported Workflows

No matter which method is used, the resulting data is basically the same.
The first two methods load the data directly from the eMS database when the
software is started. The third method works off of a cached copy of the data.
Ways to start Process Simulate:

• Method 1: Open Process Simulate (connected) Directly

• Method 2: Open Process Simulate (connected) from Process Designer

• Method 3: Open Process Simulate Disconnected

Method 2 will not be discussed in this course. See the EMS127 Process
Designer Basics course for more information about Process Designer.

To avoid confusion, Method 3 will not be discussed until the last chapter
of this course.

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 Basic Concepts

Method 1: Starting and Exiting Process Simulate Directly

To start Process Simulate:

• If the Process Simulate icon is present on your desktop,

double-click it to launch the application. If not, start the Process Simulate
application from the Windows Start menu, as follows:
o Select Start -> Programs ->Tecnomatix -> Engineering Applications
-> Process Simulate .

• Login (using your eMS database login id)

• Click [OK].

• Select a project from the project list.

• Click [OK].

• In the Process Simulate Navigation Tree, browse to a RobcadStudy or

LineSimulationStudy.

• Right click the study and select Load in Standard Mode .

To exit Process Simulate:

• Select File -> Exit.

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Basic Concepts

Method 2: Starting and Exiting Process Simulate from Process Designer

To start Process Simulate:

• If the Process Designer icon is present on your desktop,

double-click it to launch the application. If not, start the Process Simulate
application from the Windows Start menu, as follows:
o Select Start -> Programs ->Tecnomatix -> Planning Applications ->
Process Designer .

• Login (using your eMS database login id)

• Click [OK].

• Select a project from the project list.

• Click [OK].

• In the Process Designer Navigation Tree, browse to a RobcadStudy or

LineSimulationStudy.

• Right click the study and select Open with Process Simulate.

To exit Process Simulate:

• In Process Simulate, select File -> Exit.

• In Process Designer, select File -> Exit.

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 Basic Concepts

Activity: Starting Process Simulate

Perform the related activity using the electronic activities.

Launch the activity window.

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Basic Concepts

Basic Options Setup

This Topic, describes some basic options setup.
More details will be provided about the data structure in a later topic.

It contains the following subtopics:

• Data Structure

• Activity: Setting and Viewing Basic Options

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 Basic Concepts

Data Structure

3D Data File Types (Dataset):

.CO or .COJT: An object prototype (part or resource) either constructed using
Process Simulate modeling commands, imported, or CAD-Linked from a
CAD system. Objects are stored as folders (containing .JT files) under the
system root.
System Root Folder:
The system root folder contains several folders of 3D Data Files and other
external files referenced by nodes within the Tecnomatix eMS database.
object prototypes are referenced from this area into a Resource Library or Part
Library within the Tecnomatix eMS database. Part prototypes are instanced
from these libraries into the product tree. Resource prototypes are instanced
from these libraries into stations in the resource tree. Studies are made from
these stations. Data from these studies is sent to Process Simulate.
eMS stands for e-Manufacturing Server

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Basic Concepts

Activity: Setting and Viewing Basic Options

Perform the related activity using the electronic activities.

.

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 Basic Concepts

Check In and Check Out

This topic describes everything you wanted to know about Check In and
Check Out.
Because Process Simulate allows multiple users to work simultaneously on
the same project, a check out procedure ensures that only one person at a
time may edit a node. Other personnel may view checked-out nodes but
cannot edit them until the person who checked them out checks them in.
It contains the following subtopics:
• Check In and Check Out Basics

• Checking Nodes In and Out

• Check In

• Check Out

• Cancel Checkout

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Basic Concepts

Check In and Check Out Basics

When an user starts Process Simulate, all nodes that the logged-in user
checks out pertain to that user and may be edited only by that user. Other
users may view these nodes but may not modify them in any way.
Similarly, nodes that the logged-in user creates are checked out to that user.
Other users may edit these nodes only after the user who checked them out
checks them in. A green check next to a node indicates that the currently
logged in user has checked out that node and can edit it; a red X next to a
node indicates that another user has checked out the node and the current
user can only view it. A node with neither a green check nor a red X is
available to any user to check it out as desired.

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 Basic Concepts

Checking Nodes In and Out

The Check Out , Check In and Cancel Check Out commands are
located in three places:
• The Edit menu on the top menu bar.

• The short-cut menu that appears after right-clicking a node.

• As buttons in the main Process Simulate toolbar.

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Basic Concepts

Check Out

The Check Out command locks specified nodes for editing only by the person
who checked them out. Selecting Check Out opens a check out window
that lists the nodes that the command checks out. This window contains
a Check Out With Hierarchy checkbox; if that button is not selected, the
window displays only the selected nodes. Selecting Check Out With Hierarchy
causes the window to list all of the checked-in nodes under the selected nodes.

A green check mark adjacent to a node symbol indicates that you have
checked out that node, and no one else can edit it.
If someone else has checked out a node, a red X next to the node symbol
indicates that you may neither edit it nor check it out: you have only viewing
privileges for that node. For nodes marked with a red X, Process Simulate
displays the node information that was current when the other user checked
out the node. If the user who checked out the node made changes after
checking it out, those changes are visible only to that user, until the user
subsequently checks in the node.
The Intended for extensive data change option checks out data with
the intention of performing extensive modifications to the checked-out
objects (for example, changing attributes of most of the objects using
Table View). If this option is not checked, check-out takes less time, but
performance may be slightly affected when modifying an object the
first time. Performance of the check out of mature data is improved if
this is not checked.

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 Basic Concepts

Check In

The Check In command unlocks nodes that you locked, and returns them
to the public workplace. Like Check Out , selecting Check In opens
a check-in window that lists the nodes that the command checks in. This
window contains all of the nodes that need to be checked in together with the
selected nodes. Selecting Check in With Hierarchy causes the window to list
all of the checked-out nodes under the selected nodes.

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Basic Concepts

Cancel Checkout

This is the main undo function.

The Cancel Check Out command unlocks the selected nodes and all nodes
related to them, and also cancels all changes that were effected to these
nodes while they were checked out. These nodes are thus returned to the
public workplace in their condition before they were checked out. Selecting
Cancel Check Out opens the Cancel Check Out window that lists the
nodes that the command cancels and checks in. Selecting Cancel Check Out
With Hierarchy causes the window to list all of the checked-out nodes under
the selected nodes.

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Get Check In and Check Out Status

In cases when a number of nodes are still checked out by other users, you can
run Get Objects Checked Out By Others to generate a list of those objects
and the users who checked them out. You can log the list to a file, and then
contact the users to request that they check in the objects.
Add this command to the toolbar or menus using Tools —> Customize.

Subsequently, you can run Get Checked In Objects to generate a list of

those objects, and check out all of them.
Add this command to the toolbar or menus using Tools —> Customize.

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Basic Concepts

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 Basic Concepts

Creating High-Level Resource and Operation Trees

The Resource and Product Trees will be associated to the operation tree.
It contains the following subtopics:
• Creating Object Basics

• Activity: Create the High-Level Operation Tree

• Activity: Create the High-Level Resource Tree

• Activity: Associate the Trees Together

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Basic Concepts

Creating Objects Basics

To create a new database object:

1. Right click the desired part object in a Navigation Tree and select New .

2. Check the desired object types and enter the desired Amount.

3. Enter a name for the object, or take the default.

Rules for object names in the New window:

1. It’s OK for multiple objects to have the same name.

2. Names can be up to 256 characters long and contain any enterable

character in any language.

3. The last name entered for an object type will be the default name for that
object type the next time it is created

4. Names can contain “wild cards” contained in square brackets. For

example of creating 3 objects with this name: station [1] would produce
objects with these names: station 1, station 2, and station 3.

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 Basic Concepts

Activity: Create the High-Level Operation Tree (1)

Perform the related activity using the electronic activities.

.

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Basic Concepts

Activity: Create the High-Level Resource Tree (2)

Perform the related activity using the electronic activities.

.

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 Basic Concepts

Activity: Associate the Trees Together

Perform the related activity using the electronic activities.

.

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Basic Concepts

Using the Navigation Tree

This topic describes how to use the Navigation Tree viewer. It is one of the
primary ways to view information directly on the database without having
to load the data.
It contains the following subtopics:
• Navigation Tree Basics

• Navigating with the Mouse

• Navigating with the Keyboard

• Right Click Expanding

• Right Click Collapsing

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 Basic Concepts

Navigation Tree Basics

Usage:
Information can be viewed by either expanding the tree or double-clicking on
the nodes in the tree.
Navigation Tree Toolbar:
The concept of Home, Back, Forward, and History on a web browser are
applied to browsing nodes in project.

• Home - Returns to the view where the project node is the root of the
tree.

• Forward - The same as double clicking on the selected node in the

Navigation Tree.

• Back - Returns to the previous view (i.e. the project root) then expands
and selects the node that was double clicked from this view.

• History - Jump to a view with a specific node as the root of the

Navigation Tree.

• Hide/Show columns - toggles the display of the variants column.

(Button not used in class)

Method 1: To open another Navigation Tree:

• Right click an object and select Navigation Tree . (Not always available).

Method 2: To open the Navigation Tree:

• From the View menu, select Open with —> Navigation Tree .

Method 3: To open the Navigation Tree:

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Basic Concepts

• From the toolbar, select Navigation Tree .

To close the Navigation Tree:

Click Close in the right-hand corner of the Navigation Tree window.

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 Basic Concepts

Navigating with the Mouse

• To select a node, pick it with the left mouse button.

• To select multiple, nonconsecutive nodes, press the [Ctrl] key and select
the various nodes.

• To select multiple, consecutive nodes, pick on the first node; then press
the [Shift] key and pick on the last node of the series.

• To expand a collapsed node, double-click on it (or press the + next to the

node).

• To collapse an expanded node, double-click on it (or press the - next to

the node).

• To scroll the tree vertically and horizontally, drag the elevator in the
vertical and horizontal scroll bars; or pick the arrows at either end of
the scroll bar.

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Basic Concepts

Navigating with the Keyboard

• To move the selection up and down the tree one node at a time, press the
corresponding up and down arrow keys. If multiple nodes are selected,
this procedure selects the node below the last selected node and deselects
the previously selected nodes. (Nodes are not moved with this operation;
only the selected node is changed).

• To expand a collapsed node, press the right-arrow key.

• To collapse an expanded node, press the left-arrow key.

• To expand all levels, press the [*] key on the keypad area of the keyboard
(i.e. not the [*] above the [8] key).

• To move the selection up and down the tree one window at a time, press
the [Page Up] and [Page Down] keys.

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Right Click Expanding

The Expand right click sub-menu displays X levels of sub-trees under a

selected node. It operates on a single node in the tree.
1. Select the node intended to be expanded.

2. Right click the node and select Expand, and select the level.

The Expand right click sub-menu, determines the number of levels of nodes
that the hierarchical tree displays. It functions for a single node; if more than
one node is selected, it operates on the selected node while right clicking.

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Basic Concepts

Right Click Collapsing

To quickly collapse nodes in the tree up to the level of the currently selected
node:
1. Select the node intended to be collapsed.

2. Right click the node and select Collapse Level.

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Examining Object Types

This topic describes the basic object types found in the eMS database (shown
in Process Simulate).
Other object types will be described later in this course.

It contains the following subtopics:

• Basic Object Types

• Activity: Examine the Object Types that are Available

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Basic Concepts

Basic Object Types

eMS (i.e. Process Designer, Web-Based BOP Manager, and Process Simulate)
accommodates a large variety of object types. An unique icon associated with
each object type identifies it in the Tree view containing the type. The table
below lists and briefly describes most of these object types, and shows the icon
that corresponds to each object type.
Icon Type Representation
Project An entire project.
Collection A container of object types including other collections.
Shortcut
A folder containing shortcuts to object types.
folder
Part A single part.
Compound An assembly comprising one or more parts or
part subassemblies.
Operation A single operation.
Compound
An operation comprising one or more sub operations.
operation
Resource A single resource.
Compound
A collection of one or more resources.
resource
Operation
The operations library.
library
Parts library The parts library.
Resource
The resources library.
library
Tx Process An IPA containing Tx Process Assemblies, Parts, and
Assembly Compound Parts.*

* Tx Process Assemblies are the product assemblies produced from each

station along the line. More on this later.
New objects can be created only from the objects that they are related
to. For example a compound part can be created only from a compound
part, a part library, a folder or a project. An operation can be created
only from a compound operation, process object, operation list and
operation library

Process Simulate supplies a variety of icons to depict standard

resource types (robots, fixtures, guns, etc); however, these icons can be
customized and new icon types can be added to the database.
We will explain how to add and edit objects (nodes) throughout the
training.

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Activity: Examine the Object Types that are Available

Perform the related activity using the electronic activities.

.

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Basic Concepts

The Concept of Prototype and Instance

This topic describes what a prototype and instance is and how you can see the
relationship between them.
It contains the following subtopics:
• Library Nodes (of Parts, Operations and Resources)

• Prototype / Instance Basics

• Seeing the Connection

• Viewing Object Properties

• Activity: Examine the Part Library

• Activity: Examine the Resource Library

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Library Nodes (of Parts, Operations and Resources)

Libraries are repositories of standard parts, of standard operations, and of

resources; they facilitate and standardize the planning process. The libraries
may be built from imported data, and they may be edited as desired from
within Process Designer or Process Simulate.
Libraries can only be opened with the Navigation Tree viewer (not with the
Product Tree viewer, Operation Tree viewer, or Resource Tree viewer). We
discuss this again later in class.

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Basic Concepts

Prototype / Instance Basics

The objects depicted on this page are for discussion only and are not
part of the data found in the training. Once we understand the concept
of the prototypes and instances described on this page, we will look at
our data (which is more complex).

For example: we have a product assembly that contains a metal plate and
two bolts. The Product Tree would look like this in Process Simulate:

The Part Library would look like this (assuming both bolts are the same type):

The library contains a list of unique parts called part prototypes. The product
tree describes the hierarchy, part position, and number of each part prototype
in the product assembly. The Plate in the library is linked to the plate in the
product tree. The Bolt in the library is linked to both bolts in the product tree.
So the parts in the product tree are called instances of the part prototype.
Whenever a change is made to the attributes of the part prototype, the
instances will also reflect that change.

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Seeing the Connection

There are two ways to see the connection. For example:

• Dragging and dropping a part from the Part Library onto the magnifying
glass of the Navigation Tree (with the Product Tree as its root) will
expand the product tree and highlight all the instances of this prototype.

• Dragging and dropping a part from the Product Tree onto the magnifying
glass of the Navigation Tree (with the product library as its root) will
expand the Part Library and highlight the part’s prototype.

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Basic Concepts

Viewing Object Properties

The Properties viewer offers a way to view the properties of a specific object
within Process Simulate. This window has several behaviors; depending
on how the content controls are set.
Methods To open Properties Viewer:

• From the View menu, select Open with -> Properties .

• Right click the node and select Properties .

Properties Viewer Content Controls:

• Synchronize Selection - Allows the selection of a specific viewer to
synchronize with. Either choose a viewer to synchronize to or disconnect
the synchronization.

• Unlock - Contents of the Properties viewer does change when different

objects are selected. If the Properties viewer has been synchronized to
another viewer, its contents will only change if an object in that viewer
is selected.

• Lock Displayed Information - Contents of the Properties viewer does

not change when different objects are selected.

To close the Properties Viewer:

Click Close in the right-hand corner of the window.

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Activity: Examine the Part Library

Perform the related activity using the electronic activities.

.

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Basic Concepts

Activity: Examine the Resource Library

Perform the related activity using the electronic activities.

.

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Creating a Study
In this Topic, we will create an empty study in the Navigation Tree to open
Process Simulate. For other Activities in class, we will use pre-existing
studies.
It contains the following subtopics:
• Introduction to Studies

• Activity: Setting the Working Folder

• Activity: Creating a New Study

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Basic Concepts

Introduction to Studies
There are two types of viewers in Process Simulate. One type access the data
in the database directly (i.e. the viewers under the View —> Open with menu
such as Navigation Tree, Properties, etc...). Changes made in one of these
viewers affects the database instantaneously.
The other type are the “loaded” viewers (i.e. the viewers under the View —>
Viewers menu such as Object Tree, Graphic Viewer, etc...). Once a study is
loaded, the data from that study is opened into all the “loaded” viewers all
at once. Changes made in these viewers are stored in the memory of the
user’s computer and will not affect the database until the user specifically
chooses to update the database.
Typically a study is the object that is loaded in order to use the “loaded”
viewers. Although creating studies in Process Designer is optional,
it is a requirement in order to work in Process Simulate. The study
contains references to a subset of data from in a project. (Usually just
one manufacturing area).

It doesn’t matter if RobcadStudy or LineSimulationStudy studies are

created.

Ways of loading studies:

Studies can be loaded in two different modes. Although both modes have a lot
of functionality in common, there are specific actions of Process Simulate that
can only be carried out in one mode or the other.

• File —> Load in Standard Mode

• File —>Load in Line Simulation Mode

This command is discussed in the WKP215S course

Study Mode use cases:

After loading a study in one mode, it can be easily switched to other mode to
complete specific actions. It takes less time to switch modes than to reload
the study in the other mode.

• File —>Standard Mode

o Add product data

o Create and validate path reachability

o Add new variants

o etc ...

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• File —>Line Simulation Mode

This command is discussed in the WKP215S course

o Validate controls logic

o Check for reachability and collision problems

o etc ...

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Basic Concepts

Activity: Setting the Working Folder

Perform the related activity using the electronic activities.

.

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Activity: Creating a New Study

Perform the related activity using the electronic activities.

.

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Basic Concepts

Process Simulate Introduction

It contains the following subtopics:
• Process Simulate Basics

• Process Simulate Commands

• Status and Title Bars

• Viewer Area

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Process Simulate Basics

Selected list of Process Simulate uses:

• The Process Simulate product is used to plan and validate manufacturing
processes.

• It is a hierarchical processing tool that links product data with

manufacturing resources and operations. This results in an integrated
framework for a complete production-engineering process.

• As a system for the top-down creation or bottom-up), modification and

navigation of process data, Process Simulate coordinates and simplifies
the task of process planning and validation.

• It integrates manufacturing process planning, analysis, validation, and

optimization.

• Process Simulate is an integral part of Siemens PLM Software Tecnomatix.

Process Simulate uses an object-oriented interface similar to other

Windows-type applications. This means that you must first select the
object(s) that you would like to work on, after which the options required
become available.

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Process Simulate Commands

The Process Simulate commands can be accessed from the following three
places:
• Menu bar: The menu bar is located along the top of the Process Simulate
window. It displays the version of Process Simulate, the name of the
module, the name of the cell, the full path name of the working project
directory, Pick Level and the menu buttons pertaining to the selected
module.

• Toolbars: The toolbars are located just below the menu bar. These contain
shortcuts for functions available on the menu bar.

• Right-click popup menus: Different popup menus are displayed by

right-clicking various places in the Process Simulate window.

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Status and Title Bars

• Title Bar: The title bar is located at the very top of the Process Simulate
window. It displays the version of Process Simulate and the name of the
study that is currently opened.

• Status Bar: The status bar is located at the very bottom of the Process
Simulate window. It displays the status of the last executed command and
the systems readiness to execute the next command.

To configure what is shown on the Status Bar, right click it and

select the desired options. For example: Check In/Out State,
Study Mode, Login User, Project Version, Variant Filter, or Pick
Coordinate.

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Viewer Area

The viewer area takes up most of the Process Simulate window. The next
topic is completely dedicated to it.

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Process Simulate Viewer Overview

It contains the following subtopics:
• Viewer Overview

• Operation Tree Viewer

• Object Tree Viewer

• Objects Tree Viewer Nodes

• Activity: Browsing the Process Simulate Scene

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Basic Concepts

Viewer Overview
All of these can be opened from the View -> Viewers menu:
1. Collision Viewer - Used to setup 3D collision checking for the loaded scene
and display the results (covered in this course)

2. eMS Library Browser — Another way to search for and find objects in
libraries covered in the EMS127 Process Designer Basics course).

3. Graphic Viewer – Used to view 3D objects in the scene (covered in this

course)

4. Logical Collections Tree – Used to display the In-Process Assembly tree

(covered in the EMS127 Process Designer Basics course)

5. Material Flow Viewer — This viewer is related to event-based simulation

and is not covered in this course (covered in the WKP215S Process
Simulate on eMS Intermediate Robotics (CEE) course).

6. MFG Viewer – Used to view and edit information for manufacturing

features (i.e. weld spots, PLPs, continuous MFGs, etc…) (covered in the
WKP115T Process Simulate on eMS Basic Robotic Simulation course)

7. Modules Viewer — This viewer is related to event-based simulation and

is not covered in this course (covered in the WKP215S Process Simulate
on eMS Intermediate Robotics (CEE) course).

8. Object Tree – Provides a structural view of product, plant, and other

non-process objects (covered in this course)

9. Operation Tree – Used to view the Process Structure and related

simulative operations (covered in this course

10. Path Editor – Used to view and edit the operations/simulation paths

11. Sequence Editor – Used to view and edit the Process Structure (initially
covered in this course)

12. Signal Viewer — This viewer is related to event-based simulation and is

not covered in this course (covered in the WKP215S Process Simulate on
eMS Intermediate Robotics (CEE) course).

13. Simulation Panel — This viewer is related to event-based simulation and

is not covered in this course (covered in the WKP215S Process Simulate
on eMS Intermediate Robotics (CEE) course).

14. Snapshot Editor – Used to view, edit, and use snapshots. (covered in
this course)

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All of these can be opened from the View -> Open with menu:
1. Navigation Tree — used to browse hierarchies of database objects.

2. Relations Viewer – Used to view database relationships between the

currently selected object and other objects in the scene. (covered in the
EMS127 Process Simulate Basics course)

3. Properties — lists the attributes of the selected database object (covered

in all courses).

These viewers are only available in Process Simulate on eMS (not in

Process Simulate on Teamcenter):
1. Navigation Tree (covered in all courses)

2. Modules Viewer (covered in the WKP215S Process Simulate

Intermediate Robotics (CEE) course)

3. Signal Viewer (covered in the WKP215S Process Simulate

Intermediate Robotics (CEE) course)

4. Simulation Panel (covered in the WKP215S Process Simulate

Intermediate Robotics (CEE) course)

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Basic Concepts

Operation Tree Viewer

The hierarchy of process, operations, activities, and simulative operations

required to produce the target product (i.e. Process A contains operation
B and operation C. This means that Process A includes operation B and
operation C.
A PERT or Gantt chart should be used to view the order (a.k.a. sequence)
of the operations. The operations plan is a logical structure; it starts with a
single, all-inclusive operation (e.g., Plant, Line, Zone, Station), and expands to
include specific operations. Each operation in the hierarchy points both to the
parts or subassemblies upon which the operation is performed as they flow in
and out of the operation, and also to the resources that the operation utilizes.
An operation is the central object in the database that connects
product-manufacturing resources together in an integrated process.
Process Simulate provides several views of the Operation Plan: tree view and
Gantt view (Sequence Editor). Tree view shows the hierarchy of individual
operations that constitute the Operation Plan. The tree view does not show or
imply dependencies between operations.
A hierarchy of operations may be created by adding operations to
compound operations. Adding can be done either by creating new
operation under the existing compound operation, or by dragging
existing operations to the compound operations.

To open the Operation Tree Viewer:

• From the View menu, select Viewers, and then Operations Tree (View ->
Viewers -> Operation Tree).

To close the Operation Tree Viewer:

• Click Close in the right-hand corner of the window.

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Object Tree Viewer

The Object Tree viewer displays a hierarchy of the elements of the currently
loaded study.
Displayed objects (except weld points, locations, and paths) can be blanked
or displayed from the Object Tree viewer via special display status squares
next to the element names.
Objects in the tree can be selected in order to work on them.
Elements are displayed in the Object Tree viewer regardless of whether they
are blanked or displayed in the Graphic Viewer (unless a filter has been
applied to the Object Tree viewer).
To open the Object Tree Viewer:
• From the View menu, select Viewers, and then Objects Tree.

To close the Object Tree Viewer:

• Click Close in the right-hand corner of the window.

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Basic Concepts

Object Tree Viewer Nodes

The Object Tree displays a listing of the current study and its contents. A
study is made up of objects, frames, and paths (simulative operations).
Clicking the + icon next to a node in the tree will expand it to display the
next level down. Clicking the - icon will hide everything in that node except
the tasks.
Main Types of Objects:
• Group

• Component

• Entity

• Engineering Data (More on this later)

The following is a partial list of elements that can be nodes at the first or
second level of the tree:
• Study

• Collection

• Part (object)

• Resource (object)

• Compound Part (Group of Parts)

• Compound Resource (Group of Resources)

• Note

• Section

• Dimension

• Label

• Frame

• (etc...) Several other objects are available depending on your eMS

customization.

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Activity: Browsing the Process Simulate Scene

Perform the related activity using the electronic activities.

.

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Basic Concepts

Window Layout Management

This topic contains the following topic:
• Docked and Floating Viewers

• On Demand Window Viewing

• Save/Restore Window Layouts

• Activity: Docking and Floating Windows

• Activity: Saving a Window Layout

• Activity: Using a Window Layout

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Window Layout Basics

It describes several techniques for managing the many viewer windows of

Tecnomatix. Typically these techniques are used in parallel.
• Opening and Closing Views – Viewers can be opened or closed at any
time, based on need.

• Docked or Floating Viewers – Viewers can be docked or floated at any

time, based on need.

• On Demand Window Viewing – All docked windows (tree, Gantt,

PERT, etc.) can be collapsed or expanded on demand, providing more
screen space for main tasks (i.e. Graphic View). The status of windows is
saved in the layout.

• Save/Restore Window Layouts – Tecnomatix window layouts can be

saved and reused. Saving a layout stores the following information to the
database and can be used to restore this information in a later session
of Tecnomatix:
o Which viewers are currently open

o Size and placement of the open viewers (If a viewer is not open, in a
later session, it will not be opened. However, when it is opened later it
will go to predefined position stored in the layout.)

o Can save public or private layouts for all open windows.

o Can switch between several layouts during one session.

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Basic Concepts

Docked and Floating Viewers

To undock (float) a viewer:

• There are several methods to do the first step:
o Method 1: Pick the desired tab in the viewer area. Then drag the
window using the tab’s title.

o Method 2: Double click the tab’s title.

o Method 3: Pick the desired tab in the viewer area. From the title area
of the viewer, click Window Position and select Floating.

o Method 4: Pick the desired tab in the viewer area. Right click the title
area of the viewer and select Floating.

To dock a floating viewer:

• Methods to Return to the Previously Docked Position:
o Method 1: Pick the desired viewer area and then double click its title
area

o Method 2: Pick the desired tab in the viewer area. Right click the title
area of the viewer and select Docking.

• Methods to Change the Docking Position:

o Pick the desired viewer (floating or docked) then begin dragging it
using the tab’s title.
The viewer can now be dropped into another tab group or used
to start a new tab group.

o Shared/Stacked Viewer Area Edge Method:

A four-way arrow indicator appears in the center of the docked
viewer you are dragging across.

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Drag the floating viewer to one of the arrows of the four-way arrow
indicator. It will dock the viewer along that edge of the viewer
you are dragging across.

Or drag the floating viewer across another docked viewer. The

four-way indicator is now applicable to this viewer.

o Whole Viewer Area Edge Method:

Single arrow indicators are shown along the middle of each edge of
the Process Simulate viewer area.

Drag the floating viewer to one of these indicators.

The viewer will dock along that edge and take up the entire edge.

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Basic Concepts

On Demand Window Viewing

A viewer such as the Navigation Tree can be shown “On Demand”

(unpinned ). This means that there is an icon along the left edge of the
Process Simulate window named Navigation Tree .
If you mouse over it, the window will be shown. The window will remain
displayed until you are either not mousing over the Navigation Tree icon or
window.
To disable this feature and keep the Navigation Tree displayed, click on the
tack in the title area of the viewer to pin it down.

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Save/Restore Window Layouts

Saving a Window Layout:

1. Open, position, and size all windows you want as part of this layout.

2. From the Process Simulate toolbar, click Layout Manager . The Layout
List window opens.

3. From the Layout List window, click New.

4. In the New Layout window, click Use Current for both options and click
[OK].

5. From the Layout List window, click the name and press the [F2] key to
change the name.

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Basic Concepts

The list of layouts on your computer may be different.

Using a Window Layout:

When a layout is applied, it will open the windows (including position),
toolbars, and menus from the saved layout.
1. From the Process Simulate toolbar, select the Layout Drop-down and
choose the desired layout.

The list of layouts on your computer may be different.

2. The layout is applied to all open and successively opened windows.

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Activity: Docking and Floating Windows

Perform the related activity using the electronic activities.

.

Process Simulate on eMS Basic Robotic Simulation Student Guide 1-79

Basic Concepts

Activity: Saving a Window Layout

Perform the related activity using the electronic activities.

.

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Activity: Using a Window Layout

Perform the related activity using the electronic activities.

.

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Basic Concepts

Summary
Subjects learned in this topic:
• The Navigation Tree viewer was used to build and view basic product,
operation, and resource trees.

• Window Management, study objects, and basic options was discussed.

• The concept of prototype and instances was discussed.

• The concepts of System Root, projects, libraries, and objects was be

introduced.

Instructor Note:
Summary instructor notes.

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Lesson

2 Process Simulate on eMS

Environment

Purpose
To describe the Process Simulate on eMS Environment.

Objectives
After you complete this chapter, you should be familiar with:
• The menu and toolbar options available in Process Simulate.

• Various right click popup menus available in Process Simulate.

• How to use the mouse to control objects displayed in the Graphic Viewer,
as well as changing the viewpoint and view center of a selected object.

• Customize window features such as adding new toolbars, adding and

removing items from existing toolbars, and modifying items in the menu
bar.

• How to select and blank objects using selection filters.

• How to select and blank objects using the Display By Type window.

• Discuss other functions that can be used in Process Simulate such as

resizing the Process Simulate window.

• How to perform measurements and entity selection

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Process Simulate on eMS Environment

• The chapter will finish by discussing how to access online help for a
command.

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 Process Simulate on eMS Environment

Working with Viewers

In this topic we will work more extensively with the Graphic Viewer. These
viewers require that data is Loaded (or Added) to them. Also, all loaded
viewers are synchronized.
It contains the following subtopics:
• Graphic Viewer

• Object Tree Basics

• Right Click Menus

• Working with Groups

• Automotive Activity: Getting an Overview of the Objects in the Object

Tree

• Airplane Activity: Getting an Overview of the Objects in the Object Tree

• Structure Activity: Getting an Overview of the Objects in the Object Tree

• Activity: Object Tree Basics and Groups

• Activity: Using the Right Click Popup Menu

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Process Simulate on eMS Environment

Graphic Viewer

The Graphic Viewer is the 3D window showing all the current displayed
elements. Pausing over an object in the Graphic Viewer will display a tool tip
containing the name of the object.

In general 3D data displayed in the Graphic Viewer, associated to

product and resources, can be in either .COJT (a.k.a. .JT) or .CO format.

To open the Graphic Viewer:

• From the View menu, select Viewers, and then Graphic Viewer.

To close the Graphic Viewer:

• Click Close in the right-hand corner of the second row of Process
Simulate window.

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Object Tree Basics

Clicking the + icon next to a node in the tree will expand it to display the
next level down. Clicking the - icon will hide everything in that node except
the tasks.
The following is a partial list of elements that can be nodes at the first or
second level of the resource or part tree:
• Part A single part.

• Compound Part An assembly comprising one or more parts or

subassemblies that will be stored back to the product tree associated to
the opened study.

• Resource A single resource. (Default icon)

• Compound Resource A group comprising one or more resources that will

be stored back to the resource tree associated to the opened study.

• Robot A robot resource.

• Container A container resource.

• Human A human resource.

• PrStation Compound resource that contains a list of resources for the

station.

• (etc...) Several other objects are available depending on your eMS

database customization.

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Right Click Menus

Right clicking a (non-kinematic) object in the Object Tree viewer:
Displays a popup menu that contains shortcut commands and a number of
options that are also found in other menus.

• Blank – Blank the selected objects.

• Display Only – Blank all unselected objects, leaving the selected

objects displayed.

• Zoom to Selection – Zoom to the selected objects (centering the

displayed geometry in the Graphic Viewer), and set the center of rotation
to the geometric center of the selected objects.

• Modify Color - Enables the user to select a new color for the currently
selected object(s).

Right clicking in the Object Tree viewer (not on a node):

The following popup menu is displayed:

• Display All – Display all entities in the Graphic Viewer.

• Toggle Display – Blank all displayed objects and display all blanked
objects.

• Options – Open the Options window (Same as Tools -> Options).

Right clicking in the Graphic Viewer (on a non-kinematic object):

The following popup menu is displayed:

• Blank – Blank the selected objects.

• Display Only – Blank all unselected objects, leaving the selected

objects displayed.

• Zoom to Selection – Zoom to the selected objects (centering their

displayed geometry in the Graphic Viewer), and set the center of rotation
the geometric center of the selected objects.

• Modify Color - Enables the user to select a new color for the currently
selected object(s).

Right clicking in the Graphic Viewer (not on an object):

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The following popup menu is displayed:

• Display All – Display all entities in the Graphic Viewer.

• Toggle Display – Blank all displayed objects and display all blanked
objects.

• View Point – Change the view orientation to a set of predefined view

points: Front, Top, Right, Left, Bottom, Back, Q1, Q2, Q3, and Q4.

• Zoom to Fit - Zoom to the displayed objects (centering their displayed

geometry in the Graphic Viewer).

• Options – Open the Options window (Same as Tools -> Options).

Undo / Redo:
• The Edit -> Undo and the Edit -> Redo commands can be used
for the last action performed on a selected object in the Graphic Viewer.
By selecting the command repeatedly, Undo/Redo can be performed for
successively earlier/later operations, as required.

• Undo/Redo capabilities are supported for placement commands,

display/hide commands, notes, labels, color manipulations, etc…

Users cannot undo actions after selecting File -> eMServer Selective
Update , or eMServer commands such as Check In , Check Out
, and Edit -> Delete .

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Working with Groups

Individual parts/resources or compound parts/compound resources can be

grouped to establish additional hierarchy levels in the tree. If a group is
selected and then shifted or rotated, the objects in the Graphic Viewer that
are in the group will also be moved. Each object can also be shifted or rotated
independently of the group.
This group will be stored only in the study and will not affect the original
resource tree structure after eMServer Selective Update is clicked.
A group can contain any combination of other groups, resources, compound
resources, parts, or compound parts.
Use groups in various Process Simulate tools to blank/display, create flow
operations, create collision pairs, export to Excel, etc ... Groups enable
assembly feasibility studies in early stages, even before process is defined.
• View —> Viewer —> Logical Collections Tree

• Tools —> Group —> Create Group

• Tools —> Group —> Flatten Hierarchy

• Tools —> Group —> Replace Compounds with Groups

• Tools —> Group —> Export Groups to Excel

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Automotive Activity: Getting an Overview of the Objects in the Object Tree

Perform the related activity using the electronic activities.

.

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Airplane Activity: Getting an Overview of the Objects in the Object Tree

Perform the related activity using the electronic activities.

.

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Structure Activity: Getting an Overview of the Objects in the Object Tree

Perform the related activity using the electronic activities.

.

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Activity: Object Tree Basics and Groups

Perform the related activity using the electronic activities.

.

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Activity: Using the Right Click Popup Menu

Perform the related activity using the electronic activities.

.

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Graphic Viewer Setup and Control

In this topic we will discuss mouse view control, view control menus, and
basic Graphic Viewer setup.
It contains the following subtopics:
• Graphic Viewer Control Overview

• Finding the View Control Menus

• Graphics Background Options

• Mouse Movement Options

• Rotation Methods

• View Control with the Mouse

• View Control with the Space Mice

• Basic Viewing Command Usage

• Activity: Graphic Viewer Control

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Graphic Viewer Control Overview

The Direct Model graphics engine is used by Tecnomatix applications such

as Process Simulate, Process Designer, and Plant Simulation. It is a set of
libraries capable of reading, writing and rendering .JT files.

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Finding the View Control Menus

Only selected buttons will be covered during this topic, while others
will be covered later in class when appropriate. At this point we will
look at these menus from the 10,000 foot level.

There are several ways to access the view control features:

• Using the Mouse.
Moving the mouse, in conjunction with pressing the various mouse
buttons allows you to pan, zoom, and rotate.

• Using a Space Mouse (3D manipulator).

• Using the View menu.

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• Using a right click popup menu.

o Right clicking in the Graphic Viewer (not on an object) displays the
following popup menu:

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• Using the toolbar to access view control functionality.

• Choose Tools -> Options and select the Graphic Viewer tab in the Options
window. (The Performance tab will be discussed in a later topic).

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Graphics Background Options

A different color can be selected for each of the four corners of the Graphic
Viewer. the background colors fade progressively toward the center of the
viewer.
• Choose Tools -> Options.

• From the Options window, select the Appearance tab.

• Select Background color.

• Choose Corners from the drop down that currently says Vertical or Solid.

• Choose a color for each corner.

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• Click Preview and close the Options window.

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Mouse Movement Options

There are two mouse movement modes: direct viewing and continuous
viewing:
• Direct viewing: Objects only move when you move your mouse. This is
the PC default configuration. This option is more similar to how other 3D
systems manipulate the Graphic Viewer .

• Continuous viewing: Objects continue to move at the initial speed of

mouse movement. This is the UNIX (i.e. Robcad) default configuration.

These options can be set by selecting Tools -> Options. From the Options
window, select the Graphic Viewer tab.

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Rotation Methods
There are two methods:
• The Process Simulate users option causes the rotation to be the same
as Robcad and Process Simulate.

• The Vis users option rotates in the opposite direction as the Process
Simulate users method. Also it allows rotating about any axis.

o To point the Z-axis up and rotate about it: (works the same for both
Process Simulate users and Vis users rotation methods)
Right click in the Graphic Viewer and select View Point.

Select any view except Bottom or Front. Notice the Z-axis of the
working frame is pointing up.

Pick in the Graphic Viewer.

Continuously click the left or right arrow keys.

o To point the Y-axis up and rotate about it: (works differently for
Process Simulate users or Vis users rotation methods)
Right click in the Graphic Viewer and select View Point .

In the View Point window, select the Top view. Notice the Y-axis of
the working frame is pointing up.

Pick in the Graphic Viewer.

Continuously click the left or right arrow keys.

o To point the X-axis up and rotate about it: (works differently for
Process Simulate users or Vis users rotation methods)
Right click in the Graphic Viewer and select View Point .

In the View Point window, the Left view.

Pick in the Graphic Viewer.

o Click the down arrow key 3 times. Notice the X-axis of the working
frame is pointing up.

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o Continuously click the left or right arrow keys.

You can also rotate by carefully moving the mouse horizontally in the
Graphic Viewer left and right while depressing the [Ctrl] and [Alt] keys.

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View Control with the Mouse

You can use the mouse to control how objects are displayed in the Graphic
Viewer .
The following instructions apply to a three-button mouse. If you do not
have a three button mouse, use one of the other described techniques or
see the online help for information on One-Button view control.

• Middle Button: Use the middle button for zooming in or out of the Graphic
Viewer. Moving the mouse left or right affects the direction of the zoom.
To zoom out, move the mouse left; to zoom in, move the mouse right. The
distance the mouse moves across the screen affects the magnitude of the
zoom, when continuous viewing is set. (Also see the Setting the Mouse
Movement Mode section which follows).

• Right Button: Use the right button for panning in the Graphic Viewer.
Moving the mouse in any direction affects the direction panned, when
continuous viewing is set.

• Middle and Right Buttons: Use these buttons together to rotate the
object’s viewpoint in the Graphic Viewer. Moving the mouse in any
direction changes the viewpoint. The distance the mouse moves across
the screen affects the amount of rotation, when continuous viewing is set.

• [Alt] – Left Mouse Button: To zoom to a specific area, hold down the [Alt]
key and draw a box around a small area of interest with the left mouse
button.

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View Control with the Space Mice

In order to use a Space mouse, the 3DConnexion driver must be installed and
started before starting the Tecnomatix software. Pictured below is the Space
Explorer. Other models can also be used:

This tool can be used to intuitively pan, zoom, and rotate the object.
Here are the default settings:

• Pan Right/Left - nudge left and right

• Pan Up/Down - push down or pull up

• Zoom - nudge toward or away from you

• Tilt - rotate front/back

• Spin - spin around

• Roll - rotate left/right

If you have one of these you will not need to learn how to pan, zoom, and
rotate with a mouse.
For more information on space mice see www.3dconnexion.com.

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Basic Viewing Command Usage

To change the viewpoint of the study:
1. Use one of the methods described in the previous section to access the
view control menus. For the purpose of this activity, we will use the first
option, and select View -> Graphic Viewer -> View Point .
By default, the View Point window closes after you select a view. If
you want to keep it on the screen, you need to "pin" it to the desktop.
This is done by clicking Pin in the View Point window.

2. In the View Point window, select Front.

3. Select a different view from the list to see how the viewpoint changes.
The Q1, Q2, Q3 and Q4 views are isometric views for quadrants 1,
2, 3 and 4, respectively.

To display all the entities in the Graphic Viewer:

• Right click in the Graphic Viewer and select Display All from the
displayed popup menu.

The Display All option is also available from the View menu.
The Toggle Display option alternates the display in the Graphic
Viewer between blanked and displayed objects.

While panning in the Graphic Viewer, it is possible that all the objects will
be panned off the screen. To return them to the screen, Right click in the
Graphic Viewer (not on an object), and select Zoom To Fit from the
displayed popup menu.

The Zoom To Fit option can also be accessed from the View menu,
as well as by clicking Zoom To Fit on the toolbar.

To zoom in to the Graphic Viewer:

• Press [Alt] while holding down the left mouse button, and draw a box
around an object(s) in the Graphic Viewer that you want to zoom in on. To
zoom back out, Right click in the Graphic Viewer (not on an object) and
select Zoom To Fit from the displayed popup menu.

To zoom in to an object in the Graphic Viewer:

Right click an object in the Graphic Viewer, and select Zoom To Selection
from the displayed popup menu.
To change the view center of an object:

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By default, Process Simulate rotates the graphic around the 0,0,0 (world
origin) coordinates of the study. If you want to rotate the study around a
different point, you must select it using the View -> Graphic Viewing -> View
Center command.
Before selecting an option, you need to first select the object in the
Graphic Viewer.

1. Using one of the methods described In this topic, rotate the study in any
direction and note the center of rotation.

2. Click an entity in the Graphic Viewer. Note where the white asterisk is
located.

3. Use one of the methods previously described to access the View Control
menu. For the purpose of this Activity, we will use the first option, and
select View -> Graphic Viewing -> View Center .

4. Rotate the study again. The view center is now set to where the white
asterisk was located.

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Activity: Graphic Viewer Control

Perform the related activity using the electronic activities.

.

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Customizing the User Configuration

There are three primary ways to do this:
• Process Simulate on eMS Tools -> Options – The contents of the Options
window are discussed throughout class as needed.

• Process Simulate on eMS Tools -> Customize - The Customize window

enables users to add new toolbars, as well as add and remove items from
existing toolbars. It also enables users to add, rename and delete items
in the menu bar.

• Tecnomatix Doctor Tools menu – This menu contains options that are set
before starting Process Simulate on eMS that affect its general behavior.

The Tecnomatix Doctor is not covered in this course, but it can be started
by selecting Start —> Programs —> Tecnomatix —> Administration
Tools —> Tecnomatix Doctor.

It contains the following subtopics:

• Accessing and Using the Customize Window

• Resetting and Saving Customizations

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Accessing and Using the Customize Window

There are two ways to access the Customize window:

• Select Tools -> Customize, or right click the toolbar and select Customize
from the displayed popup menu, as shown below:

To create a new toolbar:

1. Use one of the methods previously described to access the Customize
window. Here we will use the first option, and select Tools -> Customize.

2. Select the Toolbars tab, as shown below:

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3. Create a new toolbar by clicking New and entering MyToolbar in the

Toolbar name field of the displayed window. A new, empty toolbar window
appears on top (or underneath) of the Customize window.

4. Drag this new toolbar to the left of the customize window.

5. Select the Commands tab, as shown below:

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6. Select the buttons to be added to the new toolbar by dragging and

dropping them from the Commands area to the new toolbar.

7. When you are finished, click Close.

8. Drag and drop the new toolbar next to the other toolbars ofProcess
Simulate.

To change the menu behavior:

The behavior of the menus (top menus or right click menus) can be changed.
• Buttons can be added or removed from them.

• Menu animations can be switched between: None, Unfold, Slide, or Fade.

• Menu shadows can be toggled on or off.

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Resetting and Saving Customizations

To reset the toolbars to their original configurations:

This procedure is sometimes necessary after upgrading to a new version
of Process Simulate.

1. Use one of the methods previously described to access the Customize

window. For this Activity, we will use the first option, and select Tools ->
Customize.

2. Select the Toolbars tab, and remove all toolbar customizations by clicking
Reset.

3. Return to the default settings by clicking Default Setting.

To save customizations:
If you are not in the Standard layout, customization changes will be
saved only in the current layout, and only after the Update Layout
command (in the Layout Manager) is used.

Your customizations are saved automatically when you exit Process

Simulate. However, you can also manually store your settings by
clicking Save Customization on the Customize window.

Click Save Customization. The next time you restart Process Simulate, it
automatically loads the changes you made to the environment. You can revert
to the default menus, toolbars, and colors, as required.
For Windows XP: Your personal settings are stored in an XML file under
your Documents and Settings folder, according to the Tecnomatix
software and version that you are using. For example, for Process
Simulate v10.0:C:\Documents and Settings\Username\Local
Settings\Application Data\Tecnomatix\Process Simulate\10.0

For Windows 7: Your personal settings are stored in an XML file

under your Users folder, according to the Tecnomatix software
and version that you are using. For example, for Process Simulate
v10.0:C:\Users\Username\AppData\Local\Tecnomatix\Process
Simulate\10.0

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Entity Selection
It is important to remember that Process Simulate uses an object oriented
interface, meaning that you must first select what you want to manipulate,
and then choose the operation to be performed.
It contains the following subtopics:
• Selection Techniques

• Pick Level

• Toggling Detailed or United Representation

• Viewing and selecting PMI

• Activity: Selecting Objects in the Graphic Viewer

• Activity: Additional Methods of Multiple Entity Selection

• Activity: Using Toggle Display

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Selection Techniques

Selection Techniques:
• The [Shift] Key: — enables you to select more than one entity in a
consecutive list. Pick the first entity, then hold down the [Shift] key and
pick the last entity in the list. This key works in the Tree viewer only.
Selected entities are highlighted in green in the Graphic Viewer.

• The [Ctrl] Key: — enables you to select more than one entity. Hold
down the [Ctrl] key and pick each desired object. This key works in the
Tree viewer and the Graphic Viewer. Selected entities are highlighted in
green in the Graphic Viewer.

• Selection Window: — can be drawn in the Graphic Viewer by holding

down the left mouse button and dragging the mouse diagonally downward
or upward across several displayed entities.

• Pick Level: — Described in the next topic

• Mouse Wheel:
o Using Mouse Wheel to Go Up One Level in Tree:
1. Select an object in the Graphic Viewer.

2. Scroll up one click with the mouse wheel to go up one level of

hierarchy and highlight the parent of a selected node in the tree
and Graphic Viewer.

3. Continue all the way up the tree.

o Using Mouse Wheel to Go Down One Level in Tree:

1. Select an object in the Graphic Viewer.

2. Scroll down one click with the mouse wheel to go up one level of
hierarchy and highlight the parent of a selected node in the tree
and Graphic Viewer.

3. Continue all the way up the tree.

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Pick Level

Pick Level:
Choose the Pick Level from the pull-down list on the toolbar. The following
options are available”
• Component: The entire object is selected when any part of it is selected.

o Whole object – with all objects only the whole object can be selected.

o Engineering Data – each object can be selected independently (i.e. a

frame, cross section, note flag, dimension, etc…).

• Entity: When selecting objects shown in United Representation (the

default): Only the entity (that is, part of the whole object) is selected.
Here is what can be selected:

The results of the Entity Pick Level are dependant on whether

the selected object is shown in united representation or detailed
representation. Described in the next topic

o Whole Object – with non-kinematic objects only the whole object can
be selected.

o Kinematic Link – On Kinematic objects, each link can be selected

independently (i.e. on a human, the arm and hand are separate
kinematic links).

o Engineering Data – each object can be selected independently (i.e. a

frame, cross section, note flag, dimension, etc…).

o Object Frames – Frames within an object can be selected

independently.

A short cut key to toggle between the two Pick Levels is the [F12] key.

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Toggling Detailed or United Representation

In order to improve performance in Process Simulate, access to individual

entities (i.e. geometry within an object) is limited. This is referred to as the
United Representation of an object, which is the default loading behavior
for all objects.
However, in special situations, access to specific entities is required to perform
a task. This is referred to as the Detailed Representation of an object.
The Detailed Representation of an object is stored as part of the scene
data. .

We will have several topics dedicated to scene data later in this course.
For now, don’t worry about this type of data.

To temporarily access all entities of an object:

• Select the object

• Select Modeling —> Entity Level —> Load Entity Level .

• Pick and use the entities as desired.

• Select the object

• Select Modeling —> Entity Level —> Unload Entity Level .

To access specific entities of an object on a long term basis:

More is described on modeling objects later in the course.

• Start modeling the object

• Choose the desired entities and select Modeling —> Edit —> Set as
Preserved Objects .

• End modeling the object

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Viewing and selecting PMI

According to www.wikipedia.com: Product and manufacturing
information, also abbreviated PMI, conveys non-geometric attributes
in 3D computer-aided design (CAD) and Collaborative Product
Development systems necessary for manufacturing product components
or subsystems. PMI may include geometric dimensions and tolerances,
3D annotation (text) and dimensions, surface finish, and material
specifications. CAD application literature may also refer to PMI
synonymously with Geometric Dimensions and Tolerances (GD&T) or
Functional Tolerancing and Annotation (FT&A).
Industry standards for defining PMI include ASME Y14.41-2003 Digital
Product Data Definition Practices and ISO 1101:2004 Geometrical
Product Specifications (GPS) – Geometrical tolerancing – Tolerances
of form, orientation, location and run-out. In an effort to unify the
visualization of PMI across the different existing solutions, Adobe
Systems has released a version of the Myriad CAD font that allows to
display PMI from almost any CAD application. Similarly, Siemens PLM
Software offers downloadable font sets for multiple languages such as
for Asian character sets. The ISO STEP-NC standard also handles a
wide range of PMI information.
The PMI annotation is created on the 3D CAD model, associated to edges
and faces, and can be exported into neutral formats such as Siemens
JT. This information can then be used by a number of down-stream
processes. Although PMI can be used to generate annotation on a
traditional 2D drawing the data can be visualized within the 3D
model by other departments, either in the CAD/CAM system or in a
3D Product visualization tool, such as Siemens Teamcenter Lifecycle
Visualization, thus reducing the need for drawings. Some 3D model
formats enable computer-aided manufacturing software to access
PMI directly for CNC programming. The PMI also may be used by
tolerance analysis and Coordinate-measuring machine (CMM) software
applications if the modeling application permits.

By default PMI contained in a part or resource are not shown. However once
it is loaded using Modeling —> PMI —> Load PMI , it will be shown in the
Graphic Viewer and Object Tree. It is also possible to select, blank, display,
etc.. based on the specific type of PMI. More on that in another topic.

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Displaying and Hiding all PMI for a specific part or resource:

• Modeling —> PMI —> Load PMI — Show PMI in the Graphic Viewer
and Object Tree for the selected object.
There are many different types of PMI. By default all types of PMI
are loaded with the Load PMI command. However, which PMI
types that are loaded can be configured by selecting Tools —>
Options, selecting the General tab, and clicking PMI Types.

• Modeling —> PMI —> Unload PMI — Hides PMI in the Graphic Viewer
and Object Tree for the selected object.

• PMI Scaling toolbar — allows changing the font and font size (scaling)
for the selected PMI.

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Activity: Selecting Objects in the Graphic Viewer

Perform the related activity using the electronic activities.

.

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Activity: Additional Methods of Multiple Entity Selection

Perform the related activity using the electronic activities.

.

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Activity: Using Toggle Display

Perform the related activity using the electronic activities.

.

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Introduction to Selection Filters (Optional)

There are several filter tools in Process Simulate. The first one we will
discuss is the Selection toolbar.
It contains the following subtopics:
• Selection Filter Basics

• Activity: Blanking all the Frames (Optional)

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Selection Filter Basics

Edit -> Selection -> Select with Filter – Can be used to select objects
based on their type. The same functionality can also be found on the Selection
toolbar.
Selection Filters Available:
• Select All

• Selection Type All

• Select Type None

• Selection Type Part

• Selection Type Resources

• Selection Type Mfg

• Selection Type Weld Points

• Selection Type Path

• Selection Type Global Locations

• Selection Type Frames

• Selection Type Notes

• Selection Type Points

• Selection Type Lines/Curves

• Selection Type Solids/Surfaces

• Selection Type PMI

• Save Selection

• Retrieve Selection

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Activity: Blanking all the Frames using Selection Filters (Optional)

Perform the related activity using the electronic activities.

.

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Introduction to Display By Type

In this Topic we will discuss the Display By Type window.
It is similar to the Selection toolbar (described in the previous topic), but
the Display By Type window is easier to use and has more functionality.

It contains the following subtopics:

• Display by Type Basics

• Activity: Blanking all the Frames

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Display by Type Basics

To open it: select View -> Display By Type .

In the Display By Type window, select the object type(s) then select the
desired action from the toolbar.
Display by Type Actions:

• Show Selected Types

• Hide Selected Types

• Show Only Selected Types

• Show All

• Blank All

• Delete Selected Types

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Available Types for Display by Type

• Part Appearances

• Guns

• Robots

• Human Models

• MFGs

• Dimensions

• Points

• Paths

• Locations

• Lines/Curves

• Solids/Surfaces

• Frames

• Devices

• Notes

• Labels

• Sections

• PMI
There are currently 34 PMI type filters available in Process
Simulate.

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Activity: Blanking all the Frames using Display By Type

Perform the related activity using the electronic activities.

.

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Measurement and Units

In this topic we will look at the relationship between the measurement tools
and the current unit.
It contains the following subtopics:
• Units

• Linear Measurement

• Dimensions

• Activity: Relationship Between Measuring and Units

The measurement tools can be found in two places:

• On the Tools toolbar

• On the Tools -> Measurements menu:

o Minimal Distance

o PTP Distance

o Angle by 3 Points

o Create Measurement

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Units
In general, the results of any measurement command are shown in the
current units, as set in the Tools -> Options menu. The default unit types are
defined for data stored as numeric values in the database.

Configurable units of measure:

• Linear: mm, cm, m, inch, ft

• Angular: deg, rad

• Mass: kg, lbs

• Time: sec, min, 1/10 min, 1/100 min, 1/1000 min, hour, day, TMU, RU,
MODAPTS, SAM

There are several industry specific time units supported by default:

• 1 minute = 10 “1/10 min”

• 1 minute = 100 “1/100 min”

• 1 minute = 1000 “1/1000 min”

• 1 minute = 0.0167 hours

• 1 minute = 0.0007 days

• 1 minute = 1666.6667 TMU

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• 1 minute = 1000 RU

• 1 minute = 465.1163 MODAPS

• 1 minute = 333.3333 SAM

The modified units are supported in the Gantt, Units tab, measurements, etc…

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Linear Measurement

There are two linear measurement commands found in the Tools ->
Measurements menu:

• Minimal Distance – Measures the distance between two selected

objects from the closest point on the exterior of each object.

• PTP Distance – Measures the distance between two pick points. The
pick points do not have to be on an object.

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Dimensions

Using the dimension commands is kind of like using the measurement

commands. However, the measurement commands create a temporary
dimension in the Graphic Viewer; while dimensions add permanent
measurements in the Graphic Viewer. We will create some dimensions later
in this course. These commands are found in the Tools -> Measurements ->
Create Dimension menu .

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Activity: Relationship Between Measuring and Units

Perform the related activity using the electronic activities.

.

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Process Simulate on eMS Environment

Graphical Visualization and Performance

In this topic, we will discuss ways to modify graphical visualization of objects
and display performance.
It contains the following subtopics:
• Graphical Visualization

• Dynamic Clipping

• Performance Options

• Performance Recommendations

• Activity: Changing Visualization Performance

• Activity: Changing Graphical Visualization

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Graphical Visualization
Graphical Visualization of an object is affected by many factors such as:
• Object Specific Settings:
o Color

o Transparency

o Shading

o Textures

o Displayed Entities

• Global Settings
o Lighting

o Performance Settings

Toggling All Objects’ Visualization:

There are four display modes available:

• Shaded Mode

• Feature Lines Over Solid

• Feature Lines

• Wireframe Mode

Display modes temporarily change the visualization of all the displayed

geometry in the Graphic Viewer between shaded and feature line (also known
as Hidden Line Removal) mode. There are a few methods to do this:
• Press the [F10] key (With each click of this button the display mode is
changed in this order: Shaded, Feature Lines Over Solid, Feature Lines,
and then Wireframe Mode.

• Select the desired display mode directly either from the toolbar or View
menu. i.e.View -> Shaded Mode

Changing Specific Object Visualization:

Shaded / Wirefame / Transparent – Used to permanently change

the display of a single object (or group of objects). These commands are not
meant to affect all displayed objects. There are two methods to do this:

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• Right click the desired object or objects and select Object Viewing and
then the desired mode.

• Select View -> Object Viewing and then the desired mode such as
Transparent .

Object Textures
3D objects can be shown in the Graphic Viewer with object textures, if the
textures were added to the .JT file in a CAD or visualization system (i.e. NX
or Teamcenter Visualization).

Lighting
Select Tools -> Options. From the Options window, select the Graphics
Viewer tab.

When Second Light Source is selected, you can define the Intensity of a
second light source in the Graphic Viewer using the Intensity slide bar.

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Dynamic Clipping

The Dynamic Clipping and Dynamic Clipping Planning Settings

options enable you to view points of interest blocked from view by intervening
objects.
In Process Simulate, the view displayed in the Graphic Viewer is the view as
observed by an external viewer located at a fixed point (known as the camera
view point). Any object located between the camera and the point of interest
may partially or fully block the view. The Dynamic Clipping and Dynamic
Clipping Planning Settings options define an adjustable clipping plane
which hides all the objects between the camera and the clipping plane. The
clipping plane is always parallel to the camera’s viewing plane and objects
that straddle the clipping plane are clipped (truncated).
To configure dynamic clipping:

1. Use View —> Graphic Viewer —> View Center to set the desired point
of interest at the center of the Graphic Viewer display.

2. Select View —> Dynamic Clipping Planning Settings .

3. In Dynamic Clipping Plane Settings window, move the Clipping Plane

slider between Camera and View Center as desired.

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Performance Options
Select Tools -> Options. From the Options window, select the Performance
tab.
Direct Model Settings:

• Use background loading – loads newly loaded parts in the background

and redraws the model at a specified interval, instead of immediately
as each part is turned on.
o Specify in seconds how frequently to update the scene in the Graphic
Viewer

o A wireframe bounding box is displayed in the Graphic Viewer for parts

whose geometry is not yet loaded due to background loading.

• Fixed Frame Rate – controls the rate at which your model is redrawn in
the Graphic Viewer. Use the Fixed Frame Rate to increase or decrease
the number of frames per second (FPS) that are drawn while the view
is changing.

• Memory Limit – An amount including virtual and physical memory. If

you exceed the memory limit, further part loading halts and parts not
rendered in the last few frames are unloaded until memory usage falls
below the specified percentage.

• Rendering Mode – to render the Graphic Viewer contents. Results

will vary according to your hardware. Machines with a server-client
architecture should benefit greatly from using OpenGL Display Lists.
Other machines with sufficient memory also may achieve a significant
boost in performance. However, if your machine does not have enough
memory, rendering performance may not improve, and you should not
enable the option.

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OpenGL Buffer Objects allows for improved memory consumption.

With this option, loading a large amount of data into the display
demands less memory with the benefit of OpenGL rendering mode
acceleration.

When loading a study that has some object JTs with units that are
not in millimeters, in some cases the application may color an object
black when running a simulation or moving the object (or another
one) using the Placement Manipulator. Setting the Rendering Mode
to use OpenGL Buffer Objects prevents this from occurring.

Level of Details (LOD):

LOD gives anywhere from a 100% to 200% improvement in visualization and
simulation performance speed, and has been a part of Tecnomatix software
for years. All new objects (i.e. .CO or .COJT folders containing .JT 3D data)
have LOD information.
At the heart of this technology is the fact that an object that is far from the
viewer’s eye does not need to be displayed at the same level of detail as an
object that is close to the viewer.

Ways of Using LOD:

There are two ways to use LOD: It can affect the speed of both simulations
and graphic view manipulations.

• The LOD slider can be used to increase or decrease performance by

changing the precision of the displayed objects. In this way both
simulation and Graphic Viewer manipulation are affected.

• However, if Decrease Level of Detail while changing View Point is also

selected, then the lower display precision is only used during graphics
view manipulations.

• Cull parts with less than % – Specify the percentage of the Viewing
window that a part must cover before the part is drawn. Parts that are
less than or equal to this size are not drawn in the Graphic Viewer .

Using Culling Percentage can reduce image quality. However, you

can zoom-in to improve the quality of the image.

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Performance Recommendations
In order to increase performance of simulation, Object Notes, Sections,
and Measurements:
• Make sure you have installed the latest OpenGL graphics adapter
driver

• Have 2GB of RAM

• Use OpenGL Display Lists (consumes more memory) and Culling

Percentage

Here are the recommended performance settings by use case:

• For Assembly tasks with only a few objects in the Graphic Viewer where
image quality is not a high priority: Default settings

• For Assembly tasks with many objects in the Graphic Viewer where image
quality is not a high priority: Use Culling Percentage and OpenGL
Display Lists (may consume more memory)

• For very large studies: Default settings & use Culling Percentage and
Fixed Frame Rate.

• Studies for Documentation tasks, where image quality is required: Set the
Quality slider to High, & Memory limit to the client machine’s RAM Limit.

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Activity: Changing Visualization Performance

Perform the related activity using the electronic activities.

.

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Process Simulate on eMS Environment

Activity: Changing Graphical Visualization

Perform the related activity using the electronic activities.

.

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Additional Commands
This topic describes other misc. commands.
It contains the following subtopics:
• Window Manipulation

• Toolbar Manipulation

• Searching for Objects

• Expand to selection

• Collapse to Selection

• Display Tooltips

• Display or Hide the Floor

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Window Manipulation

To resize Process Simulate window:

• Click Maximize to maximize Process Simulate window so that is

covers the entire screen. To restore it, click Restore Down .

• If you wish to work with other tasks not associated with Process Simulate,
it is recommended that you send Process Simulate window to the Taskbar
at the bottom on the Windows desktop by clicking Minimize . When
you wish to return to Process Simulate, click Process Simulate on the
Taskbar, as shown below:

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Toolbar Manipulation

To Move Toolbars:
Move the toolbar by selecting and dragging using the two vertical gray bars
on the far-left edge of the toolbar.

After a toolbar is dragged from a toolbar area it will show the toolbar name
as the name of the toolbar window.

Toolbars want to “stick” to the top, bottom, left, or right edges of the viewer
area.

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Searching for Objects

1. Continue with the same data opened in the previous Activity.

2. Select an object in the Object Tree to search below, such as the top level
folder.

3. Select Edit -> Find.

4. Search for entities in the tree that contain the letters fr*

An asterisk [*] is used as a wild card in the find window. So

searching for fr* will locate all objects that begin with the letters fr.

5. Select Find Next to find the next occurrence.

6. Select Cancel when done.

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Expand to selection

To expand to selection:
When an object is selected in the Graphic Viewer, the Objects Tree viewer will
expand and highlight the selected object.
• This behavior can be toggled by selecting Tools -> Options

• In Options window, select the General tab.

• Select or unselect the check box named Expand tree to show Graphic
Viewer selection.

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Collapse to Selection

To collapse to selection:
• Pick an object in the Objects Tree viewer

• Right click on nothing

• Select Collapse -> Collapse Level.

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Display or Hide the Floor

To display or hide the floor:

Select View -> Display Floor to toggle the floor on and off.
• When the floor is displayed the menu option will look like this:

• When the floor is hidden the menu option will look like this:

Select View -> Adjust Floor . In the Adjust Floor window, click Auto Adjust
to adjust the floor width and length to match the extends of the farthest
3D objects.

To toggle between perspective and parallel viewing:

• Select View -> Graphic Viewer -> Perspective/Parallel , or click

Perspective/Parallel on the toolbar. This changes the view perspective
in the Graphic Viewer.

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Accessing Online Help and Release Notes

This topic describes how to use the help and release notes.
It contains the following subtopics:
• Quick Help Topics

• Online Help

• Release Notes

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Quick Help Topics

To display the software version number:

• Select About from the Help menu, as shown below:

To display information about a command:

• Place the cursor on a toolbar button for a few seconds. A yellow tool tip is
displayed containing a short description of the icon:

• Or place the cursor on a toolbar icon and look in the lower left corner of
the Process Simulate window. An one-line description of the button’s
purpose is displayed:

Errors that occur are also displayed on this line.

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Online Help

To access online command help by Index:

1. If the Help window is not already opened: From the Help menu, select
Contents.

2. In the Process Simulate Reference Manual window, click on the Index tab.

3. Double-click a topic from the list. The help topic is displayed in the
right-hand pane of the window.

4. When you are finished, close the window by clicking Close.

To access online command help using the Contents tab:

1. If the Help window is not already opened: From the Help menu, select
Contents.

2. Click the Contents tab of the Process Simulate Reference Manual window.

3. Double-click a purple book, such as File Menu. The File Menu sub-topics
are displayed.

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4. Select one of the sub-topics. The help topic is displayed in the right-hand
pane of the window.

5. When you are finished, close the window by clicking Close.

To access online command help by search:

1. If the Help window is not already opened: From the Help menu, select
Contents.

2. Click the Search tab of the Process Simulate Reference Manual window.

3. Enter a single word to search for in the help. Or for multiple keywords,
type the word OR between keywords.

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4. Select List Topics.

5. Double-click a topic from the list. The help topic is displayed in the
right-hand pane of the window.

6. When you are finished, close the window by clicking Close.

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Release Notes

From the Windows Start menu, select Start -> All Programs -> Tecnomatix ->
Tecnomatix Release Notes.
You must have Adobe Acrobat Reader installed to read the release notes.

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Summary
Subjects learned in this topic:
• The menu and toolbar options available in Process Simulate were
discussed.

• Various right click popup menus available in Process Simulate.

• How to use the mouse to control objects displayed in the Graphic Viewer,
as well as changing the viewpoint and view center of a selected object
was discussed.

• Customize window features such as adding new toolbars, adding and

removing items from existing toolbars, and modifying items in the menu
bar.

• How to select and blank objects using the Display By Type window.

• Discuss other functions that can be used in Process Simulate such as

resizing the Process Simulate window.

• How to perform measurements and entity selection

• Discuss other functions that can be used in Process Simulate such as

resizing the Process Simulate window.

• The chapter finished by discussing how to access online help for a

command.

Instructor Note:
Summary instructor notes.

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Lesson

3 Placement Commands

Purpose
To discuss placement tools provided by Process Simulate.

Objectives
After you complete this chapter, you should be familiar with:
• Several placement commands will be used to properly position objects
within studies.

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Placement Commands

Introduction to Placement
Placement commands can be used to change the position and orientation
of product, resources, frames, etc...
In the next few topics, the various tools required to position instances are
discussed.
It contains the following subtopics:
• The Placement Tools

The basic placement methodology is as follows

• Select the desired object (or several objects using the [Ctrl] key).

• Use the placement commands to move the objects into the desired position.

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The Placement Tools

In this topic, we will cover the three primary placement techniques available
in detail. A topic will be dedicated to each. At this point we will only give
the names of the commands:
• Fast Placement (there is no window) enables placing several objects
quickly by dragging them around the graphics window.

• The Placement Manipulator window enables on-screen shifting and

rotating of objects on their X-, Y-, and Z-axes.

• The Relocate window enables placing an object so that it maintains its

original orientation, place an object so that it takes on the target frame
orientation, or place an object relative to two different frames.

• Restore Design Relative Position – returns the object to its position and
orientation stored in the database (i.e. the position before placement
was performed; as long as you have not updated the database with your
changes).

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Placement Commands

Introduction to Fast Placement and Restore Design Relative Position

In this topic, we will cover the Fast Placement command and the Restore
Design Relative Position command.
It contains the following subtopics:
• Fast Placement Usage

• Activity: Using Fast Placement

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 Placement Commands

Fast Placement Usage

Fast Placement can be used on multi selections. Using fast

placement for several objects draws a bounding box which contains all
the selected objects.

After clicking Fast Placement , the left mouse button’s function is

changed to fast placement mode. To get out of this mode, either:

• Click Fast Placement. again.

• Click Select .

• Press the [ESC] key.

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Placement Commands

Activity: Using Fast Placement

Perform the related activity using the electronic activities.

.

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 Placement Commands

Changing Pick Behavior and Creating Frames

This topic describes how to change pick intent, change pick level, and create
reference frames.
It contains the following subtopics:
• Setting Pick Intent

• Setting Pick Level

• Basic Techniques for Creating Frames

• Advanced Techniques for Creating Frames

• Activity: Creating a Frame

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Placement Commands

Setting Pick Intent

Choose the Pick Intent from the pull-down list on the toolbar. The following
options are available:

• Snap: The location selected will be either:

o The closest mid point of an edge – pick on a surface near the middle
of the edge.

o An end point of an edge – pick on a surface near the corner of the edge.

o The center of a face – pick on the middle of an edge bounding the

desired surface.

• Self-origin: This is the only Pick Intent that depends on the setting of the
Pick Level. If the Pick Level is set to Component, then the self-origin of
the object is always selected, no matter where the object is picked. If the
Pick Level is set to Entity, then the self-origin of the currently picked
entity is selected.

• On Edge: The location selected will be the closest point along the closest
edge.

• Where Picked: The location selected will be the point picked.

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 Placement Commands

Setting Pick Level Refresher

Pick Level was described earlier in this course. Recall that it can be set
to either Component or Entity either directly or using the [F12] key

The Pick Intent and Pick Level should generally be set to their default
values of Snap and Component. Unless otherwise specified, this
Student Guide assumes that they are set this way.

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Placement Commands

Basic Techniques for Creating Frames

To create a Frame:

1. Select Modeling -> Create Frame .

2. Choose a frame creation technique, such as Frame by 6 values .

3. Define a location for the frame.

Techniques to create frames or define custom reference frames:

Techniques to create frames or define custom reference frames:
• Frame by 6 values

• Frame by circle center

• Frame by 3 points

• Frame between 2 points

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Advanced Techniques for Creating Frames

• Define reference frame button:

Frame by circle center :

Frame by 3 points :

Frame between 2 points :

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Placement Commands

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Activity: Creating a Frame

Perform the related activity using the electronic activities.

.

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Placement Commands

Introduction to Placement Manipulator

In this topic, we will cover the Placement Manipulator command and
other commands that relate to it. The Placement Manipulator command
will be described in detail later In this topic. We will start by explaining
the “other” commands.
It contains the following subtopics:
• Reference Frame Definitions

• Placement Manipulator Basic Options

• Placement Manipulator Advanced Options

• Activity: Shifting and Rotating Instances On-screen

• Activity: Relationship Between Placement Manipulator Measuring and

Units

• Activity: Incremental Shifting of Objects from a Reference Frame

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Reference Frame Definitions

We will now learn how to use the placement commands to move instances to
their proper positions. The key to understanding and effectively working in
Process Simulate lies in thoroughly understanding the following definitions.
Understanding these definitions will allow you to grasp the concept behind
the placement commands.
• Point/Position — A location defined by X, Y and Z values relative to a
reference frame. Position does not possess orientation. For example: (X,
Y, Z) is a point/position.

• Frame — A location having both position and orientation, that is, an axis
system. The origin point of a frame is a position. For example: (X, Y, Z,
Rx, Ry, Rz) is a frame.

• World Frame — The permanent origin of the graphics space. The default
position of every object is relative to this. It does not have a graphical
representation.

• Working Frame — Sits at the World Frame by default. It can be

temporarily moved to any position or orientation. It is the reference frame
having red (X), green (Y), and yellow (Z) axes.

o Select Modeling -> Set Working Frame to move it.

The small reference frame in the lower left corner of the Graphic
Viewer, with the same coloring as the Working Frame, is nothing
except a visual of the Working Frame orientation. It is useful in
cases when real Working Frame is not currently visible.

• Self-Origin — An unique frame assigned to each prototype. Its position

and orientation is assigned to that of the World Frame when modeling
the prototype (i.e. the object’s origin frame). This is the local origin of a
prototype or instance, not the center of gravity.

• Geometric Center — It is the default reference frame for many commands

in Process Simulate including the placement commands.

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Placement Commands

Placement Manipulator Basic Options

The Placement Manipulator consists of several parts:
Translation control buttons area:

• Set the step size.

• Relative movement: After selecting an axis, you can translate in the

negative or positive direction by the defined step size .

• Absolute movement: Enter the distance for the selected axis and press
[Enter].

Rotation control buttons area:

• Works like the translation, except for rotation.

Frame of reference selection area:

• Can select one of the standard reference frames from the drop down, or
pick anything from the Graphic Viewer.

The Manipulator Frame:

Even though the actual position and orientation of the Manipulator

Frame is set by the Frame of Reference box, it always resides at the
geometric center of the object.

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• Grab a colored axis and drag to constrain the linear movement along
that axis

• Grab a colored axis and drag to constrain the rotational movement along
that axis

• Grab a white square and drag to constrain the planar movement along
that plane.

Reset position and close command area:

• Click Reset to undo all positional and rotational changes to the object
since the window was opened.
To undo all positional and rotational changes since the object was
last saved to the database (i.e. via a database update), click Reset
Design Relative Location .

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Placement Commands

Placement Manipulator Advanced Options

The Placement Manipulator consists of several parts:

Frame of reference selection area:
• Construct or modify the position and orientation of a temporary reference
frame using one of the frame creation techniques to the right of the Frame
of Reference box.

• Pick in the Frame of Reference box and pick anywhere in the Graphic
Viewer or the Object Tree.

Additional options area:

For additional options, click Expand Dialog

• Select the desired frame of reference to view its value, or type in the
desired coordinates here.

• Snap by step size works in conjunction with Step Size and dragging the

Manipulator Frame.

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Activity: Shifting and Rotating Instances On-screen

Perform the related activity using the electronic activities.

.

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Placement Commands

Activity: Relationship Between Placement Manipulator Measuring and Units

Perform the related activity using the electronic activities.

.

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Activity: Incremental Shifting of Objects from a Reference Frame

Perform the related activity using the electronic activities.

.

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Placement Commands

Introduction to Relocate
In this topic, we will cover the Relocate command and other related
commands.
It contains the following subtopics:
• Relocate Command Overview

• Basic Relocate Command Usage

• Advanced Relocate Command Usage

• Activity: Relocating an Object Relative to Two New Frames

• Activity: Relocating an Object Relative to Two Existing Frames

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 Placement Commands

Relocate Command Overview

The Relocate command can be used to place and move objects. To access
the Relocate command, you first need to select an object and then click
Relocate on the toolbar. The Relocate window is displayed:

You can use the Relocate window to do many things:

• Relocate an object relative to two frames.

• Relocate an object along one or two axes only.

• Relocate an object so that it maintains its original orientation.

• Relocate an object so that it takes on the target frame orientation.

• Create a temporary or permanent frame to display the From frame or To

Frame.

• Choose to either move the object or copy it (create a new instance at the
destination).

Many of these possibilities are discussed in detail in the following topics.

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Placement Commands

Basic Relocate Command Usage

Relocating an Object Relative to Two Frames:
This is a relative positioning command. It moves the selected elements along
a vector defined by two frames. The default is to use the self-origin of the
object being relocated as the From frame .
Relocating an Object Along One or Two Axes Only:
If the Translate only on checkbox is selected and a single axis button (X, Y or
Z) is clicked, movement will be restricted to that axis only. The distance will
be limited to the length of the vector along that axis, as shown below:

Relocating an Object So That It Maintains Its Original Orientation:

If the Maintain orientation checkbox is selected, the object is moved the
linear distance from the From frame to the To frame without changing its
orientation, as shown in the diagram below:

Relocating an Object So That It Takes on the Target Frame

Orientation
Self-origin is the default option for the From frame. So if you only select
the To Frame, the object will be moved the linear distance from the From
frame to the To Frame, and then be rotated to match the difference between
the two frames.
In other words, if the default From frame is the self-origin of the object, the
object will be moved and rotated so that the self-origin of the object will be
superimposed on the target frame.

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Placement Commands

Advanced Relocate Command Usage

User Defined Frame and To Frames

• Construct or modify the position and orientation of a temporary reference
frame using one of the frame creation techniques to the right of the From
frame and To frame boxes.

• Pick in the From frame and To frame boxes and pick anywhere in the
Graphic Viewer or the Object Tree.

Misc.
• The Placement Manipulator and Relocate commands can be open
simultaneously for the same object. Many parts of Process Simulate are
designed to work with these two windows opened at the same time.

Querying the Position and Orientation of a Frame

• Select either the From frame or To Frame fields in the Relocate window
and pick on a frame.

Click Frame to the right of either the From frame or To Frame fields in the
Relocate window. This is a printout of the current position and orientation
of the selected frame.

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Activity: Relocating an Object Relative to Two New Frames

Perform the related activity using the electronic activities.

.

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Placement Commands

Activity: Relocating an Object Relative to Two Existing Frames

Perform the related activity using the electronic activities.

.

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 Placement Commands

Summary
Subjects learned in this topic:
• Several placement commands were used to properly position objects
within studies.

Instructor Note:
Summary instructor notes.

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Lesson

4 Quick Introduction to Kinematics

Purpose
To discuss kinematic basics in Process Simulate. We will cover kinematics in
much more detail later in this course.

Objectives
After you complete this chapter, you should be familiar with:
• How to use kinematics in Process Simulate.

• How to add poses to an object instance and create device operations.

• Get some background on inverse kinematics.

• How to use a couple of techniques to move a robot.

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Quick Introduction to Kinematics

Fundamentals of Kinematics
This topic provides a basic background on kinematics.
According to wikipedia.org: Kinematics (from Greek kinn, kinein, to
move) is the branch of classical mechanics that describes the motion of
objects without consideration of the causes leading to the motion

It contains the following subtopics:

• Kinematics Basics

• General Kinematics Usage Commands (part 1)

• Activity: Jogging the Joints of a Simple object

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 Quick Introduction to Kinematics

Kinematics Basics
The following is a list of definitions that are important to remember when
working with kinematics:
You must be in Process Simulate modeling mode to define kinematics.

Here are some basic definitions:

• Link – (also known as a rigid body) a group of entities within an object
that remain fixed, relative to one another. In this way it is the basic
non-moving segment of a kinematic chain. Default names begin with
these letters: LNK (i.e. LNK1, LNK2, LNK3)

• Joint – the basic moving segment of a kinematic chain. A joint consists

of 2 links and an axis. It defines the relative motion between these two
links relative to the axis. Default names begin with the letter J (i.e. J1,
J2, J3). There are 2 types of joints.
o Revolute joint - rotates around axis
According to wikipedia.org: Rotational, or angular, kinematics is
the description of the rotation of an object

The positive direction of rotation around an axis is defined using

the right hand rule. The right hand rule is this: Make a fist and
point your thumb straight up. Place your fist at the first point
and align your fist so that your thumb points straight toward the
second point. Now your fingers show the direction of rotation
around the axis.

o Prismatic joint - linear movement along axis

According to wikipedia.org: Linear, or translational, kinematics
is the description of the motion in space of a point along a line.

• A kinematic tree has an order established by the relationship of the joints

and links. The parent link precedes a child link in the sequence order.
When the parent link moves the child link will follow. The parent takes
the child with it.
o In a typical kinematic tree, the number of links is equal to 1 more
than the number of joints. For example: if there are 6 joints, there
will be 7 links.

o The kinematic chain is the simplest example of a kinematic tree. It is

an open loop, string linked mechanism. All the links, except the first,
have one parent. Also all the links, except the last, have one child.

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Quick Introduction to Kinematics

o There is no limit to the length of a kinematic chain. Here is an

example of a kinematic chain (a simple kinematic tree)
Kinematic Tree:

The limit of six degrees of freedom only applies when defining

a robot. This is because robots require the creation of ONE
inverse solution.

More is described on defining kinematics later in this course.

Also, we will only briefly introduce the concepts of creating simulative

operations for kinematic devices (i.e. device operations and robotic
operations) here. These topics will be covered more thoroughly later in
the WKP115T Process Simulate on Teamcenter Robotics Basics course .

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 Quick Introduction to Kinematics

General Kinematics Usage Commands (part 1)

The following commands are located on the Kinematics menu and will be
covered in this topic:

• Joint Jog - Drag the joints on the selected kinematic object one at
a time.

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Quick Introduction to Kinematics

Activity: Jogging the Joints of a Simple object

Perform the related activity using the electronic activities.

.

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 Quick Introduction to Kinematics

Creating Device Operations

In order to define a pose (each pose contains a specific value for each joint) on
the object instance, you need start with a prototype that contains kinematics.
Use Joint Jog and Pose Editor to jog the mechanism joints to a new
pose, mark the pose, and then jump to the new pose.
It contains the following subtopics:
• General Kinematics Usage Commands (part 2)

• Activity: Defining Kinematic Poses

• Activity: Creating a Simulative Operation from Poses

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Quick Introduction to Kinematics

General Kinematics Usage Commands (part 2)

The following kinematic related commands will be discussed in this topic:

• Kinematics —> Home — Jump all joints on the selected kinematic

object to the HOME pose, where (typically) all joints have a value of zero.

• Kinematics —> Pose Editor — Create, edit, and apply poses for the
selected kinematic object.

• Operation —>New Operation —> Create Device Operation — Used to

create an simulative operation to move the target device from one pose
to another pose.
This option uses direct kinematics. We will discuss direct and
inverse kinematics in the next topic.

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Activity: Defining Kinematic Poses

Perform the related activity using the electronic activities.

.

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Quick Introduction to Kinematics

Activity: Creating a Simulative Operation from Poses

Perform the related activity using the electronic activities.

.

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 Quick Introduction to Kinematics

Inverse Kinematics Review

This topic provides a background of inverse kinematics.
A Process Simulate “robot” is any kinematic device that has the ability
to perform inverse kinematics. This can include robots, lift assists,
CMMs, cranes, AGVs, forklifts, etc...

It contains the following subtopics:

• Principles of Inverse Kinematics

• Relocate Command

• Direct Kinematics

• Inverse Kinematics

• Level of Kinematic Inverse

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Principles of Inverse Kinematics

Definitions
• Device - An object with kinematics able to move to a pose.

• Robot – A device with a TCPF at the end of the kinematic chain able
to move to a pose or to a location. It could be a robot, lift assist, CMM,
forklift, etc ...

• TOOLFRAME — A frame used as the default location to mount tools to

the end of the robot’s kinematic tree.

• TCPF – Tool Center Point Frame. Initially positioned at the end of the
kinematic chain. It will be moved to a predetermined position and
orientation on a tool mounted to the end of the robot’s kinematic tree.

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Relocate Command

Inverse kinematics works kind of like the Relocate command (for

placement).
Relocate with source orientation:
Putting an object from the source frame to the target frame will:
• Move the object from the source frame to the target frame

• Orientation of the object is not affected (orientation of the source frame

is maintained)

Relocate with target orientation:

Putting an object from the source frame to the target frame will:
• Move the object from the source frame to the target frame.

• Orientation of the object is changed to the target frame

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Quick Introduction to Kinematics

Direct Kinematics

• Easy to do because simulation engine already knows the joint values

• Direct kinematics can be used for any kinematic device such as guns,
clamps, robots, etc...

How direct kinematics work:

1. You give the simulation engine a state/pose. The state/pose contains the
exact values for each joint of the mechanism.

2. The simulation engine moves the mechanism from the current position to
the destination pose

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Inverse Kinematics

• Takes more effort, because the destination pose must be calculated on the
fly. However, this gives more flexibility to the user.

• Only available for robots, lift assists, CMMs, cranes, AGVs, forklifts, etc...

How inverse kinematics work:

1. You give the simulation engine a location. The location contains the target
position and orientation of the TCPF of the robot.

2. Internally, the simulation engine tries to put the TCPF of the robot onto
the location

3. Once the simulation engine puts the TCPF on the location, it then looks
at the joint values required to reach this location

4. The simulation engine moves the mechanism from the current pose to the
calculated pose which places the TCPF of the robot on the target location.

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Quick Introduction to Kinematics

Level of Kinematic Inverse

The goal is to put, with target orientation, the TCPF of the robot onto the
target location (both the position and orientation of the target location are
used). This is referred to as a Full Inverse.
Sometimes it is not possible for the robot to perfectly place its TCPF onto a
location. However, it may be able to put with source orientation onto the
location (only the position of the target location is used). This is referred to
as a Partial Inverse. A partial inverse can be used to get a full inverse using
special tools in Process Simulate.
In some cases, the robot may not be able to reach the location’s position or
orientation. This is referred to as No Inverse. There are some tools in Process
Simulate to fix this situation also.

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 Quick Introduction to Kinematics

Using Inverse Kinematics

In this topic, we introduce a robot model , and use the several kinematic
related tools related to robots.
It contains the following subtopics:
• Kinematics Usage Basics

• Activity: Examining the Kinematic Tree of a Robot

• Activity: Making the Robot Move

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Quick Introduction to Kinematics

Kinematics Usage Basics

• Joint Jog - Drag the joints one at a time (Direct kinematics)

• Robot Jog - drag the TCPF of the robot while leave the base fixed,
thereby moving all the joints of the robot at once (Inverse Kinematics)

• Robot Jog with Locked TCPF - drag the base of the robot while
leaving the TCPF of the robot fixed, thereby moving all the joints of the
robot at once (Inverse Kinematics)

• Operation —>New Operation —> Create Weld Operation — Used

to create an simulative operation to move the target device alone a
path. Contrary to the name of the command, it can be used to create a
simulative operation for any inverse kinematic device including robots,
lift assists, CMMs, cranes, AGVs, forklifts, etc...
This option uses direct kinematics. We will discuss direct and
inverse kinematics in the next topic.

In this simple topic, we will only be moving the robot without a tool
mounted to the end of the robot arm. In this case the TCPF is at the
TOOLFRAME of the robot. When the Mount command is used to place
a valid tool at the end of the robot, the TCPF of the robot jumps to
the TCP frame of the mounted tool. This affects the locations that are
marked and used later in this Activity.

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Activity: Examining the Kinematic Tree of a Robot

Perform the related activity using the electronic activities.

.

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Quick Introduction to Kinematics

Activity: Making the Robot Move

Perform the related activity using the electronic activities.

.

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 Quick Introduction to Kinematics

Summary
Subjects learned in this topic:
• How to use kinematics in Process Simulate.

• How to add poses to an object instance and create device operations.

• Got some background on inverse kinematics.

• How to use a couple of techniques to move a robot.

Instructor Note:
Summary instructor notes.

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Lesson

5 Process Simulate Analysis Tools

and Study Data

Purpose
To discuss how to use the special static and dynamic collision detection tools
available in Process Simulate, and explains how to define a section plane and
use it to cut sections.

Objectives
After you complete this chapter, you should be familiar with:
• The different types of engineering data created in Process Simulate and
stored in the database.

• How to work with the Snapshot Editor.

• Several ways how to create markups

• How to create notes and more.

• How to export pictures of the scene.

• The Collision Viewer and how to setup a collision set.

• How to setup collision options to fine tune the collision reporting.

• Several factors that affect collision detection results.

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Process Simulate Analysis Tools and Study Data

• How dynamic sections of objects can be cut along the YX-, YZ-, and
ZX-planes of the working frame.

• How to do more with dynamic sections.

• How to create an .AVI movie file of all subsequent operations effected in

the Graphic Viewer using Process Simulate’s AVI Recorder commands.

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Save Scenario
This topic describes what are the different types of Scenario Data created in
Process Simulate and stored in eMS.
It contains the following subtopics:
• Scenario Data Storage in the Database

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Process Simulate Analysis Tools and Study Data

Scenario Data Storage in the Database

To save Scenario Data to the database:
No matter what option is checked, Scenario Data is always saved.

The File —> eMServer Selective Update command saves changes to the
Operation and Resource trees as well as Scenario Data.
Examples of Scenario Data found in the Object Tree include:
• Notes – Text in the Graphic Viewer with a leader line.

• Sections – 2D plane used to cut cross-sections displayed in section

viewers.

• Dimensions – Dimensions in the Graphic Viewer with a leader line.

• Labels – Text in the Graphic Viewer without a leader line associated

to a specific instance.

• Frames – a.k.a. reference frames or coordinate systems.

• Assigned Prototypes – Not used in class

• Appearances – Ability to locate the same instance of a part in multiple

locations.

• Motion Volumes — an optional solid created by the moving objects

of a simulation

• Triggers – Used with robotic painting processes

Examples of Scenario Data found elsewhere:

• Snapshots – shown in the Snapshot Editor, store a snapshot of the state
of objects in the Graphic Viewer (i.e. pan/zoom/rotate, blank/display,
current poses, mount/unmount, attach/detach, object position, etc ...)

• Mount / Unmount of tools (a.k.a. guns or grippers) on the TOOLFRAME

of a Robot (a.k.a. on the end of the robot wrist).

• Attach / Detach – sort of like gluing two objects together. Can be shown as
an optional field in the Object Tree.
Object attach / detach information can be shown in the Objects Tree
by using Customize Columns .

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• Poses of kinematic devices (i.e. OPEN and CLOSE pose for a fixture)
created in the context of a Scenario are shown in the Pose Editor.

• TCPF (Tool Center Point Frame) position/orientation of a Robot. A

frame of a robot that will be superimposed on a location during robotic
simulation. Shown as an entity in the Graphic Viewer or Object Tree.

• Groups – Discussed earlier. Shown in the Logical Collections Tree.

• Collision Set – Used to setup collision detection. Shown in the Collision

Viewer

• Detailed Representation (Discussed earlier in this course)

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Process Simulate Analysis Tools and Study Data

Scenario Data Administrative Note

Where is Scenario Data stored:

Process Simulate scenario data is stored under the .\system
root\TuneCells\{study external id} folder. There is a sub-folder here
for each study object which contains an engData_ver2.XML file. Do not
delete or modify this file manually unless instructed to do so by GTAC
(1-800-955-0000), otherwise data corruption may follow.

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Creating and Using Snapshots

In this topic we will create and use snapshots.
It contains the following subtopics:
• Snapshot Usage

• Activity: Creating Snapshots

To open the Snapshot Editor, select View -> Viewers -> Snapshot Editor. The
Snapshot Editor displays the snapshots created from engineering data. Using
the Snapshot Editor, you can create a snapshot of the working cell displayed
in the Graphic Viewer. Snapshots are used to store specific views and viewing
angles during your work for later reference.

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Process Simulate Analysis Tools and Study Data

Snapshot Usage
A snapshot preserves the current view of the scenario. The recorded view
includes the point of view, the location of objects and the visibility of objects.
Snapshots can be useful when constructing a current assembly or for
planning future assemblies.
To create snapshots:
1. Rotate, pan, zoom, blank and display entities in the Graphic Viewer.

2. Go to the Snapshot Editor.

3. Click New Snapshot . A new snapshot of the graphic image currently

displayed in the Graphic Viewer is created with the default name
Snapshot_# and the snapshot is displayed in the upper part of the
Snapshots tab.

4. You are now prompted to give it a new name. Type in the new name and
press enter.

Once you have created a snapshot, you can use the Snapshot Editor to do
the following:
Snapshot Editor toolbar:

• New Snapshot - Creates a snapshot of the objects currently visible in

the Graphic Viewer.

• Remove Snapshot - Deletes the selected snapshot.

• Edit Snapshot - Enables you to enter a name, type and description for
the selected snapshot. A snapshot must have an unique name. When a
description is entered for the snapshot, it is displayed next to the snapshot
if the snapshot is displayed in the lower part of the Snapshots tab.

• Update Snapshot - Changes the selected snapshot to the image

displayed currently in the Graphic Viewer.

• Apply Snapshot - Replaces the image in the Graphic Viewer with the
selected snapshot. By default, only the point of view is applied but you
can also select to apply the location and visibility of objects. Click the
drop-down arrow and select one or more from the following:
o Point of View

o Object’s Visibility

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 Process Simulate Analysis Tools and Study Data

o Object’s Location

o Device Poses

o Object’s Attachments

o Object’s Color

o Object’s Viewing Mode

We will discuss Add Markup and Remove Markup later in class.

Snapshot Editor right click (on nothing in the Snapshot Editor

window) menu:

• List

• Small Icons

• Large Icons

• Sort Snapshots

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Process Simulate Analysis Tools and Study Data

Activity: Creating Snapshots

Perform the related activity using the electronic activities.

.

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Using the Markup Editor

In this topic we will use the Markup Editor to create markups.
It contains the following subtopics:
• Markup Editor Usage

• Markup Editor Toolbar

• Activity: Creating Markups

The Markup Editor enables you to take a snapshot of the currently displayed
image in the Graphic Viewer . The image itself cannot be modified, but
labels and callouts can be added to the snapshot. You can print or send the
snapshot by e-mail to other engineers in your organization, for example,
for consultation.

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Markup Editor Usage

Ways to open the Markup tool:

• Method 1: Select File -> Outputs -> Markup Editor . This method
exports the markups to a picture file in a selectable folder.

• Method 2: On the Snapshots Editor, select a snapshot, and pick Add

Markup from the Snapshot toolbar. This method stores the markups,
so that they can be modified later.

• Method 3: Select File —> Outputs —> Attach File . Attaches the created
picture, markup, or video as a dataset on the selected object. First select
an object that exists in eMS, select Attach File , create a new snapshot
(you can select the font size of the text in the notes and the image size),
add a markup to the snapshot.

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Markup Editor Toolbar

• Save As File — Saves the image as a .BMP or .JPG file in a specified

location.

• Send Mail Message — Enables you to send the image by e-mail as

an attached file.

• Print — Enables you to print the image.

• Cut — Cuts a selected object (callout, text box or line) to the clipboard.

• Copy — Copies a selected object (callout, text box or line) to the

clipboard.

• Paste — Pastes the contents of the clipboard to the Markup Editor.

• Delete — Deletes a selected object (callout, text box or line) from the
Markup Editor.

• Group — Groups two or more selected objects (callout, text box or

line) in the Markup Editor into a single group and enables the objects
to be manipulated together.

• Ungroup — Ungroup one or more selected groups.

• Bring to Front — Places selected objects (callout, text box or line) in

front of other unselected and overlapping objects.

• Send to Back — Places selected objects (callout, text box or line)

behind other unselected and overlapping objects.

• Select Objects — Activates Select mode, enabling you to select objects

(callout, text box or line) in the Markup Editor

• New Line — Enables you to draw a line.

• New Arrow — Enables you to draw a line with an arrowhead.

• New Rectangle — Enables you to draw a rectangle. (To make a

square, hold the [Shift] key while dragging).

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• New Ellipse — Enables you to draw an ellipse. (To make a circle,

hold the [Shift] key while dragging).

• New Scribble Polygon — Enables you to draw a freeform shape.

• Add Note — Enables you to add notes to objects.

• New Text — Enables you to add text to the snapshot.

• New Text Box — Enables you to draw a text box in the snapshot.

• Fill Color — Enables you to modify the color of a selected object

(callout, text box or line).

• Set Font — Enables you to change the font of text.

• Line Style — Enables you to modify the width, color and style of lines
and arrows.

• Arrow Style — Enables you to modify the arrowhead style.

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Activity: Creating Markups

Perform the related activity using the electronic activities.

.

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Adding Text in the Graphic Viewer

In this topic we will describe how to create text in the Graphic Viewer.
It contains the following subtopics:
• Graphic Viewer Text Usage

• Activity: Setting the Note Options

• Activity: Creating Notes in the Graphic Viewer

• Activity: Creating Dimensions in the Graphic Viewer

Text can be added directly into the Graphic Viewer by using the note
commands or the label commands. They can be used to show attributes of
objects, highlight problem areas, or add other textual information to the view.

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Graphic Viewer Text Usage

Text can be added directly into the Graphic Viewer using several techniques:
• Notes — Have a leader line, are associated to the study, and are always
the same size (irrespective of the zoom).

• Labels — Do not have a leader line, are associated to the object, and
change size when zooming

• Dimensions — As apposed to measurements, which are temporary and

only one can be created at once, dimensions are persistent in the study
and many can be created at once. (Dimensions and measurements were
mentioned earlier in this course. See Measurement and Units)

To work with Notes:

Notes are objects that display as free text with a leader line in the Graphic
Viewer and the Notes folder of the Object Tree. The Note commands
are located under: Tools -> Notes. Notes can be shared between Process
Designer, Process Simulate:

• Create Note

• Object Notes

• Edit Note

• Toggle Note Visibility

• Update Object Notes

• Automatic Note Placement

• Note Settings

To work with Labels:

Labels are objects that display as free text in the Graphic Viewer and the
Labels folder of the Object Tree. There are many options to define the
formatting for a note. The Label commands are located under: Tools ->
Labels.
• Object Labels

• Create Label

• Modify Label

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To work with Dimensions:

Dimensions are objects that display as free text in the Graphic Viewer and
the Dimensions folder of the Object Tree. The Dimension commands are
located under: Tools -> Measurements -> Create Dimension .
Types of dimensions:

• Point-to-point Distance - Measures the point-to-point distance

between two objects.

• Minimal Distance Dimension - Measures the shortest distance

between two objects.

• X-Axis Distance - Measures the distance along the X-axis between

two objects.

• Y-Axis Distance - Measures the distance along the Y-axis between

two objects.

• Z-Axis Distance - Measures the distance along the Z-axis between

two objects.

• Normal to Source Curve Dimension

• Normal to Target Curve Dimension

Selected attributes of dimensions:

• Dimensions can be hidden or displayed from within this tree.

• The dimensions are stored with the engineering data.

• Process Simulate dynamically updates the dimension values when users

move the measured objects to new locations in the Graphic Viewer.

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Activity: Setting the Note Options

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Activity: Creating Notes in the Graphic Viewer

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Activity: Creating Dimensions in the Graphic Viewer

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Storing Pictures of the Scenario

In this topic, we will describe how to output pictures of the Graphic Viewer
contents.
It contains the following subtopics:
• Activity: Outputting the Graphic Viewer to a File or Printer

Static images of scenarios can be created in .BMP, .JPEG, .GIF or .TIFF

format.
Output types may vary based on the image output command used.

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Activity: Outputting the Graphic Viewer to a File or Printer

Perform the related activity using the electronic activities.

.

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Introduction to Collision Detection

In this topic, we will learn about how to setup and use collision detection.
It contains the following subtopics:
• Collision Detection Basics

• Collision Viewer

• Defining a Collision Set (List Pair)

• Rules of Thumb

• Activity: Collision Viewer and Fast Collision Sets

• Activity: Defining Collision Sets (List Pairs)

Tecnomatix collision detection tools can temporally change the colors of

objects in the Graphic Viewer and the Collision Viewer.

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Collision Detection Basics

There are three levels of detection granularity:

• Near Miss – Objects are highlighted in yellow if they come within a
predefined clearance envelope of each other

• Collision Contact – Objects can optionally be highlighted in red if they

are touching each other (or orange if near miss detection is activated).

• Collision Penetration – Objects are highlighted in red if they exceed the

allowed penetration depth with each other.
Valid values for Allowed Penetration Value are between 0 and 5 mm.

Collision detection types:

• Dynamic collisions – Collisions that occur during a simulation or while
objects are being placed.

• Static collisions – Collisions that are occurring without moving the

objects.

Collision options:
When a collision occurs the object’s color is always changed to red in the
Graphic Viewer and the Collision Viewer. Optionally a simulation can be
stopped when a collision is detected and/or a sound is played at regular
intervals while in a collision state.

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Collision Viewer
The Collision Viewer displays all current occurring collisions, near misses
and contacts. It enables you to define, detect and view collisions in the data
currently displayed in the Graphic Viewer, as well as view collision reports.
The Collision Viewer is composed of several panes:
• The left pane contains an editor for creating and managing collision sets.
It can be closed or opened by clicking Show/Hide Collision Sets .

• The right pane displays collision results and includes viewing options.
The right pane of the Collision Viewer can be further divided into two
more panes. We will discuss these other two panes later in this course.

To open the Collision Viewer:

• From the View menu, select Viewers, and then Collision Viewer.

To close the Collision Viewer:

Click Close in the right-hand corner of the window.
The left pane of the Collision Viewer includes the following options:

• New Collision Set - Enables the definition of a new collision set.

• Remove Collision Set - Enables the deletion of a previously created

collision set.

• Edit Collision Set - Enables changing the definition of a previously

created collision set.

• Fast Collision - Enables creating a new collision set quickly based on

the selected objects. This collision set is displayed in the left pane of the
Collision Viewer under the name fast_collision_set. The collision set
created with this option is a self set, which means that all the objects
within the set are checked for collision against each other. Only one fast
collision set may exist in a study. If you create another one, it replaces the
previous fast collision set.

• Emphasize Collision Set - A toggle used to emphasize the selected

collision set in blue and yellow in the Graphic Viewer.

• All Displayed Objects - When checked, it checks for collisions among

all objects displayed in the Graphic Viewer. This option ignores defined
collision sets. Enabling this option can have a severe impact on system
performance. It is not suggested to check this checkbox.

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Two basic options from the right pane of the collision viewer:
• Show/Hide Collision Sets - Shows or hides the collision set editing
pane of the Collision Viewer.

• Collision Mode On/Off - Activates/deactivates Collision mode.

Collisions are detected only when Collision mode is on.

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Defining a Collision Set (List Pair)

Collision detection is accomplished by searching for a collision between

objects in one list and objects in another list. This means that list pairs must
be created before collision detection is possible.
Multiple list pairs can be defined. A default name is automatically given for
each list pair, although another name can be specified.

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Rules of Thumb

• Manually create the collision set for tool to product assembly checks.

• Use fast collision set to check between one part and tool; or when checking
collisions between all the parts of a product assembly.

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Selection Toolbar

There are several filter tools in Process Simulate. One that we have not
discussed yet is the Selection toolbar. Using it, you filter your selections by
various types such as: Parts, Resources, Mfg Features, Weld Points, Paths,
Global Locations, Frames, Notes, Points, Lines/Curves, Solids/Surfaces, or
PMI. Normally this toolbar sits along the right edge of the Graphic Viewer.
However the same functionality can be found by selecting Edit -> Selection
-> Selection.

Basic Usage:

• From the Selection toolbar, click Select with Filter .

• From the Selection toolbar, choose one or more of the selection types.

• Click Selection Type All .

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Activity: Collision Viewer and Fast Collision Sets

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Activity: Defining Collision Sets (List Pairs)

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More on Collision Detection

This topic describes features that enable users to detect and focus on collision
areas for more accurate analysis of collision pairs.
It contains the following subtopics:
• Collision Introduction

• Configuring Level of Detection Granularity

• Near Miss Value Setup

• Collision Report Level

• Activity: Collision Setup and Collision Viewer

• Activity: Filtering Collision Results

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Collision Introduction

Selected options from the right pane of the collision viewer:

• Collision Options — Enables you to set default collision set options.

• Freeze Viewer — Depressing this button freezes the Collision Viewer

to prevent dynamic updating of the collision report as objects are moved in
the Graphic Viewer. Click it again to update the Collision Viewer report.

• Color Colliding Objects — Toggles the color highlighting of

colliding objects to facilitate clear viewing of colliding objects. If Show
Colliding Pair is active, this function toggles the highlighting between
red/transparent blue and the original colors of the objects.

• Show/Hide Colliding Contour - Places a curve in the Graphic Viewer

at the point of collision. This button is used to isolate collision problems.

It is suggested to use Freeze Viewer , blank one of the objects,

then zoom to a selected object from the contour viewer. For example,
blank the man to see a “chalk outline” of where his hands are
hitting the table.

• Show Colliding Pair — Defines how the collision status of a pair

of colliding objects is displayed. This button is used to isolate collision
problems:
o Color Selected Pair

o Show Selected Pair Only

• Export to Excel — Creates a MS Excel report (CSV file) of the contents

of the Collision Viewer. For example (depending on your data this picture
may look different):

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• Collision Depth — Calculates the depth of penetration of colliding

objects. It uses this information to display a vector along which to
withdraw one of the colliding objects to resolve the colliding status.

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• Filter Collision Results — Filters the collision results. Choose one of

the following options. This button is used to isolate collision problems:
o List Colliding Pairs (highlighted in red)

o List All Pairs (displays the distance between all the visible objects
in the cell)

• Show Hide Collision Details

• Show/Hide Contour View — Opens another pane on the right side of

the Collision Viewer containing selectable collision curves.

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Configuring Level of Detection Granularity

Checking options for penetration and near miss will affect what is shown in
the collision window.
Collision setup options are found on the Collision tab of the Options window
and can be accessed by either:
• Selecting Tools -> Options and then choosing the Collision tab, or

• Clicking Collision Options in the Collision Viewer.

o Collision Near-Miss - When selected, objects selected for collision

detection that are within the near-miss envelope value are colored
yellow. This value can range between 0 and 10,000 mm.

o Collision Contact - When selected, each colliding pair is checked for

permitted contact (i.e. a tool touching a surface). Any penetration
value less than the Allowed Penetration Value is considered in contact,
but not colliding. Objects selected for collision detection that exceed
the Allowed Penetration Value are considered in a true collision.
The default Near Miss and Allowed Penetration Value are
defined using the Options window. However, each Collision Set
can have its own unique value specified in the left pane of the
Collision Viewer.

Distinguishing the levels of detection granularity:

• Collision
o Colliding objects are marked in red

o Object in contact are marked in red (as colliding)

o Performance: High

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• Collision while contact objects are excluded

o Colliding objects are marked in red

o Object in contact are excluded from the collision reports

o Performance: Mid

• Collision with near miss

o Colliding and contact objects are marked in red

o Objects in near miss are marked in yellow

o Performance: Mid

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• Collision with contact and near miss

o Colliding objects are marked in red

o Object in contact are marked in orange

o Objects in near miss are marked in yellow

o Performance: Low

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Near Miss Value Setup

In order to check for near misses, as well as collisions, Check for Collision
Near-Miss option must be checked, a near-miss value must be specified, and
collision detection should be switched on. There are two methods to specify a
near miss value:
• Global Method: If a near-miss value is not defined for a pair in the Near
Miss column of the Collision Editor window, the system will use the global
Near-Miss Default Value specified on the Collision tab of the Options
window.

• Collision Set specific Method: After you have defined the list pairs for
collision checking, open the Options window by right-clicking in the
Graphic Viewer, and select the Collision tab. To show both collisions and
near misses, select the Check for Collision Near-Miss checkbox. Enter
a Near-Miss Default value.

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Collision Report Level

This setting is affected by whether Detailed Representation has been loaded

for the objects in question.
There are two settings:
• Component Level — Similar to the Pick Level of Component, it is used
during collision detection to display found collisions in the Graphic Viewer
and Collision Viewer.

• Lowest available level — Similar to the Pick Level of Entity, it is used

during collision detection to display found collisions in the Graphic Viewer
and Collision Viewer.

Advanced Collision Options window, opened by clicking Advanced,

is specific to robotic processes. It will be discussed in the WKP115T
Process Simulate on eMS Basic Robotics Simulation course.

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Activity: Collision Setup and Collision Viewer

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Activity: Filtering Collision Results

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Factors that Affect Collision Detection

This topic describes factors that affect collision detection.
It contains the following subtopics:
• Collision Factors

• Discussion: Factors that Affect Collision Detection (Not an Activity)

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Collision Factors

There are several factors that affect collision detection:

When creating collision sets in Engineering Compatibility Mode
(suggested study mode that is set in the Tecnomatix Doctor), only
objects (not entitles) can be added.

• Simulation Time Interval: Collision sets are only processed at the graphics
update time interval. A collision will only be detected if it occurs at a
time interval boundary, meaning that it is possible for a collision to occur
between updates and therefore not be detected. The smaller the interval,
the less likely it is that this will occur. This value can range between 1
(fastest) to 0.0000001 (slowest). The default value is 0.2. This can be
set by either:
o Selecting Tools —> Options, choosing the Simulation tab, and
entering a value for Simulation Time Interval.

o Clicking Set Time Interval in the Sequence Editor and entering a

value for Time.

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The display of Simulation Time Interval is affected by the Time

display unit and number of decimal places specified on the Units
tab of the Options window.

• Speed and Acceleration: The speed and acceleration of an object can

affect the detection of collisions. If they are very high, it may be advisable
to reduce the update time interval.
o For robotic paths this can be set on each location of the path (i.e. set
on the Path Editor or Teach Pendant).

o For non-robotic paths this is set by specifying the duration of the

operation (i.e. set on the Operation Properties).

• Display/Blank: Process Simulate only detects collisions of displayed or

visible parts. Collisions involving blanked items will not be detected.
o This can be done

Blanking and displaying objects is affected by the Pick Level setting.

If Freeze Viewer is depressed the collision state of objects will

not be updated, even if they are blanked.

• Display Precision of Entities: Process Simulate determines collisions

based on the graphical distance between entities. The graphic display
precision of an entity affects this graphical distance. The display precision
for surfaces can be set when the object is brought into the system via a

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translator. A higher precision results in a closer approximation of the

mathematical model. Although Process Simulate will run more slowly
with a higher precision setting.

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Discussion: Factors that Affect Collision Detection (Not an Activity)

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Cutting Sections with Section Planes

In this topic, we will discuss how to cut sections.
It contains the following subtopics:
• Basic Section Cutting Usage

• Optional Activity: Creating and Moving a Section Plane

• Optional Activity: More on Cutting Sections

Objects can be cut into sections along the YX-, YZ-, and ZX planes of the
working frame, which then appears in the Section Viewer.

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Basic Section Cutting Usage

The section cutting tools are located in the Tools —> Section menu.
Section Plane Cutting Tools:
• New Section Plane — Creates and positions a cutting plane. Imagine
the part is a loaf of bread: the result of cutting the part with this plane
would be one slice of bread, one half of the loaf, or the other half of the loaf.

• Section Manager — Enables you to create new sections.

• Section Alignment — See the next topic for more information.

• Flip Section Plane Direction — Choose which half of the loaf of bread
(i.e. your part that is being cut) or the other half of the loaf.

• Adjust section plane size — Changes the visualization of the section

plane in the Graphic Viewer (but does not affect the result of the section).

• Activate section — Section that is cut in the main Graphic Viewer.

• Deactivate section — Turns of the cutting of a section in the main

Graphic Viewer.

• Clip section — Shows everything on the negative side of the section

plane, and clips everything on the positive side of the section plane.

• Cut section — Shows the contours of the assembly at the plane cut
by the section.

• Capping — Adds definition to the cutting edge so as to know when

there is space between the parts.

• Hatching — Adds definition to the cutting edge so as to know when

there is space between the parts.

• New section viewer — Cuts the selected section in a new Section

Viewer.
You can open up to five Section Viewers for the same section in order
to view the contents of the view from different angles.

• Orient View to Section Plane — Changes the view to look toward the
positive Z-axis of the plane, while the distance between the "Eye" to the
view center remains unchanged.

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• Show Section Contours — Displays contours in Clip mode

• Save section Contour as Component — Saves the section as a new

.COJT or a .JT file.

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Section Plane Alignment Tools

The section plane alignment tools are located in the Tools —> Section —
Section Plane Alignment menu.
Section Plane Alignment Tools:

• Align to X — Aligns the section plane to the YZ-plane of the working

frame.

• Align to Y — Aligns the section plane to the XZ-plane of the working

frame.

• Align to Z — Aligns the section plane to the XY-plane of the working

frame.

• Align to Point — Places the origin of the plane at a selected picked

position.

• Align to Line between Two Points — Aligns the plane at the center of
two points you pick in the Graphic Viewer.

• Align to Edge — Aligns the plane perpendicular to the point you pick
on a 2D object. The orientation is set arbitrarily.

• Align to Surface — Aligns the plane normal to a selected surface with

the origin of the plane at the picked location.

• Align to View Plane — Aligns the Z-axis of the plane to the "view from" ®
"view to" vector and aligns the positive Y axis of the plane to the up vector
of the camera. The position of the section plane is not changed.

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Optional Activity: Creating and Moving a Section Plane

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Optional Activity: More on Cutting Sections

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Cutting Sections with Section Volumes

In this topic we will describe how to create section volumes.
It contains the following subtopics:
• More Section Cutting Usage

• Optional Activity: Creating and Moving a Section Volume

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More Section Cutting Usage

The section cutting tools are located in the Tools —> Section menu.
Section Volume Cutting Tools:
Many of the commands related to section planes can also be used for
section volumes. The commands listed here are specific to section
volumes.

• New Section Volume — a cutting box is created and can be positioned.

The results of cutting the part with this box would be the portion of the
part that is inside or outside of the box. The edges of the 3D cutting box
can be dragged to get a different size section.
The location of the cutting box (volume) is determined based on
what is selected (i.e. nothing selected, one object selected, or
multiple objects selected)

• Clip Inside — used when creating a section volume.

• Clip Outside — used when creating a section volume.

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Optional Activity: Creating and Moving a Section Volume

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Recording Process Simulate Simulations to an .AVI File

In this topic, we will discuss how to record a video of a Process Simulate
simulation using the AVI Recorder .
It contains the following subtopic:
• Activity: Outputting a Simulation to an AVI File

The File —> Outputs —> AVI Recorder command creates a movie file of
all subsequent operations effected in the Graphic Viewer .
The Audio Video Interleaved (.AVI) format was developed by Microsoft as a
special version of the Resource Interchange File Format (.RIFF).
While recording an .AVI file on computers with powerful graphic cards
(16 MB and higher), the graphical view may be jumpy during recording.
However the resulting AVI recording will be smooth

Simulation Time Interval

Simulation time interval can affect how fast the resulting video plays your
simulation.
• Selecting Tools —> Options, choosing the Simulation tab, and entering a
value for Simulation Time Interval.

• Clicking Set Time Interval in the Sequence Editor.

The display of Simulation Time Interval is affected by the Time display

unit and number of decimal places specified on the Units tab of the
Options window.

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Activity: Outputting a Simulation to an AVI File

Perform the related activity using the electronic activities.

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Movie Manager
This topic describes how to use Movie Manager to create AVIs of
simulations.
It contains the following subtopics:
• Introduction to Movie Manager

• Activity: Using Movie Manager

Movie Manager is a tool to “bulk create” AVIs for several operations at

once and associate them to the operations.

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Introduction to Movie Manager

The File —> Outputs —> Movie Manager command runs a simulation in
the background, records an .AVI file, and associates the file with the operation.
Administrators must make sure that DirectX End-User
Runtime is installed on the client machines in order to view
movies in the preview pane. You can download DirectX from:
http://www.microsoft.com/downloads/details.aspx?familyid=CB7397F3-094

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Activity: Using Movie Manager

Perform the related activity using the electronic activities.

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Summary
Subjects learned in this topic:
• The different types of engineering data created in Process Simulate and
stored in the database.

• How to work with the Snapshot Editor.

• Several ways how to create markups.

• How to create notes and more.

• How to export pictures of the scene.

• The Collision Viewer and how to setup a collision set.

• How to setup collision options to fine tune the collision reporting.

• Several factors that affect collision detection results.

• How dynamic sections of objects can be cut along the YX-, YZ-, and
ZX-planes of the working frame.

• How to do more with dynamic sections.

• How to create an .AVI movie file of all subsequent operations effected in

the Graphic Viewer using Process Simulate’s AVI Recorder commands.

Instructor Note:
Summary instructor notes.

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Lesson

6 Other Selected Basic Topics

Purpose
To discuss other selected topics related to Process Simulate basics.

Objectives
After you complete this chapter, you should be familiar with:
• Get an overview of which Process Designer commands are available in
Process Simulate.

• How to use Process Simulate Disconnected.

• Putting It All Together

• Where Do We Go From Here

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Other Selected Basic Topics

Process Designer Commands in Process Simulate

This topic overviews which Process Designer commands are available in
Process Simulate.
It contains the following subtopic:
• List of Project Management Commands in Process Simulate

• List of eMServer Tools in Process Simulate

• List of Other Process Designer Commands in Process Simulate

• Activity: Using Some Project Management Commands

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List of Project Management Commands in Process Simulate

Some functionality of Process Designer is also available in Process Simulate:

• File —> Project Management —> Set as Working Folder — Taught in the
EMS127 Process Designer Basics course and this course.

• File —> Project Management —> Import eBop Customization — the

ability to import a file containing object and attribute customizations.
Needed to run some functions in process simulate. Not taught in this
course.

• File —> Project Management —> Export eBop Customization — the

ability to export a file containing object and attribute customizations.
Needed to run some functions in process simulate. Not taught in this
course.

• File —> Project Management —> Create Engineering Libraries — Used

to import existing 3D data (.CO or .COJT) resources or parts into the
database for use in Process Designer or Process Simulate. Not taught in
this course

• File —> Project Management —> Update Engineering Libraries — Not

taught in this course

• File —> Project Management —> Export selected eBop to file — Taught
in course

• File —> Project Management —> Import eBop file — Taught in the
EMS127 Process Designer Basics course and this course.

• File —> Project Management —> Import eBop Project — Taught in the
EMS127 Process Designer Basics course

• File —> Project Management —> New Project — Taught in EMS127

Process Designer Basics course and this course.

• File —> Project Management —> Attribute Map Generator — Not taught
in this course

• File —> Project Management —> Create Legacy Cell — Not taught in
this course

• File —> Project Management —> Robcad Connectivity Studies —

Not taught in this course

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Other Selected Basic Topics

List of eMServer Tools in Process Simulate

Some functionality of Process Designer is also available in Process Simulate:

• Tools —> eMServer —> Configured Update eMS — Not taught in

course

• Tools —> eMServer —> Create Library Preview — Not taught in

course

• Tools —> eMServer —> eMS Library Browser — Taught in EMS127

Process Designer Basics

• Tools —> eMServer —> Merge Studies — Taught in WKP215S

Process Simulate on eMS Basic Robotic Simulation

• Tools —> eMServer —> New — Taught in EMS127 Process Designer

Basics

• Tools —> eMServer —> Power Bar — Taught in EMS127 Process

Designer Basics

• View —> Open With —> Properties — Taught in EMS127 Process

Designer Basics

• Tools —> eMServer —> Variant Filter — Taught in EMS213 eMS Data
Management, Variants, and Importing and EMS229 Process Designer
General Assembly

6-4 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Other Selected Basic Topics

List of Other Process Designer Commands in Process Simulate

Some functionality of Process Designer is also available in Process Simulate:

• Edit —> Delete — Taught in EMS127

• File —> eMServer Selective Update — Taught in EMS127 Process

Designer Basics and this course.

• File —> Load in Standard Mode — Taught in EMS127 Process

Designer Basics and this course.

• File —> Close Project — Taught in EMS127 Process Designer Basics

and this course.

• File —> Open Project — Taught in EMS127 Process Designer Basics and
this course.

• View —> Open With —> Navigation Tree — Taught in EMS127 and
this course

• View —> Open With —> Properties — Taught in EMS127 and this
course

• Retrieve Detailed Representation — Taught in the EMS127 Process

Designer Basics course

• Set Update eMS Configuration — Not taught in course

• Reconcile Instances — Not taught in course

• Cancel Check Out — Taught in EMS127 Process Designer Basics

and this course.

• Change Password — Not taught in course

• Check In — Taught in EMS127 Process Designer Basics and this course.

• Check Out — Taught in EMS127 Process Designer Basics and this

course.

Process Simulate on eMS Basic Robotic Simulation Student Guide 6-5

Other Selected Basic Topics

Activity: Using Some Project Management Commands

Perform the related activity using the electronic activities.

.

6-6 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Other Selected Basic Topics

Using Process Simulate Disconnected

This topic describes how to use Process Simulate Disconnected.
It contains the following subtopics:
• Process Simulate Disconnected Introduction

• Disconnected System Root

• Saving a .PSZ file

• Process Simulate Disconnected Usage

• Updating back the eMS Database

• Activity: Starting and Exiting Process Simulate Disconnected

• Activity: Updating Process Simulate Disconnected from the eMS Database

• Activity: Updating the eMS Database from Process Simulate Disconnected

Process Simulate on eMS Basic Robotic Simulation Student Guide 6-7

Other Selected Basic Topics

Process Simulate Disconnected Introduction

• Process Simulate Disconnected does not require a server. It can only

work with.PSZ files.

• The .PSZ file is generated by first running Process Simulate on eMS

(connected) and selecting either File -> Save (This is NOT the same as
File -> Save Scenario from Process Designer). File -> Save saves
the current loaded study as a .PSZ file in the specified folder.

• Process Simulate Disconnected can open, edit, and save the .PSZ file.

• The .PSZ file can be opened by Process Simulate on eMS (connected) and
used to update the original study in the eMS Database.

6-8 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Other Selected Basic Topics

Disconnected System Root

• Process Simulate Disconnected has its own local system root (see the
Options menu).

• The default Process Simulate Disconnected system root is the eMS

system root.

• You can create and modify the local system root.

Process Simulate on eMS Basic Robotic Simulation Student Guide 6-9

Other Selected Basic Topics

Saving a .PSZ file

In Process Simulate (connected) the File —> Save As and File —> Save
commands have two options:
• Save only the study
o In this case, the library objects present in the study will not be saved.
When the .PSZ file is opened no library objects will be found. An error
message stating no objects found will be displayed.

• Save the study and its library objects to a local system root
o In this case, the library objects present in the study will be saved in a
separate zip file. This file must be unzipped into the local system root
before opening the .PSZ file with Process Simulate Disconnected.
Failure to do so will result in library objects not being found.

6-10 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Other Selected Basic Topics

Process Simulate Disconnected Usage

1. Save from Process Simulate (connected) a study as a .PSZ file with a zip
file for the library objects.

2. Launch Process Simulate Disconnected and set the local system root.

3. Unzip the library objects zip file under the local system root.

4. Open the .PSZ file.

5. Work on the .PSZ file.

6. Save the .PSZ file.

7. Reloading the .PSZ file to insure that the changes have been saved.

8. Exit Process Simulate Disconnected.

Process Simulate on eMS Basic Robotic Simulation Student Guide 6-11

Other Selected Basic Topics

Updating back the eMS Database

It is important update back to the eMS the changes that have been made
offline. To do so:
1. Launch Process Simulate (connected).

2. Opening the .PSZ file with the File —> Open in Standard Mode
command.

3. Select File —> eMS Selective Update – this action will update the
study originally used to generate the .PSZ file with the changes made
offline.

4. Load the corresponding study and verify eMS has been updated.

6-12 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Other Selected Basic Topics

Activity: Starting and Exiting Process Simulate Disconnected

Perform the related activity using the electronic activities.

.

Process Simulate on eMS Basic Robotic Simulation Student Guide 6-13

Other Selected Basic Topics

Activity: Updating Process Simulate Disconnected from the eMS Database

Perform the related activity using the electronic activities.

.

6-14 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Other Selected Basic Topics

Activity: Updating the eMS Database from Process Simulate Disconnected

Perform the related activity using the electronic activities.

.

Process Simulate on eMS Basic Robotic Simulation Student Guide 6-15

Other Selected Basic Topics

Summary
Subjects learned in this topic:
• Got an overview of which Process Designer commands are available in
Process Simulate.

• How to use Process Simulate Disconnected.

Instructor Note:
Summary instructor notes.

6-16 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
Lesson

7 Modeling and Kinematics

Overview

Purpose
To provide an overview of what is available in Process Simulate modeling.

Objectives
After you complete this chapter, you should be familiar with:
• An overview of Process Simulate basics learned earlier in relation to the
functionality we will learn about in the preceding topics.

• An overview of the modeling tools.

Process Simulate on eMS Basic Robotic Simulation Student Guide 7-1

Modeling and Kinematics Overview

Overview of Process Simulate Basics

Provides an overview of Process Simulate basics learned earlier in relation to
the functionality we will learn about in the preceding topics. .
It contains the following subtopics:
• Starting Out

• Process Simulate Basics Review

• Modeling Basics

• Other Basics

• Activity: Starting Process Simulate

• Activity: Setting the Working Folder

7-2 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Modeling and Kinematics Overview

Starting Out this activity

Earlier we learned many things about Process Simulate that will be quickly
reviewed in this topic. This is not meant as a replacement to that course.
We learned about the abilities of Process Simulate to layout the contents of a
study; however, there are two basic modes in Process Simulate:
• Layout mode – (learned in the Process Simulate Basics course) used to
modify the contents and layout of objects (i.e. product and resources) and
processes (i.e. paths) in a study. In this case we are inserting instances
(references) of an object prototype into a study. Studies are stored in
special folders in the project known as a studyfolder.

• Modeling mode – (we will learn about it in this course) used to modify
the contents and layout of entities and kinematics in an object. In this
case we are modifying the object prototype. Object prototypes are stored
as .JT files in .COJT folders under the system root.

Process Simulate on eMS Basic Robotic Simulation Student Guide 7-3

Modeling and Kinematics Overview

Process Simulate Basics Review

In the Process Simulate Basics course we learned how to use various buttons
on these menus to affect whole objects in Process Simulate:
• File menu – Used to open and close projects

• Edit menu – used to Copy, Paste, Delete, etc...

• View menu – used to modify the visualization of objects in the Graphic

Viewer (i.e. Blank and Display).

• Kinematics menu – Used to move kinematic devices either directly, along

a path, or between poses (states).

• Tools menu – Used to move and query objects in the study (i.e. shift,
rotate, place, put, and transfer panel).

7-4 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Modeling and Kinematics Overview

Modeling Basics

In this course we will learn how to use various buttons on these menus to
affect individual entities in objects in Process Simulate:
• Edit menu – used to Copy, Paste, Delete, etc...

• View menu – used to modify the visualization of objects in the Graphic

Viewer (i.e. Blank and Display).

• Modeling menu – used to create new objects, change existing ones, and
save/undo changes to the objects.

• Kinematics menu – used to create and modify the kinematic definition of

the modeling object. Used to move kinematic devices either directly, along
a path, or between poses.

• Tools menu – Used to move and query entities in the modeled object (i.e.
shift, rotate, place, put, and transfer panel).

Process Simulate on eMS Basic Robotic Simulation Student Guide 7-5

Modeling and Kinematics Overview

Other Basics

• Pick Level – Entity and Component

• Pick Intent – Snap, Where Picked, On Edge, and Self-origin

• LOD – Level of Detail

7-6 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Modeling and Kinematics Overview

Activity: Starting Process Simulate and Setting the Working Folder

Perform the related activity using the electronic activities.

.

Process Simulate on eMS Basic Robotic Simulation Student Guide 7-7

Modeling and Kinematics Overview

Activity: Opening Your Study

Perform the related activity using the electronic activities.

.

7-8 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Modeling and Kinematics Overview

Process Simulate Basic Modeling Tools

This topic provides an overview of the basic modeling tools.
It contains the following subtopic:
• Modeling and Kinematics Functionality

Process Simulate on eMS Basic Robotic Simulation Student Guide 7-9

Modeling and Kinematics Overview

Modeling and Kinematics Functionality

Many objects used in Process Simulate are 3D objects which where
translated from other 3D systems. There are many formats supported
for translation using either the Importer.exe user interface or the
CAD Translator command line techniques: .ASY, I-DEAS (.IDI),
STL, .IGES, .CO, .RF, .JT, .DXF, CATIA v5 (.CATProduct and
.CATPart), ProEngineer, NX, etc... For more information contact GTAC
1–800–955–0000.

Modeling and Kinematics Functionality

• Can move the working frame

• Can create new parts, compound parts, resources, and compound

resources.

• Several ways to get existing objects into a study

• Can start modeling, end modeling, saving modeling changes, or throw

them away

• Can align or duplicate entities

• Can create new reference frames within an object

• Can create 2D entities

• Can create 3D entities

• Can modify existing 2D and 3D entities (i.e. Boolean, sweeps, extrudes,

revolutions, scaling, etc…

• Reload original modeling configuration – discards the current modeling

changes and reloads the stored modeling configuration from the eMServer.

Kinematics Functionality
• Can create or modify kinematic definitions

• Can define objects as various tool types (i.e. grippers, weld guns, etc…)

• Can move a kinematic object’s joints (i.e. Robot Jog, Robot Jog with locked
TCPF, or Joint Jog)

• Create kinematic poses

• Jump to a kinematic object’s poses

• Jump or move a kinematic object to various locations (inverse kinematics)

7-10 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Modeling and Kinematics Overview

• Check robot reachability interactively or automatically

• Mount or unmount tools to kinematic object

• Add or remove external axis (i.e. gantries or 7th axis) definitions to a

kinematic object

• Examine robot properties.

Process Simulate on eMS Basic Robotic Simulation Student Guide 7-11

Modeling and Kinematics Overview

Summary
Subjects learned in this Ttopic:
• An overview of Process Simulate basics was performed.

• An overview of the modeling tools.

Instructor Note:
Summary instructor notes.

7-12 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
Lesson

8 Modeling Basics

Purpose
To provide a description of how to model in Process Simulate.

Objectives
After you complete this chapter, you should be familiar with:
• How to do some basic modeling in Process Simulate.

• How to create solids using solid primitives and Boolean operations.

• How to create 2D entities and use them to build 3D solids.

• How to create a gun shank.

• How to model a simple robot.

Process Simulate on eMS Basic Robotic Simulation Student Guide 8-1

Modeling Basics

Modeling Concepts
This topic describes how to do some basic modeling in Process Simulate.
It contains the following subtopics:
• Introduction to Modeling

• Modeling Methodology

• Solid Modeling Overview

• Other Notes

8-2 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Modeling Basics

Modeling Overview

The Process Simulate modeling menu allows you to create geometry that
can be used in Process Simulate. You can also import data from other
supported 3D formats. See the EMS213 eMS Data Management, Variants,
and Importing course.
This chapter will cover the concepts of Process Simulate modeling. In addition
to creating geometry, Process Simulate modeling provides tools to create
kinematics (joint motion) to the geometry so that Robots, CMMs, heads, guns,
moveable fixtures, and so on can have realistic motion.
Objects that can be created in modeling:
• Solids (3D entities)

• Wireframe (typically 2D entities)

• Kinematics

• Frames

• Smart component information

• Conceptual Conveyor Definitions

• Etc…

Process Simulate on eMS Basic Robotic Simulation Student Guide 8-3

Modeling Basics

Modeling Methodology
Modeling Methodology
1. Open a project in Process Simulate.

2. Load the study into Process Simulate.

3. Set the modeling scope to a loaded object (resource or part) or create

a new one.

4. Design prototype geometry

5. Edit geometry

6. Define kinematics

7. Add logic block information as desired.

8. If changes are good then end modeling, else reload the object.

In Process Simulate:
• An icon overlay displays to indicate that an object is currently being
modeled.
This has changed from previous versions, when a lock icon was used
to indicate that an object is not under modeling. The lock icon is still
used to indicate other types of restrictions for objects.

• A Modeling window layout is shown in the Layout list. In general the

Standard or Modeling window layouts can be used to display the modeling
functionality. Other standard window layouts do not show all of the
kinematic and geometric modeling tools on the Modeling menu.

• The Modeling toolbar contains various features from the Modeling menu.

Example Modeling Fucntionality:

After users model the 3D geometry of an object, if they wish to undo the
changes, the Reload Component command reloads an object’s initial 3D
geometry as it exists in the library (before beginning the current modeling
session). This command does not revert other types of modifications that may
have been made, such as renaming the object, assigning it to operations,
adding properties, etc. Reload Component is available as long as End
Modeling has not been used to terminate the modeling session and save
the modified object back to the library.

8-4 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Modeling Basics

Solid Modeling Overview

Process Simulate is not a parametric modeling system, however
geometry can be modeled and created here. It is primarily meant as a
process design and verification system. It is not a replacement for high
end CAD systems like NX, I-DEAS, or Solid Edge. For more complex
geometry, translators are used to bring in objects from a CAD system
(For a complete list of translators, see the online help).

Solid Creation:
• Primitives - Process Simulate works with 5 basic solid primitives. Out of
these primitives, a designer can create many required shapes:

o Box

o Cylinder

o Cone

o Sphere

o Torus

• Other Solid Creation Tools - Process Simulate supports several

operations to use 2D data to make solids:
o Sweep by Circle

o Sweep by Curves

o Sweep by Rectangle

o Extrude

o Revolve

Solid Modification:
There are only a few ways that a solid can be modified:

• Scale

• Scale Object between Points

• Boolean Operations - These are key operations for the solid modeler.
Process Simulate supports the following operations:

Process Simulate on eMS Basic Robotic Simulation Student Guide 8-5

Modeling Basics

o Unite - Creates a solid out of all the volume occupied by two or

more solids.

o Subtract - Creates a solid by using the volume of one solid to

remove volume from another solid.

o Intersect - Creates a solid out of the common volume of two solids.

8-6 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Modeling Basics

Other Notes

Prototypes:
You always model an object prototype. An object instance in a study is a
copy of a prototype with a pointer to the prototype.

When an object prototype is saved, the Self-origin is placed at the World

Frame (The World Frame is the default location of the Working Frame).
The location of each entity in the prototype is relative to its Self-origin.

Concurrent usage of modeled prototypes:

In order to allow modeling of .JTs loaded by other Tecnomatix
applications: select Tools —> Options, select the eMServer tab, and
check Use local copy of the System Root files. Then click Settings
to setup the Local Files Cache Settings. 3D data files will be loaded
from the “Local Files Cache” instead of the system root End Modeling
operation updates the System Root. On the next session the local files
cache will be updated by the new file version

Process Simulate on eMS Basic Robotic Simulation Student Guide 8-7

Modeling Basics

Solid Creating with Primitives

This topic describes how to create solids using solid primitives and Boolean
operations.
It contains the following subtopics:
• Solid Creation Basics

• Activity: Modeling a Table

8-8 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Modeling Basics

Solid Creation Basics

In this topic, we will use solid primitives and Boolean operations to make a
simple object. In this topic we will use the following modeling functionality:

• Modeling —> Create Part Resource —> New Resource

• Modeling —> Create 3D —> Box Creation — creates a solid box by

specifying Length, Width, Height, and entity Self Origin.

• Modeling —>Create 3D —> Cylinder Creation (optional) — creates a

solid cylinder by specifying Radius, Height, and entity Self Origin.

• Modeling —> Create 3D —> Cone Creation (optional activity step) —

creates a solid cone by specifying Lower Radius (bottom of cone), Upper
Radius (top of cone), Height, and entity Self Origin.

• Modeling —> Create 3D —> Torus Creation (optional activity step)

— creates a solid torus (donut made by sweeping a circle around an axis)
by specifying Major radius (distance from the center of the donut to the
center of the swept circle), Minor radius (radius of the swept circle), and
entity Self Origin.

• Modeling —> Edit —> Unite (optional) — takes the given Unite entities
and generates one new solid that encompasses the same volume.

• Modeling —> Edit —> Subtract — removes the volume of the Subtract
entities (the cutting entity) from the Entity (the entity to be cut).

• Modeling —> End Modeling

• Modeling —> Set Modeling Scope — makes a “local” copy of the

.COJT in the study, opens the object for modeling, and sets it as the
parent of every new entity you create.
If modeling more than one object simultaneously, use this command
to switch which will be the parent of newly created entities.

If copying a component in a study, a new instance is created.

However, if you copy a modeled component, a new prototype is
created.

Process Simulate on eMS Basic Robotic Simulation Student Guide 8-9

Modeling Basics

Activity: Modeling a Table

Perform the related activity using the electronic activities.

.

8-10 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Modeling Basics

Using Wireframe to Create Solids

This topic describes how to create 2D entities and use them to build 3D solids.
It contains the following subtopics:
• Wireframe Basics

• Activity: Revolving 2D Entities to Make a Solid

• Activity: Extruding 2D Entities to Make a Solid

Process Simulate on eMS Basic Robotic Simulation Student Guide 8-11

Modeling Basics

Wireframe Basics

• Modeling —> Create 2D —> Create Polyline — creates a single entity

that is made up of a series of connected straight lines.

• Modeling —> Create 2D —> Create Curve — creates a single curved

entity through the selected control points.

• Modeling —> Create 2D —> Create Circle — creates a circle by

specifying a Center Point and a Radius.

• Modeling —> Create 2D —> Fillet — creates a curve with the specified
Radius at the intersection of two lines or curves.

• Modeling —> Create 2D —> Split Curve on Intersection — splits a

curve where it intersects another curve or surface.

• Modeling —> Create 2D —> Merge Curves — combines two or more

curves into one curve

• Modeling —> Edit —> Revolve — sweeps a curve around an axis to

create a solid.

• Modeling —> Edit —> Extrude — sweeps a curve along an axis to

create a solid.

8-12 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Modeling Basics

Activity: Revolving 2D Entities to Make a Solid

Perform the related activity using the electronic activities.

.

Process Simulate on eMS Basic Robotic Simulation Student Guide 8-13

Modeling Basics

Activity: Extruding 2D Entities to Make a Solid

Perform the related activity using the electronic activities.

.

8-14 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Modeling Basics

Modeling Gun Shanks

This topic describes how to create a gun shank.
It contains the following subtopics:
• Tools Used

• Activity: Sweeping 2D Entities to Make a Solid

Process Simulate on eMS Basic Robotic Simulation Student Guide 8-15

Modeling Basics

Tools Used

We will use the following modeling functionality that we have not used yet:

• Modeling —> Create 2D —> Create Arc — creates a curved arc

through three points.

• Modeling —> Create 3D —> Sweep —> Sweep Circle — sweeps a

circle around an axis
The start and end radius of the circle can be different.

• Modeling —>Create 3D —> Cylinder Creation (optional) — creates a

solid cylinder by specifying Radius, Height, and entity Self Origin.

• Modeling —> Create 3D —> Cone Creation (optional activity step) —

creates a solid cone by specifying Lower Radius (bottom of cone), Upper
Radius (top of cone), Height, and entity Self Origin.

• Modeling —> Duplicate Objects — depending on the Pick Level,

copies entities or components across an X, Y, and Z grid.

• Modeling —> Edit —> Mirror Objects — depending on the Pick Level,
mirrors entities or components across a specified plane.

8-16 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Modeling Basics

Activity: Sweeping 2D Entities to Make a Solid

Perform the related activity using the electronic activities.

.

Process Simulate on eMS Basic Robotic Simulation Student Guide 8-17

Modeling Basics

Modeling a More Complex Object

This topic describes how to model a simple robot.
It contains the following subtopics:
• Tools Used

• Using the Working Frame to Build

• Ways of Creating and Placing Objects in Modeling

• Activity: Modeling a Simple Robot for Kinematics

8-18 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Modeling Basics

Tools Used

we will use the following modeling functionality that we have not used yet:

• Modeling —> Set Working Frame — Temporarily changes the position

and orientation of the Working Frame from the World Origin (origin of
the study) to a specified one. This affects many of the Process Simulate
commands including modeling and placement commands.

• Modeling —> Edit —> Unite — Takes the given Unite entities and
generates one new solid that encompasses the same volume.

We will now begin modeling some more complex objects. However, we have
another agenda here besides learning how to model better. We will use this
activity to explain and use the working fame and the placement editor while
building a detailed object.

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Modeling Basics

Using the Working Frame to Build

The working frame is a special frame in Process Simulate. It can be placed

anywhere on the screen. Many of the menus in Process Simulate place objects
on the working frame (where ever it is in the cell) by default. This can be
a very powerful tool.
• The Frame option is used to place the working frame where ever you
want it

• The World option will place the working frame back on the world origin
(the default location for the working frame)

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 Modeling Basics

Ways of Creating and Placing Objects in Modeling

Method 1:
Create an entity at the Working Frame then move it with Placement tools
Method 2:
Move the Working Frame then create the entity at the new location of the
Working Frame
Method 3:
Use the optional Frame prompt, in most entity creation windows, to locate
the Working Frame when you create an entity.
We will practice all three methods in the next activity.

Process Simulate on eMS Basic Robotic Simulation Student Guide 8-21

Modeling Basics

Activity: Modeling a Simple Robot for Kinematics

Perform the related activity using the electronic activities.

.

8-22 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Modeling Basics

Summary
Subjects learned in this topic:
• How to do some basic modeling in Process Simulate.

• How to create solids using solid primitives and Boolean operations.

• How to create 2D entities and use them to build 3D solids.

• How to create a gun shank.

• How to model a simple robot.

Instructor Note:
Summary instructor notes.

Process Simulate on eMS Basic Robotic Simulation Student Guide 8-23

Lesson

9 Kinematics Basics

Purpose
To provide an introduction to Process Simulate kinematics.

Objectives
After you complete this chapter, you should be familiar with:
• How to create some different types of object kinematics.

• How to add lead and follow factor to object kinematics.

• How to add cranks to a kinematic tree.

• How to create a kinematic tree with branching.

• How to add specific poses to kinematic object.

• How to define an object, as a gun.

• How to assign attributes

• How to add kinematics to an object and move it around.

• Get some background on inverse kinematics.

• How to create and use inverse kinematics devices.

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Kinematics Basics

Kinematics Background
This topic describes how to create some different types of object kinematics.
More is described on modeling objects earlier in this course.

It contains the following subtopics:

• Ways to Get Kinematic Objects into Process Simulate

• Kinematics Background Basics

• Kinematics Basics

• Joint Parameters

• Final Note

• Instructor Demo: Simple Kinematics

• Activity: Simple Kinematics (Part 1)

• Activity: Simple Kinematics (Part 2)

• Activity: Simple Kinematics (Part 3)

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 Kinematics Basics

Ways to Get Kinematic Objects into Process Simulate

• Model them in Process Simulate

• Model them in another CAD system and convert them into a format that
Process Simulate can read (i.e. .JT DirectModel files)

No matter where the geometry is created, the kinematics are added

in Process Simulate.

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Kinematics Basics

Kinematics Background Basics

According to wikipedia.org: Kinematics (from Greek, kinein, to move) is
the branch of classical mechanics that describes the motion of objects
without consideration of the causes leading to the motion.

Now let’s learn how to start with a geometric object and add kinematics
to object prototypes. In this topic we will use the following kinematics
functionality:

• Kinematics —> Joint Jog

• Kinematics —> Pose Editor

• Kinematics —> Kinematics Editor

o Create Link

o Create Joint

Ways to Get Geometry into Process Simulate

• Model them in Process Simulate.

• Model them in another CAD system and translate them into Process
Simulate.

No matter where the geometry is created, the kinematics are added in

Process Simulate.

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 Kinematics Basics

Basic Kinematics
The following is a list of definitions that are important to remember when
working with kinematics:
You must be in Process Simulate modeling mode to define kinematics.

Here are some basic definitions:

• Link – (Also known as a rigid body) a group of entities within an object
that remain fixed, relative to one another. In this way it is the basic
non-moving segment of a kinematic chain. Default names begin with
these letters: LNK (i.e. LNK1, LNK2, LNK3)

• Joint – The basic moving segment of a kinematic chain. A joint consists

of 2 links and an axis. It defines the relative motion between two links
relative to the axis. Default names begin with the letter J (i.e. J1, J2, J3).
There are 2 types of joints.
o Revolute joint - rotates around axis
According to wikipedia.org: Rotational or angular kinematics is
the description of the rotation of an object

The positive direction of rotation around an axis is defined using

the right hand rule. The right hand rule is this: Make a fist and
point your thumb straight up. Place your fist at the first point
and align your fist so that your thumb points straight toward the
second point. Now your fingers show the direction of rotation
around the axis.

o Prismatic joint - linear movement along axis

According to wikipedia.org: Linear or translational kinematics
is the description of the motion in space of a point along a line.

• A kinematic tree has an order established by the relationship of the joints

and links. The parent link precedes a child link in the sequence order.
When the parent link moves the child link will follow. The parent takes
the child with it.
o In a typical kinematic tree, the number of links is equal to 1 more
than the number of joints. For example: if there are 6 joints, there
will be 7 links.

o The kinematic chain is the simplest example of a kinematic tree. It is

an open loop, string linked mechanism. All the links, except the first,
have one parent. Also all the links, except the last, have one child.

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o There is no limit to the length of a kinematic chain. Here is an

example of a kinematic chain (a simple kinematic tree)
Kinematic Tree:

The limit of six degrees of freedom only applies when defining

a robot. This is because robots require the creation of ONE
inverse solution.

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Attributes of a Kinematic Joint

1. The joint angle

2. The axis

3. The joint type

4. The distance between the two links of the joint

5. The length of the link (distance between two joints)

6. The angle between two links (parent to child)

The last four attributes cannot be changed; they are fixed.

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Methodology to Define a Kinematic Device

1. Envision the kinematic chain and create a kinematic tree on paper.

• What are the links, what type of joints, and so on).
Whenever modeling kinematics, first draw a kinematic tree.
Each box represents a link. A joint is represented by drawing an
arrow from the parent link to the child link.

o The first link is always the fixed link.

o A link cannot contain any of the geometry of any other link.

2. Create the links.

• Verify that desired entities have been selected as part of the desired
link.

3. Create the axis for each joint.

• An axis is defined by its two end points. The positive direction is from
the first point to the second. (right hand rule).

4. Define each joint (parent link, child link, axis and joint type).
• Joints are defined between one object/assembly to a second
object/assembly. The father is the stationary object.

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5. Define a range for each joint.

6. Create other joints in the same way.

7. Test the joints on mechanism using joint jog.

8. Save and close the object prototype.

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Instructor Demo: Simple Kinematics

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Activity: Simple Kinematics (Part 1)

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Activity: Simple Kinematics (Part 2)

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Activity: Simple Kinematics (Part 3)

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Kinematics Basics Summary

This topic provides a summary of the basic kinematic theory learned in the
last topic. The kinematics of a door, containing two joints, is defined and
then used in a simulation.
This is considered a review from the Process Simulate Basics course,
and can be performed as an instructor demo if desired.

It contains the following subtopic:

• Activity: Add Joints to a Simple object

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Activity: Add Joints to a Simple object

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Kinematics Basics

Leading Joint and Follow Factor

This topic describes how to add lead and follow factor to object kinematics.
It contains the following subtopics:
• Lead and Follow Basics

• Description

• Kinematic Functions

• Activity: Leading Joints and Follow Factors (Gun)

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Lead and Follow Basics

In this topic we will use the following kinematics functionality that we have
not used yet:

• Kinematics —> Kinematics Editor

o Joint Kinematics Functions

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Description of Joint Dependencies

In this topic we will define a simple algebraic expression relating one joint’s
movement to another. When the leading joint (independent) moves, the
dependant joint moves according to the expression.
The follow factor (a simple algebraic expression) is the amount by which the
leading joint is multiplied as it affects the dependant joint’s value.

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Kinematic Functions

Think of the independent joint as being x and the dependant joint as y. The
only way to change the value of y is to change x.
y = x + 2; If x = 2 then y = 4
Therefore, if:
• Joint J9 is independent

• Joint J8 is dependant on joint J9

• The value of J8 is defined as J9 + 2

• So if J9 = 2 then J8 = 4

• This is why J9 will be available jogging but J8 will not be available.

Whenever calculating the follow factor for a joint pair and one joint is
prismatic and the other is rotational, the units for the rotational joint
are radians NOT degrees.

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Activity: Leading Joints and Follow Factors (Gun)

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Introduction to Kinematic Cranks

This topic describes how to add cranks to a kinematic tree.
It contains the following subtopics:
• Crank Basics

• First Draw the Kinematic Tree

• Cranks

• Links and Joints of Cranks

• Activity: Kinematic Looping

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Crank Basics

In this topic we will use the following kinematics functionality that we have
not used yet:

• Kinematics —> Kinematics Editor

o Create Crank

There is often a need to create joints whose motion is described as a function of

other joints. Very often, these functions are complex. One very common device
is a bar actuated by a piston or solenoid. The bar pivots about one end when
the other end is moved by the piston. The piston must also be free to pivot.

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First Draw the Kinematic Tree

The first step in designing any kinematic device is to draw the kinematic tree.
Typically we represent each link as a box. We then draw arrows from the
parent link to the child link to show their kinematic relationship. Each of the
arrows are labeled to show which joint they represent.
For example, if we wanted to have four jogable joints, we would need to have
at least five links (one more link than joints). In some situations, such as a
crank, we will have five links and four joints, but only one of the joints is
jogable (independent). The other joints are dependant, using a function, on
other joints in the mechanism.

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Cranks

The Kinematics Editor enables you to define a crank, which is a kinematic

structure consisting of at least one independent joint and multiple dependent
joints that are joined in a kinematic loop. The following crank types can be
defined:
• Four-bar linkage — Crank consisting of four links and four rotational
joints, only one of which is independent (known as a "double crank" in
Process Simulate).

• Slider — Crank consisting of three rotational joints and one prismatic

joint, for example, a piston.

Cranks are created using a wizard that takes you step-by-step through the
process, including selecting the type of crank to be defined, the coordinates of
each crank joint and the entities that make up the links of the crank.

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Links and Joints of Cranks

The resulting kinematic structure from the crank creation wizard will contain
5 links, 3 dependant joints, and 1 independent joint.
The crank creation wizard can only be run once for any set of four links.
Changes can be made manually after that.

Cranks include the following links:

1. Fixed - The link that is not moved by the joints of the crank being defined.
(It may, however, be moved by a joint defined in a different kinematic
structure, including another crank.)

2. Input — The link moved by an independent joint.

3. Coupler — Link moved by a dependent joint.

4. Output — Link moved by a dependent joint that completes the kinematic

structure.

5. The Kinematics Editor also adds a dummy link (one without geometry)
to complete the loop of the kinematic structure (it is a surrogate for the
fixed link).

If you select a dependent joint and open the Joint Kinematics

Functions editor, you can view the calculations entered by the
system automatically to operate the joint. More on this later...

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Instructor Demo: Kinematic Looping

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Activity: Kinematic Looping

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Kinematic Branching
This topic describes how to create a kinematic tree with branching.
It contains the following subtopics:
• Branching Basics

• Gun Example of Kinematic Branching

• Activity: Gun Kinematic Definition (Part 1)

• Activity: Gun Kinematics (Part 2)

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Branching Basics

It is possible to have a more complex kinematic tree than a simple chain.

A kinematic link can have more than one child. This is how we create
a branching kinematic tree. Here is a simple example of an open-loop,
branching mechanism.
Kinematic Tree:

A kinematic tree has only one base and one TCP link. Usually, this is
not a robot. If the mechanism has a TOOLFRAME, and has an inverse
solution, only one branch is affected by the Move Loc command.

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Gun Example of Kinematic Branching

Let’s recall some of the simple kinematic trees we created so far. In general
they had one base link, which was connected to link1 by a joint. Link1 was
then connect to link2 and link2 was connect to link3 etc... This kinematic
chain was linear.
However in more complex kinematic examples, we may have kinematic
branching like in the following activity. This gun has 5 joints and 5 links that
are kinematically related (i.e. only one independent joint).

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Activity: Gun Kinematic Definition (Part 1)

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Activity: Gun Kinematics (Part 2)

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Defining Speed and Acceleration

This topic describes how to define joint speed and acceleration.
It contains the following subtopics:
• Speed and Acceleration Basics

• Activity: Speed and Acceleration

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Speed and Acceleration Basics

An important part of any kinematic definition is the maximum speed

and acceleration permitted for each joint. It improves the fluidity of the
simulation as well as makes cycle calculations time more accurate.
Definitions
• Speed - The maximum speed of a joint in the current linear or angular
unit per second.
o If the joint is a new joint for which no value is specified, the default is
100 mm/sec for prismatic joints or 90 degrees/sec for rotational joints.

• Acceleration - The maximum acceleration of a joint in the current linear

or angular unit per second per second.
o If the joint is a new joint for which no value is specified, the default
is 200 mm/sec2 for prismatic joints or 180 degrees/sec2 for rotational
joints.

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Activity: Speed and Acceleration

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Kinematics Basics

Defining Poses on the Gun Prototype

This topic describes how to add specific poses to a kinematic object.
It contains the following subtopics:
• Pose Definition Basics

• Activity: Defining OPEN, SEMIOPEN, and CLOSE Poses

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Pose Definition Basics

In this topic we will use the following kinematics functionality:

• Kinematics —> Home

• Kinematics —>Pose Editor

• Kinematics —>Joint Jog

In order to define a pose on the prototype, it must contain kinematics. Any

kinematic object can have poses stored with it. For example, spot weld guns
need to have the following three poses created for them (case sensitive):
CLOSE, OPEN, and SEMIOPEN.

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Activity: Defining OPEN, SEMIOPEN, and CLOSE Poses

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Defining an object as a Tool

This topic describes how to define an object so that it will be recognized as a
gun.
It contains the following subtopics:
• Tool Definition Basics

• Tool Definition

• How Do I Define a Gun for Searching?

• Activity: Create the TCP and MNT Frames

• Activity: Defining an object as a Spot Weld Gun

• Activity: Defining an object as a Gripper

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Tool Definition Basics

In this topic we will use the following kinematics functionality:

• Modeling —> Create Frames —> Frame by 6 values

• Modeling —> Tool Definition

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Tool Definition

The Tool Definition option appears in the Kinematics menu and in the
Kinematics toolbar. It enables you to define a device or mechanism as a tool,
for example, a weld gun. In this sense, a tool means an object that can be
mounted to a robot to enable it to perform a task such as welding or gripping
a part. The tool definition contains critical information about the position of
the TCPF on the robot on the tool.

Defining a resource as a “tool”, allows using the Mount Tool

command to position and attach the tool to the robot’s wrist and place
the TCPF of the robot (default controller) on the predefined frame of the
tool. All tools must contain kinematics.

Options for Tool Definition Types:

• Gun — defines the resource as a pneumatic spot weld gun or pedestal

welder. The gun should contain OPEN, SEMIOPEN, and CLOSE poses
that will be automatically used when spot welds are simulated.
These pose names are case sensitive.

• Servo Gun — defines the resource as a servo spot weld gun. In this case
the Mount Tool command will also define the joint of the gun as an
external axis of the robot to facilitate setting the gun’s joint value at each
location.

• Pneumatic Servo Gun — are not defined as robot external axes, so it is

controlled by OLP commands.

• Gripper — defines the resource as a gripper. They should contain poses

for setting the joint values at the part pick up and drop off locations. The
gripping entities defined here determine what objects will be attached to
the gripper at the part pick up locations.

• Paint Gun — defines the resource as a paint gun. Need to define the paint
gun tip frame (nozzel). It has dummy kinematics and is only used for
calculation of paint thickness and visualization of trigger states during
simulation.

• Other — defines the resource as something other what is specifically listed

(i.e. an arc weld torch). It is not necessary for you to define kinematics
for the object, since dummy kinematics will be automatically added to
the object.

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How Do I Define a Gun for Searching?

A object must be defined as a gun in order to participate in a Geometric

Gun Search .
Geometric Gun Search is a Process Simulate tool that is discussed later
in this course. It allows us to choose the best weld gun from a library of weld
guns based on various attributes and whether the gun can spot weld along
the path in your study without collision.
The gun defining is done while the gun is open in Process Simulate modeling.
The following is required to define an object as a gun:
• The object must be a device

• The device must have a TCP (Tool Center Point) frame

• At least the CLOSE state must be defined, but it is recommended to define

all the states (OPEN, CLOSE, SEMIOPEN).
These pose names are case sensitive.

• It must be defined using Tool Definition .

If these minimum demands are fulfilled, the object can be defined as a gun.
If there is a need for other states of the gun (OPEN, SEMIOPEN), they should
be defined as well.
To avoid a collision alert between the gun tips and the car part during the
Geometric Gun Search, you can define entities which do not participate
in the collision detection, using the no collision list command in gun define
toolbox. The selected entities will not participate in the collision detection
of the Geometric Gun Search. The no collision list does not affect regular
Process Simulate collision detection once you bring the gun into the study.

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Activity: Create the TCP and MNT Frames

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Kinematics Basics

Activity: Defining an Object as a Spot Weld Gun

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Activity: Defining an Object as a Gripper

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Assigning Attributes
This topic describes how to assign attributes.
It contains the following subtopic:
• Attribute Assignment Basics

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Attribute Assignment Basics

To add custom attribute values to a gun for use in the Power Bar searching,
the attributes must first be defined.
Usage:
1. In the Navigation Tree, browse into the Resource Library.

2. Select the gun prototype.

3. Check out the gun prototype.

4. Select View -> Open with -> Properties .

5. Select the Attributes tab.

6. Enter values for the desired attributes.

7. Check in the gun prototype.

• In the Navigation Tree, right click on the gun prototype and select
Check In .

• Click [OK].

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Adding Kinematics to a Simple Robot

This topic describes how to add kinematics to an object and move it around.
It contains the following subtopics:
• Simple Robot Kinematics Basics

• Activity: Adding Kinematics to a Robot Model

• Activity: Using Direct Kinematics to Move the Robot

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Simple Robot Kinematics Basics

In this topic, we will add kinematics to a simple robot. In this activity we

assume that the geometry was already created (either in Process Simulate or
somewhere else).

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Activity: Adding Kinematics to a Robot Model

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Activity: Using Direct Kinematics to Move the Robot

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Inverse Kinematics Device Creation and Usage

This topic describes how to create and use inverse kinematics devices.
It contains the following subtopics:
• Inverse Kinematics Definition

• Description

• Activity: Adding a Toolframe

• Activity: Using Inverse Kinematics to Move the Robot

• Activity: More Inverse Kinematics (Optional Extra Credit)

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Inverse Kinematics Definition

In this topic we will use the following kinematics functionality:

• Kinematics —> Kinematics Editor

o Create Toolframe

• Kinematics —> Robot Jog

• Kinematics —> Robot Jog with Locked TCPF

• Kinematics —> Mount Tool

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Inverse Kinematics Description

This topic describes how to create inverse kinematics devices. In general it

is easy. Just add a TOOLFRAME to the end of the primary branch (i.e. the
end effector) of the kinematic tree. However, not all kinematic trees can have
inverse kinematics.
Here are some basic rules:
• Use One End Effector - Make a kinematic tree with only one primary
branch. The other branches should contain dependant joints (i.e. loops).

• No Redundant Joints - Do not use redundant joints in the primary

branch.

• Look at the Primary Kinematic Branch Configuration - Follow the

kinematic tree from the fixed link to the end effector. Write down the
joint types in order. For example RPP refers to a kinematic tree where
the primary kinematic branch contains a revolute first joint, a prismatic
second joint, and a prismatic third joint. Compare this information to
the table below:

Example Primary Kinematic Branch Configurations with Inverse

Kinematics:
Primary Kinematic Branch
Number of Joints Configuration (from the regular
inverse kinematic solver)
3 PPP
3 PRP
3 PRR
3 RRR
4 PRPR
4 PRRR
4 RPPR
4 RRPR
5 PPPRR
5 PRPRP
5 RPPRR
5 RRPRR
5 RRRRR
6 PPPRRR
6 RRPRRR
6 RRRRRR

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A kinematic structure with three to six joints with a TCPF will use the
regular inverse solver. However if more than six joints with a TCPF
are needed, it will use the special inverse solver. Special inverse solver
can only be used with the default controller and is not supported by
compound equipment. In these cases if more than six joints are needed,
they should be defined into multiple devices and linked together using
either kinematic coupling or by defining external axes. This message
will be shown when defining devices with more than size joints:

Inverse Kinematics Usage:

• Robot Jog - drag the TCPF of the robot while leave the base fixed,
thereby moving all the joints of the robot at once (Inverse Kinematics)

• Robot Jog with Locked TCPF - drag the base of the robot while
leaving the TCPF of the robot fixed, thereby moving all the joints of the
robot at once (Inverse Kinematics)
In this simple topic, we will only be moving the robot without a tool
mounted to the end of the robot arm. In this case the TCPF is at the
TOOLFRAME of the robot. When the Mount Tool command is
used to place a valid tool at the end of the robot, the TCPF of the
robot jumps to the TCP frame of the mounted tool. This affects the
locations that are marked and used later in this activity.

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Activity: Adding a Toolframe

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Activity: Using Inverse Kinematics to Move the Robot

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Activity: More Inverse Kinematics (Optional Extra Credit)

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Summary
Subjects learned in this Topic:
• How to create some different types of object kinematics.

• How to add lead and follow factor to object kinematics.

• How to add cranks to a kinematic tree.

• How to create a kinematic tree with branching.

• How to add specific poses to kinematic object.

• How to define an object, as a gun.

• How to assign attributes

• How to add kinematics to an object and move it around.

• Got some background on inverse kinematics.

• How to create and use inverse kinematics devices.

Instructor Note:
Summary instructor notes.

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Lesson

10 Other Selected Modeling &

Kinematics Topics

Purpose
To provide information on other selected modeling and kinematics topics.

Objectives
After you complete this chapter, you should be familiar with:
• How to define a kinematic rail (a.k.a. 7th axis).

• How to use cranks to enhance more complex kinematic device

development.

• How to do more with kinematic functions.

• How to do a more complex example of kinematic functions.

• How to do another example with kinematic functions.

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Other Selected Modeling & Kinematics Topics

Rails, Gantries, and Positioners (External Axis Definition)

This topic describes how to define a kinematic rail (a.k.a. 7th axis), which is a
type of external axis.
It contains the following subtopics:
• External Axis Definition

• Activity: Sample Rail Creation Overview

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External Axis Definition

Rail, Gantry, and Positioner Definition:

Use what you have learned to:
• Model the desired geometry for a rail, gantry, or positioner

• Add the desired direct kinematics (no inverse is required)

In Process Simulate Rails, Gantries and Positioners are types of external

joints.
• Rail – It is a separate .COJT that consists of a single linear joint. A robot
is Attached to the child link of j1 (in the study, not in modeling).

• Gantry – It is a separate .COJT that consists of three linear joints. A

robot is Attached to the child link of j3 (in the study, not in modeling).

• Positioner – It is a separate .COJT that consists of 2 rotational joints.

The part is Attached to the child link of j2 (in the study, not in modeling).

• Other kinematic devices can be used as externals as well, these three

are provided as typical examples.

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Other Selected Modeling & Kinematics Topics

Activity: Sample Rail Creation Overview

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More Kinematic Branching and Cranks

This topic describes how to use cranks to enhance more complex kinematic
device development.
It contains the following subtopics:
• Complete Kinematic Basics

• Working with the Main Branch

• Attributes of Cranks

• Example of a Parallel Pantograph (a.k.a. four bar linkage)

• Example of a Non-Parallel Pantograph (a.k.a. four bar linkage)

• Example of a Prismatic Screw (a.k.a. slider linkage)

• RRRP Slider

• PRRR Slider

• PRRR Offset Slider

• RPRR Offset Slider

• RRRP Offset Slider

• Activity: Other slider cranks including Offset Cranks

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Complete Kinematic Basics

It is possible to have a more complex kinematic tree than a simple chain.

A kinematic link can have more than one child. This is how we create a
branching kinematic tree. Here is a simple example of an open-Crank,
branching mechanism.
Kinematic Tree

A kinematic tree has only one base and one TCP link. Usually, this is
not a robot. If the mechanism has a TOOLFRAME, and has an inverse
solution, only one branch is affected by the Move Loc command.

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Working with the Main Branch

The main chain starts at the base and ends in the TCP link. It is
recommended to build the main chain first and ensure that it works properly.
This may require making sure it has an inverse solution, if needed.

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Attributes of Cranks

Each Crank must consist of four links, and must be planar. To be planar
all the rotational joints must be parallel, and any prismatic joint must be
perpendicular to the rotational joints.
The four links are called fixed, input, coupler, and output. They occur in the
order mentioned (FICO). In a single Crank, the fixed and output links belong
to the main branch, while the input and coupler links are not accessible. The
input or the coupler is the "step" joint.
When two Cranks are connected, the output of the one Crank is the input of
the other Crank, and does not belong to the main branch.

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Example of a Parallel Pantograph (a.k.a. four bar linkage)

A Fanuc 420 is has an example of a parallel pantograph. This is a RRRR

Crank, and the bars define a parallelogram. The second link is the fixed bar,
the third link is the output bar. The vertical pantograph arm is the coupler
bar, and the horizontal pantograph arm is the input bar.

This is the same as the four−bar linkage crank.

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Example of a Non-Parallel Pantograph (a.k.a. four bar linkage)

A Kuka k662 has an example of this. This case is similar to the ABB irb 60
case. The pantograph in the ABB is a parallelogram, while in the Kuka it
is not. This difference is that in non-parallel pantographs, the motion of the
coupler cannot be calculated using a follow factor, because it is not linear. It is
the result of the structure of the robot.

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Example of a Prismatic Screw (a.k.a. slider linkage)

A Cincinnati 646 has an example of a prismatic screw (notice the sliders on

the back of the robot). Our lever attached to a piston is another example of
a prismatic screw. Each is an RPRR Crank, and the bars define a triangle.
The prismatic joint is the input joint. The prismatic joint intersects two
rotational joints (no offset allowed).

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RRRP Slider

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PRRR Slider

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PRRR Offset Slider

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RPRR Offset Slider

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RRRP Offset Slider

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Instructor Demo: Other Slider Cranks including RPRR Offset Cranks

Perform the related activity using the electronic activities.

.

10-24 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
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More on Kinematic Functions

This topic describes how to do more with kinematic functions.
It contains the following subtopics:
• Function Basics

• Process Simulate Function Definitions

• Implementation Notes

• Instructor Demo: Implementing Joint Logic with Functions (Optional

Activity)

• Instructor Demo: Kinematics Following a Surface (Optional Activity)

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Function Basics

From the Kinematic Editor window, clicking Joint Kinematics Functions

opens the Joint Kinematics Function window. It enables defining a joint
as a dependant joint. These commands define functions which receive the
values of the independent joint or joints, and which return the value of the
dependent (function) joint.
A dependant joint is a joint whose movement is totally dependent on the
motion of one or more other joints and which therefore does not constitute
an independent, accessible degree of freedom. It is not listed in the Joint jog
window together with the data for the active mechanism.
If a Joint jog window moves an independent joint, any dependent joints move
according to their functional dependence.

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Process Simulate Function Definitions

A function−joint function consists of an expression expr.
When expr includes a reference to an independent joint, that reference can
assume any of four different forms:
• t# d# Designate a rotational or prismatic joint, respectively, numbered #
in the order of the joints as determined when the mechanism is defined by
the mechanism define command. This order is determined by the system
and is subject to change if the mechanism is subsequently redefined. The
maximum allowable number of joints is 64.

• T(name) D(name) Designate a rotational or prismatic joint, respectively,

specified by its name determined when the joint was defined or as
subsequently renamed by the user.

The format of expr itself has one or more of the forms listed below. In all
of the forms, the spaces as shown are optional; thus (mnp) and ( mnp ) are
equally valid.
• ( string ) One of seven forms enclosed in parentheses ( ):

• Denavit−Hartenberg parameters one of a i o c s d t f followed by one or

more digits from 1 to Examples: (a1), (s5), (t32). The digit 0 cannot be
the first digit: (d08) is not allowed.
Accoding to Wikipedia.org: A commonly used convention for
selecting frames of reference in robotics applications is the Denavit
and Hartenberg (D-H) convention which was introduced by Jaques
Denavit and Richard S. Hartenberg. However Denavit−Hartenberg
parameters will not be discussed or used in this course.

• TCP matrix one of n o a p followed by one of x y z. Examples: (nx), (ay).

• Inverse TCP matrix m followed by one of n o a followed by p. Examples:

(mnp), (map).

• Tool matrix h followed by two digits each in the range 0 to 3. Examples:

(h10), (h33).

• Base matrix b followed by two digits each in the range 0 to Examples:

(b03), (b32). 0 or ±1: 0 or 1 or −Examples: (0), (−1).

• Sine or cosine abbreviation Uppercase S or C for rotational joints,

or lowercase s or c for prismatic joints, followed by one or more digits
from 0 to 9, to express the sine or cosine of the specified joint in radians.
This expression abbreviates references to joints in the format d# or t#; it
does not abbreviate expressions using D(name) or T(name). Examples:

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(S9) means (sin(t9)) for rotational joint 9; (s9) means (sin(d9)) for
prismatic joint (C1) similarly means (cos(t1)) and (c1) means (cos(d1)). An
expression like (sin(T(j2))) cannot be abbreviated.

• ( number ) A real number. A minus sign is prefixed if the value is negative.

If the value is a decimal fraction, a decimal point is appended and followed
by one or more digits; if the fraction is less than 1 the leading zero may be
omitted. If the value is a whole number, the .0 portion may be omitted.
Examples: (−0.21), (−.21), (200.03), (762).

• sin | cos | tan ( expr ) The respective trigonometric value of the expression
in radians. Examples: (sin(t3)), (cos(T(j3))), (tan(D(j1)/a3)).

• asin ( expr ) The arc sine of the expression, returning values in the range
−p/2 to p/Example: (asin(nx)).

• acos ( expr ) The arc cosine of the expression, returning values in the
range 0 to p. Example: (acos(nx0y−ny0x)).

• atan ( expr ) The arc tangent of the expression, returning values in the
range −p/2 to p/Example: (atan(31.7)).

• atan2 ( expr1 , expr2 ) The arc tangent of expression1 divided

by expression2, returning values in the range −p to p. Example:
(atan2(31.7,1.7)).

• sqrt ( expr ) The square root of the expression. Example: (sqrt(4)).

• ln ( expr ) The natural logarithm of the expression. Example: (ln(4)).

• exp ( expr ) The expression constituted as an exponent. Example: (exp(2)).

• pow ( expr1 , expr2 ) Expression1 raised to the power expressed by the

exponent consisting of expr. Example: (pow(10, 2)) returns 100.

• abs ( expr ) The absolute value of the expression. Example: (abs(−3))

returns 3.

• floor ( expr ) The largest integer not greater than the expression.
Example: (floor(27.9)) returns 27.

• ceil ( expr ) The smallest integer not less than the expression. Example:
(ceil(27.9)) returns 28.

• int ( expr ) The integer portion of the expression; the fractional portion
is truncated. Example: (int(27.9)) returns 27.

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• sgn ( expr ) The sign of the expression, returning 0 if the expression is

positive, 1 if the expression is negative. Example: (sgn(−3)) returns 1.

• ! ( expr ) Not the expression, where the expression is Boolean.

• rad ( expr ) The conversion of the expression to radians.

• deg ( expr ) The conversion of the expression to degrees.

• ( expr1 * expr2 ) The product of expression1 and expression2; the sign *

is optional.

• Pi – Pronounced pie, it has the value of approximately 3.14

• 1/x – Inverse of x.

• ( expr1 + expr2 ) The sum of expression 1 and expression2; expression2

may itself be a sum of two or more expressions. Example: (2+(3+(3)))
returns The parentheses are required.

• ( expr1 / expr2 ) The quotient of expr1 divided by expression2; expression2

may be a sum of two or more expressions. Example: (6/(1+2)) returns The
parentheses are required.

• ( expr1 % expr2 ) The remainder of expression1 divided by expression2;

expression2 may be a sum of two or more expressions. Example: (9%7)
returns 2.

• ( expr1 == expr2 ) Return 1 if the indicated expressions are equal, 0 if the

comparison is false.

• ( expr1 != expr2 ) Return 1 if the indicated expressions are not equal, 0

if the comparison is false.

• ( expr1 >= expr2 ) Return 1 if expression1 is greater than or equal to

expression2, 0 if the comparison is false.

• ( expr1 <= expr2 ) Return 1 expression1 is less than or equal to

expression2, 0 if the comparison is false.

• (( expr1 > expr2 ) Return 1 expression1 is greater than expression2, 0

if the comparison is false.

• ( expr1 < expr2 ) Return 1 expression1 is less than expression2, 0 if the

comparison is false.

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• ( expr1 && expr2 ) Boolean and: evaluates Boolean expressions expr1 and
expr2 in the order given and returns 1 if they are both true, 0 otherwise. If
expr1 is false, this function returns 0 and exits without evaluating expr2.

• ( expr1 || expr2 ) Boolean or: evaluates Boolean expressions expr1 and

expr2 in the order and returns 0 if they are both false, 1 otherwise. If expr1
is true, this function returns 1 and exits without evaluating expression2.

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Implementation Notes

The Process Simulate function-joint implementation is heavily dependent

on nested parentheses. When formulating a formula, ensure that the
parentheses are properly placed and balanced.
The command line and editor commands verify user-supplied functions and
issue error messages if the syntax is incorrect.

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Instructor Demo: Implementing Joint Logic with Functions (Optional

Activity)

Perform the related activity using the electronic activities.

.

10-32 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
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Instructor Demo: Kinematics Following a Surface (Optional Activity)

Perform the related activity using the electronic activities.

.

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The Train Joint - Function Example

This topic describes how to do a more complex example of kinematic functions.
It contains the following subtopics:
• Train Joint Basics

• Defining the Train Joint

• Instructor Demo: Examine the Train Joint

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Train Joint Basics

You can create many different complex devices in Process Simulate. The
following explains the theory and creation of one such device. It is called the
train joint due to its similarity with an old time steam drive train. It is a
common joint that converts rotary motion into linear motion.
There are several versions:
• One in which the wheel drives the prismatic link via bar linkage.

• Another in which the wheel drives the prismatic joint directly.

We will do the bar linkage joint first.

The model consists of four entities:
• A bracket to hold the axle, the wheel, and two connector bars.

One bar is connected to the wheel and has a rotational joint at each end. The
other bar is connected to the first bar and has linear motion.

There are three (3) joints created. The first joint (axle) is the point of rotation
of the wheel. The second joint (cpin) is the attach point of the bar to the
wheel. And the third joint (barpin) is the attach point of one bar to the other.
The resulting device will drive bar2 prismatically when the wheel turns. We
will need to solve for the values of cpin and barpin. They both need to be a
function of axle.
At any given time we know certain values. We know the joint value of axle
and the length of the bars. And at any given time, the three joints form a
triangle. Using the known values and the law of sines we can solve for the
unknown joint values.

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Defining the Train Joint

First let us define some variables:
• axle - joint value of axle joint

• RL1 - the distance from the pivot point of the wheel and the pivot point
of the connector bar.

• BA1 - first angle of triangle

• BA2 - second angle of triangle

• BA3 - third angle of triangle

• BL1 - length of connecting bar 1 (distance between pivot points)

• BL2 - length of connecting bar 2 (distance between pivot points)

From the law of sines:

• sin(BA1) / BL1 = sin(BA2) / RL1

• (RL1 / BL1 ) * sin(BA1) = sin(BA2)

Since RL1 and BL1 are both constants we can replace them with C. And we
want to find BA2 so we take the asin of both sides. Giving us:
• BA2 = asin( C * sin(BA1) )

We can now have 2 of the three interior angles of the triangle defined. And
given that the sum of the angles must be 180 we can solve for the third.
• BA1 + BA2 + BA3 = 180

• BA3 = 180 BA1 BA2

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Substituting the solution for BA2 back in:

• BA3 = 180 BA1 asin( C * sin(BA1) )

We can now have functions for BA2 and BA3 based on BA. But Process
Simulate requires that we solve for the joint values and our current functions
solve for angles. The joint value is 0 for the HOME or starting position.
The joint value at any other time is just the change in joint angle from the
starting angle. So joint value can be found by subtracting the starting joint
angle from the current joint angle.
Let’s establish some new prefixes.
• OA actual angle at start or HOME position (OA1, OA2, OA3)

• JA joint value (JA1, JA2, JA3)

Process Simulate gives us a joint value (JA1). So BA1 becomes:

• BA1 = OA1 + JA1

The joint value for BA2 is calculated by subtracting the original angle of
BA2 from the current angle of BA2.
• JA2 = BA2 OA2

Substituting our angle calculation for BA2:

• JA2 = asin( C * sin(BA1) ) OA2

Substituting joint value calculation for BA1

• JA2 = asin( C * sin( OA1 + JA1 )) OA2

For Process Simulate the constants C, OA1 and OA2 must be calculated.
• C = RL1 / BL1

In our example RL1 = 478.13 and BL1 = 1500.0

• C = 478.13 / 1500.0 = 0.3187558

• OA1 = 0 radians

• OA2 =0 radians

• JA1 = 0 radians

The actual Process Simulate function becomes:

• ( asin ( ( 0.3187558 ) * sin( ( T(axle) + (0.0) ) ) ) (0.0) )
Depending on the direction of the axis of j1, we may need to multiply
this quantity by −1.0

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The additional parentheses are required for the function parser.

Lastly we need to generate the joint values for JAgain we know that the joint
value is the current joint angle minus the original joint angle.
• JA3 = BA3 OA3

Substituting in the formulas for the angle calculations:

• JA3 = 180 BA1 asin( C * sin(BA1) ) OA3

Substituting joint value calculation for BA1:

• JA3 = 180.0 ( OA1 + JA1 ) asin( C * sin( OA1 + JA1 )) −OA3

Converting to radians and substituting for constants the actual function to

put in Process Simulate is:
• ( (3.1415927) ( ( 0.0 ) + T(axle) ) asin( ( (0.3187558) * sin( ( (0.0) + T(axle) )
) ) ) (3.1415927) )

Process Simulate allows for both positive and negative joint values. For
revolute joints the sign is determined by the right hand rule. In our
example, JA3 must rotate in the opposite direction from JAThis means
that the axis for J1 and J2 should be in the same direction but the axis
for J3 should be in the opposite direction. If all three axis are created in
the same direction, then the function becomes:

• ( (3.1415927) ( ( 0.0 ) + T(axle) ) + asin( ( (0.3187558) * sin( ( (0.0) + T(axle)

) ) ) ) + (3.1415927) )

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Instructor Demo: Examine the Train Joint

Perform the related activity using the electronic activities.

.

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The Cam Joint - Function Example

This topic describes another example with kinematic functions.
It contains the following subtopics:
• Cam Joint Basics

• Defining the Cam Joint

• Instructor Demo: Examine the Cam Joint

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Cam Joint Basics

Another popular joint is the piston or cam type joint. This joint too converts
revolute motion to prismatic motion. But there are only two joints and no
bar linkages.
The motion we need to define is such that as the wheel rotates a bar moves
back and forth. As the angle of rotation goes from 0 to 180 the bar will move
in one direction. While the angle of rotation goes from 180 to 360 the bar
will travel in the opposite direction.
If joint angle of axle is between 0 and 180 then prismatic joint value is
between 0 and maximum stroke. And the prismatic value increases as the
axle joint angle increases.
If joint angle of axle is between 180 and 360 then the prismatic joint value is
between maximum stroke and 0. The prismatic value starts at max stroke
and decreases as the axle joint angle increases.
So our basic function becomes:
• if ( axle > =180 )

• then

• prismatic = max ( axle * factor )

• else

• prismatic = axle * factor

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Defining the Cam Joint

For ease of understanding we will first define some terms and then the
function
Normalize angle:
• ANG angle to be normalized

• NF1 value to be normalized to in radians for check 2 * PI

• NF2 value to be normalized to in radians for joint value calculation PI

• INT integer portion of a number. fractional portion is truncated.

• ANORM(ANG, NF) = ( ANG ( ( INT( ANG / NF ) ) * NF ) )

Follow factor:
• PMT maximum prismatic joint travel in mm.

• RPC number of radians in cycle ( PI )

• FF = ( PMT / RPC )

Sine and Cosine:

• sine of an angle is negative if the angle is between 180 and 360.
o sin(angle) < 0 if 180 < angle < 360

• Sine of an angle is positive if the angle is between 0 and 180.

o sin(angle) > 0 if 0 < angle < 180

• How do we check for angle = 0 and angle = 180?

o cos(angle) =

o −1 if angle = 180

o 1 if angle = 0, 360

Taking our original joint value function:

• if( axle >= 180 )

• then

• prismatic = max ( axle * factor )

• else

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• prismatic = axle * factor

Substituting our definitions the joint value function becomes:

• If ( ( cos(axle) = −1) || (sin(axle) < 0) )

• then

• prismatic = PMT ( FF * (ANORM(axle, NF2) )

• )

• else

• (

• prismatic = FF * ANORM(axle, NF2)

• )

Our original function uses one joint value calculation between 0 and 180 and
another calculation between 180 and 360. Since Process Simulate does not
have an if−then−else structure we must simulate one. Booleans are provided.
They are evaluated and return 0 for FALSE and 1 for TRUE. So, to get the
affect of if−then−else, we will use two checks and a summation. We will
multiply the joint value calculation by the result of the check. If the check
is false, then the result of the joint value calculation will be multiplied by 0.
We create the checks so that only one is true at a time. Then if we add the
two functions together we will get one joint value times 0 plus one joint value
times The effect is that when one check is true we will calculate the joint
value using its associated function.
Our new function definition becomes:
• (( ( cos(axle) = −1) || (sin(axle) < 0) ) * (PMT ( (FF) * (ANORM(axle, NF2))
) ) ) ) + (( ( cos(axle) = 1) || (sin(axle) > 0) ) * ( (FF) * (ANORM(axle, NF2)) )

So we can now plug in the constants and formulas for the actual Process
Simulate function.
• PMT = 42 inches = 1066.8 mm

• RPC = 180 = PI

• NF1 = 360 = PI * 2.0 = 6.2831853

• NF2 = 180 = PI = 3.1415927

• FF = 42.0 in / PI = 1066.8 / 3.1415927 = 339.57299

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• ANG = T(axle) joint value of axle joint

The final format ready for input to Process Simulate:

• (

• ((

• cos(T(axle)) == (−1.0) ) || ( sin(T(axle)) < (0.0)

• )*

• (

• (1066.8) −

• (

• (339.57299) *

• (T(axle) (( int(( T(axle) / (3.1415927) ) )) * (3.1415927) ))

• )

• )

• )

• +

• (

• (

• cos(T(axle)) == (1.0) ) || ( sin(T(axle)) > (0.0)

• )*

• (

• (339.57299) *

• ( T(axle) (( int(( T(axle) / (3.1415927) ) )) * (3.1415927) ) )

• )

• )

• )

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Since Process Simulate produces both positive and negative joint

values, we might want to take the absolute value of the result to keep
the motion consistent regardless of the direction axle is rotated.

Since the sine and cosine functions are not continuous we may want to use
the following function instead.:
• 339.5729923 * ( (3.1415926) (abs(((rad(((deg( (T(axle)) ) ) % (360) )))
(3.1415926) ))))

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Instructor Demo: Examine the Cam Joint

Perform the related activity using the electronic activities.

.

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Compound Equipment
This topic describes compound equipment.
It contains the following subtopics:
• Compound Equipment Overview

• Equipment Basics

• Creating Equipment

• Reconciling Navigation Tree Instances

• Kinematic Coupling

• Activity: Setting up Compound Equipment

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Compound Equipment Overview

Functionality
• Support assemblies including kinematics and PLC information

• Supporting monolithic JT which includes kinematics

Why is this important to you?

• Support assemblies structures

• Support compound kinematics and PLC information

• Enable getting updates from the CAD without losing the kinematics
information (JT can be modified independently)

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Equipment Basics
Process Simulate supports the use of hierarchies of objects called Equipment.
Changing the 3D representation, name or positions of the children of such
nodes always requires modeling. Since Process Simulate does not support
changes to the hierarchy in the Object Tree, such as adding or removing
children to Equipment, it is necessary to perform these changes in the
Navigation Tree.
Users can construct a compound device from a number of Equipment objects
— Creating Equipment, Reconciling Navigation Tree Instances. Compound
devices are similar to regular devices - they are composed of links, joints and
frames. While both regular and compound devices can be constructed using
most Kinematics dialogs, the main differences between them include:
• The joints of compound devices move sub assemblies but not entities.

• Compound devices can be nested, while regular devices cannot.

• The joints of compound devices can be connected to each other using

’coupling’.

• Attachments between nested devices can be created. In contrast to

regular attachments, these attachments are saved with the prototype.
The attachment parent must be either a link geometry of a
PLMXML device or a link object of a JT device.

The joints, links and frames of compound devices are always associated with
a single node - the root node of the device.
This node is not necessarily the root node of the Equipment.

To create a compound device, start modeling this node and use the regular
Kinematics Editor to create the links and joints. The Link Properties dialog
allows you to select the link geometries. For a compound device you can select
only sub assemblies but not entities
You can create nested devices by building kinematics for both a root and a
child node of Equipment and you can connect joints of nested devices using
the Joint Function dialog. Nested devices are useful, for example, to build
fixtures consisting of several identical clamps.
Kinematics data of compound devices is stored separately from the geometric
data. Thus it is possible to update the geometry from CAD without losing
the kinematics. It is also possible to use JT kinematics as leaf nodes in
Equipment. Poses that are defined for a nested compound device contain both
the joints of the root device and all joints of the sub devices.

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Other Selected Modeling & Kinematics Topics

Also, the Logic Block command supports Connecting Subcomponents within a

Compound Instance.

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 Other Selected Modeling & Kinematics Topics

Creating Equipment

Users can create Equipment prototypes and construct their

hierarchies in Resource libraries:
1. Create a new Equipment prototype object under the desired Resource
library.

2. Drag and drop other Equipment prototypes or Tool prototypes to the new
Equipment prototype to create children.

3. Equipment can always be modified by adding or deleting children.

4. Equipment instantiation is performed the same way as the instantiation

of any other object in the Resource library.

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Other Selected Modeling & Kinematics Topics

Reconciling Navigation Tree Instances

After Creating Equipment, you can modify a prototype from the Resource
library, for example, adding a prototype instance to, or deleting it from
an Equipment prototype. In this case, there are differences between the
prototype and its instances in the Navigation Tree, as shown in the diagram
below. In the Resource library in the right pane, the Tp1 instance was added
to the EqProto3 equipment prototype. This change is not reflected in the
instance of EqProto3 in the left pane.

To reconcile (synchronize) all the instances of Navigation Tree:

The Reconcile Instances command can be added to the Process

Simulate menu by selecting Tools —> Customize.

• Select the EquipmentPrototype instance and select Reconcile Instances

. The following figure shows that the Navigation Tree instances are
now synchronized:

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 Other Selected Modeling & Kinematics Topics

Kinematic Coupling
To define coupling
1. Select the compoundEquipment being modeled.

2. Select Kinematics —> Kinematics Editor .

3. In the Kinematics Editor, select a joint of a sub-device to become

dependant and click Joint Kinematics Functions .

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Other Selected Modeling & Kinematics Topics

4. In the Joint Kinematics Function window, coupling is enabled if you are

editing compound kinematics.
Select this option if you wish to define dependency between the
selected joint and a joint of a sub device in the device hierarchy.

5. For Leading Joint, select the joint upon which to base the dependency.

6. For Factor, enter a dependency factor.

For example, if the leading joint of the sub-device is rotated by 3
degrees and you entered a factor of 5, the joint is rotated by 15
degrees.

7. Click Apply.

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 Other Selected Modeling & Kinematics Topics

The joint function is applied to the dependent joint.

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Other Selected Modeling & Kinematics Topics

Activity: Setting up Compound Equipment

Perform the related activity using the electronic activities.

.

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 Other Selected Modeling & Kinematics Topics

More Topics (Not Covered in Class)

This topic briefly describes some other kinematics related functionality not
directly covered in this course.
It contains the following subtopics:
• Advanced Kinematic Definitions

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Other Selected Modeling & Kinematics Topics

Advanced Kinematic Definitions

Functionality
• Support .e file in process simulation
The .e file, pronounced “dot e” file, is an ASCII text file stored under
the robot model’s .CO folder containing measured robot motion
parameters such as speed, accel/decel, zones, configurations, and
delay/settle times.
Simulation packages contain only limited knowledge about the
robot’s technical capabilities such as reach, speed, limits etc… Other
information such as payloads, momentum, acceleration, and similar
parameters where limited. The .e file was the initial solution for
this problem (i.e. it was the pre-RRS technique). Tecnomatix
engineers performed measurements on the robots themselves in
order to determine specific parameters (i.e. a very long process
requiring intimate knowledge of the robot).
The syntax for this file can be found in the Robcad online help.

• Allows the use and editing of former Robcad .e files

Upgrade to Version creates the motionparameters.e file (which is a
duplication of the original .e file) in the .co or .cojt folder. Comments
in the original .e file are not copied to the new motionparameters.e
file unless they are wrapped with begin text/end text tags.

• Uses Microsoft Windows legal file naming format (e.g.

motionparameters.e)
Process Simulate can read motionparameters.e files located under
..co or .cojtfolders. There are cases where users open a device for
modeling from the object folder (but not directly from a .jt file) with
integrated .e file data. If there is no motionparameters.e file under
the folder, the system creates it with the .e content when saving the
modeled device in the study/library.

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Why is this important to you?

• More accurate behavior of devices

• Reuse legacy Robcad data

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Other Selected Modeling & Kinematics Topics

Summary
Subjects learned in this topic:
• How to define a kinematic rail (a.k.a. 7th axis).

• How to use cranks to enhance more complex kinematic device

development.

• How to do more with kinematic functions.

• How to do a more complex example of kinematic functions.

• How to do another example with kinematic functions.

Instructor Note:
Summary instructor notes.

10-60 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
Lesson

11 General Robotics

Purpose
To provide an introduction to Process Simulate.

Objectives
After you complete this topic, you should be familiar with:
• The basic concepts of Process Simulate will be discussed.

• An overview of robotics

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General Robotics

Process Simulate Assembler

Process Simulate Assembly allows users to verify the feasibility of an
assembly process. It enables manufacturing engineers to determine the most
efficient assembly sequence, catering for collision clearance and identifying
the shortest cycle time. Process Simulate Assembly provides the capability
to select the most suitable tool for the process by searching a classified tool
library, performing virtual reach tests and collision analysis and simulating
the full assembly process of the product and the tool together.

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 General Robotics

Creating a Study (Again)

In this Topic, we will create an empty study in the Navigation Tree to open
Process Simulate. For other Activities in class, we will use pre-existing
studies.
It contains the following subtopics:
• Activity: Creating a New Study (Again)

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General Robotics

Activity: Creating a New Study (Again)

Perform the related activity using the electronic activities.

.

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 General Robotics

Robotics Overview
This provides an overview of key robotics terms and robotic applications.
Many of which will be used in this course.
It contains the following subtopics:
• Robotics Introduction

• Robotics Applications

• Activity: Training Data Overview

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General Robotics

Robotics Introduction
According to Wikipedia.org: The field of robotics may be more practically
defined as the study, design and use of robot systems for manufacturing
(a top-level definition relying on the prior definition of robot). Typical
applications of robots include welding, painting, assembly, pick and
place, packaging and palletizing, product inspection, and testing, all
accomplished with high endurance, speed, and precision.

This training course assumes that the attendees are somewhat familiar with
industrial robotics, their uses, and related terms such as:
• Teach pendant

• Payload

• Working envelope

• Kinematics

• Singularity

• Seventh Axis

• Degrees of freedom

• Tool center point

• etc..

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 General Robotics

Robotics Applications

The goal of this class is too make several collision free robotic simulative
operations for different robotic applications.

According to Wikipedia.org: The field of robotics may be more practically

defined as the study, design and use of robot systems for manufacturing
(a top-level definition relying on the prior definition of robot). Typical
applications of robots include welding, painting, assembly, pick and
place, packaging and palletizing, product inspection, and testing, all
accomplished with high endurance, speed, and precision.

There are many types of robotics applications. In this course we will cover
robotic path develop in these key areas:

• Spot Welding Applications — For example:

o Spot Welding with the weld gun mounted on the robot (using
pneumatic or servo weld guns)

o Ped. spot welding (Part grasped by a gripper mounted to the robot)

• Material Handling Applications — For example:

o Assembly

o Packing/Palletizing

o Part Transfer

o Etc ...

• Continuous Applications — For example:

o Arc Welding

o Gluing/Dispensing

o Laser cutting

o Painting

o Grinding/Deburring/Material Removal/Polishing

o Etc ...

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General Robotics

Activity: Training Data Overview

Perform the related activity using the electronic activities.

.

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 General Robotics

Summary
Subjects learned in this Topic:
• The basic concepts of Process Simulate will be discussed.

• An overview of robotics

Instructor Note:
Summary instructor notes.

Process Simulate on eMS Basic Robotic Simulation Student Guide 11-9

Lesson

12 Spot Welding Applications

Purpose
To provide an introduction to Process Simulate.

Objectives
After you complete this topic, you should be familiar with:
• The basic terms and processes of spot welding

• Basic Process Simulate Robotics path development process.

• Some background information regarding manufacturing feature

representation.

• How to project welds to create weld locations.

• How to make some changes to the weld path associated to the weld
operation.

• The Weld —> Multi Section tool

• How to use the Weld Distribution Center (WDC)

• The process methodology used in this topic

• Overview of how to define poses for kinematic devices.

• How to set up the Scenario.

• How to maneuver the part in and out of the fixture.

• How to create a rough mounted workpiece (external TCP or pedestal

welding ) path.

• How to orient the locations on a gripped part.

• How to use the Geometric Gun Search tool.

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Spot Welding Applications

• How to use servo guns.

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 Spot Welding Applications

Spot Welding Primer (Optional Topic)

This topic describes the basic terms and processes of spot welding.
It contains the following subtopics:
• Spot Welding Basics

• Designing a Spot-Welding Line

• Design Targets

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Spot Welding Applications

Spot Welding Basics

The automotive industry utilizes spot-welding as the most common method

of joining metal sheets. This method uses high pressure and current to melt
two sheets at their point of contact, such that when the melted areas harden
they are fused together. The process historically used for spot-welding on
a mass-production basis was hard automation, in which many points are
welded together at one time. This method is rapid, but suffers from the
disadvantage of being extremely inflexible: model changes require extensive
and expensive rebuilding of manufacturing machinery, thereby encouraging
manufacturers to continue producing obsolete models to the detriment of
their ability to compete.
The introduction of robotic spot welding, to which this document applies, has
brought a new level of flexibility to manufacturing. This process spot-welds
points one at a time, using either a general-purpose or a specially built
robot which carries a welding gun constructed from a variety of mechanical,
electrical and hydraulic components.
The points to be spot-welded usually have diameters of 6−8 mm, are spaced
10−400 mm apart, and should be located a few millimeters or more away from
the edges of the metal sheets. Spot-welding guns usually have three poses:
fully open, half open, and closed. One arm usually is movable and the other
arm is either fixed or has a very limited range of movement.
With some manufacturers, the engineer who designs the spot-welding lines
also constructs his own spot-welding guns from basic components: cylinders,
valves, transformers, etc. Other manufacturers purchase the gun as a single
unit, and the engineer needs only to select the geometry of the shanks. Still
other manufacturers stock the guns complete with their shanks, requiring
the engineer to select only the gun itself.
Welding controllers control the welding guns. They typically supply five to
sixteen different sets of welding currents and current times, and are activated
by output signals from the welding robots.

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 Spot Welding Applications

Designing a Spot-Welding Line

The engineering department responsible for designing the robotic lines,

receives drawings of the individual segments from the design department.
The engineering department then determines the number and location of the
welding points, and also designs the clamps and arranges them on the fixture.
This process is designated weld study; it produces welding points marked
on the drawing.
The next stage, frequently performed by the same department, is designing
the robotic lines; this operation includes:
• Assigning welding points to each robot

• Assigning a welding gun and shanks to each robot

• Assigning the order of welding the points and the order of the robots

• Placing the robots and the workpieces relative to each other

All of these steps, together with writing the programs for the robots, are
intended to be performed on the Process Simulate workstation.

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Spot Welding Applications

Design Targets

The entire design process may require several hours average time per
welding point.
Despite the time required, the design is prone to errors and still leaves much
work for the implementation stage, resulting in a further waste of time and
money. The final design then falls short of optimum. To minimize these
problems, the design work has several clearly defined goals:
• Determining the correct welding-gun geometry, particularly the shanks,
so as to enable reaching all welding points without collision, while
minimizing cycle time and welding-gun weight.

• Assuring reachability to all welding and intermediate (via) points, without

collision and with an optimal (minimal) cycle time.

• Assuring maximum usage of stock equipment: robots, guns, shanks, tips,

etc.

• Detecting design errors at the design stage.

12-6 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Spot Welding Applications

Process Methodology
This topic gives an overview of the basic Process Simulate Robotics path
development process.
It contains the following subtopics:
• Basic Principles

• The Process: From Least Constraints to Most Constraints

• Strategic Planning

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Spot Welding Applications

Basic Principles

Robot Program:
• When using a teach pendant, the robot is moved to a position and the
joint angles are recorded.

• Robot Program consists of ...

• A SEQUENCE of poses consisting of JOINT ANGLES with associated

INSTRUCTIONS

Process Simulate Robotics Program:

• Process Simulate Robotics uses Inverse kinematics to determine the joint
values needed to reach a given target location.

• Process Simulate Program consists of ...

• A PATH which consists of TARGET LOCATIONS (Position and

Orientation) with associated ATTRIBUTES

• With this definition of a program, the process in Process Simulate is

independent of the robot and the tool. Later, the Process Simulate
program can be downloaded to robot program, so that it can control the
robot. This gives the flexibility in Process Simulate to select a different
robot at any time before we download.

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 Spot Welding Applications

The Process: From Least Constraints to Most Constraints

In Process Simulate, we start with the simplest situation: a part and a path.
Then we slowly add one more piece to the scenario (study)–such as weld
guns, robots, fixtures, etc…–until the path is perfected. Here is the process
we follow:
1. Define the guns (geometry and kinematics), if they are not already

2. Create and load a scenario (study) with Process Simulate.

3. Layout (position) the contents of the scenario (study)

4. Project weld points to create target locations on the workpiece.

5. Check orientation of the target locations using a first approximation gun.

6. Create first approximation sequence of locations using a robotic simulative

operation (weld path).

7. Cut sections and search for valid guns to perform the welding.

8. Perform a first run along the path.

9. Add robot and test reachability of robot.

10. Check for collisions and adjust path.

11. Optimize path cycle time.

12. Repeat this process for other robots in the scenario (study)

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Spot Welding Applications

Strategic Planning

Begin the design process with strategic planning, by viewing the spot-welding
line as a whole. At the workstation equipped with the Process Simulate, load
the complete Scenario (study) with an approximate, preliminary placement of
its objects. Then observe the Scenario (study) to answer these questions:
• How should each robot be positioned relative to the workpiece?

• What type of welding gun should be used?

• Which welding points on the workpiece will each robot handle?

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 Spot Welding Applications

Weld Representation
In this topic, we will discuss some background information regarding
manufacturing feature representation.
It contains the following subtopics:
• Manufacturing Feature Types

• Viewing Manufacturing Features

• Sources for Manufacturing Features

• Sources for Basic Manufacturing Feature Orientation

• Activity: Viewing Spot Mfg Features in Process Simulate

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Spot Welding Applications

Manufacturing Feature Types

There are several types of Manufacturing Features, However, on these types

will be discussed in this course:
• Weld point – Used to represent spot welds. Does not have any associated
geometry.

• Continuous Mfg – Used to represent arc weld seams. It can

also be used to represent other continuous processes such as Arc
welding, Gluing/Dispensing, Laser cutting, Painting, Material
Removal/Grinding/Deburring/Polishing, etc… Has geometry (i.e. a curve
or line) associated to it. This type is covered in another topic later in
this course

Another Manufacturing Feature type, PLP, will not be discussed in

this course. It is used to represent the point where the part is being
constrained (i.e. clamped).

These Manufacturing Feature types represent a theoretical position (without

orientation) of the robot TCP on the part. Each Manufacturing Feature can
also contain several attributes.

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 Spot Welding Applications

Viewing Manufacturing Features

Where to Look for Mfg Features:

• Operations Tree — Mfg Features are shown here as a child of the
simulative operation they are related to (until they projected to create the
location operations)

• Graphic Viewer — Mfg Features are shown here until they are projected
to create locations (then they are blanked by default)

• Mfg Viewer — Mfg Features are always shown here.

Mfg Viewer:
This viewer contains a filterable table of Mfg features. It contains various
columns of attributes that can be added and other functionalities including:
• Find by Caption — Find a Mfg Feature based on its caption

• Unassign — Unassign a Mfg Feature from a part

• Customize — Enables you to select the MFG attributes that are

displayed in the MFG Viewer.

• Filter by Type — Filters the display of the MFG Viewer based on

the Mfg Feature type.

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Spot Welding Applications

Sources for Manufacturing Features

Manufacturing features are always tied to one or more parts. In order
to “see” a Manufacturing feature in Process Simulate in must be created
and associated to a part that is either associated to the study directly or
indirectly (indirectly means it’s associated to a part that is associated to
an operation associated to the study).

For Weld Points:

• Imported into Process Designer
o From Teamcenter (created in a CAD system like NX)

o From a XML file (created in a CAD system or external other system)

• Created in Process Designer or Process Simulate

o In the Navigation Tree, right click a Mfg Feature Library and select
New . From the New window, select Weldpoint.

o etc...

• Created in Process Simulate

o Weld —> Spot —> Create Weld Point by Coordinates

o Weld —> Spot —> Create Weld Points

o Weld —> Spot —> Create WP on Robot’s TCPF

By default Mfg Features show in the Graphic Viewer as a red square and are
also displayed in the Mfg Feature viewer.

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 Spot Welding Applications

Sources for Basic Manufacturing Feature Orientation

For Weld Points:

• Obtain Weld Orientation from Process Simulate

o Weld —> Spot —> Project Weld Points

• Obtain Weld Orientation from CAD (NX or CATIA)

o Weld —> Spot —> Obtain Weld Orientation

Using either of these two commands with weld points produces a location
operation for each Manufacturing feature. The location operation contains
the position and orientation of the robot TCP at the manufacturing feature.
The orientation of the location operation can be further refined using various
tools in Process Simulate which will be described later in class.

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Spot Welding Applications

Activity: Viewing Spot Mfg Features in Process Simulate

Perform the related activity using the electronic activities.

.

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 Spot Welding Applications

Projecting Spot Mfg Features

This topic describes how to project welds to create weld locations.
A location in Process Simulate is unique type of frame that contains the
position and orientation of the TCP frame at a point. Locations are generated
with their origins placed according to where the projection of the related
curve intersects a surface or solid it is projected onto. The locations guide the
tool center point of the robot approach vector and a vector perpendicular
to the workpiece.
Locations also contain process information specific to spot welding such as:
Gun state, Location type, Speed, etc... for each location.
It contains the following subtopics:
• Weld Location Constraints

• Projecting Weld Locations

• Activity: Projecting Weld Points

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Spot Welding Applications

Weld Location Constraints

Weld locations must be on the surface and one axis must be perpendicular to
the surface.
A Weld location’s orientation is very important.
Weld Location Orientation:
• Perpendicular — One axis has to be perpendicular to the surface being
welded in order to create a high quality and efficient weld. This axis is set
by default to Z.

• Approach Vector — Another axis indicates the direction of approach of

the weld. This axis is set by default to X.

Default approach and perpendicular axis are defined and can be

modified by selectingTools -> Options and choosing the Weld tab.

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 Spot Welding Applications

Spot Weld Permitted Devision Angle:

This refers to the amount that the surface tangent axis are allowed to deviate
from tangent (thereby deviating the Z-axis from perpendicular.
• Approach — By default the X-axis.

• Third Axis — By default the Y-axis.

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Spot Welding Applications

Projecting Weld Locations

Weld —> Spot —> Project Weld Points produces welding locations, while
maintaining the weld location constraints mentioned above. The resulting
weld locations are on the surface and one axis, by default Z, is perpendicular
to the surface.

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 Spot Welding Applications

• Select the desired Spot Mfg Features or Simulative Operation containing

Spot Mfg Features.

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Spot Welding Applications

• Check Align projection with outer surface to align the weld location with
a more accessible surface.

• Check Project on approximation only.

Only JTs in the XTBRep format support projecting weld points on
exact geometry. If the part exact geometry is not available in the
JT file (i.e., it is a location that did not retrieve the exact geometry),
users are asked whether to project based on an approximation
or skip the projection for the weld points which failed for exact
projection.

12-22 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Spot Welding Applications

Activity: Projecting Spot Weld Mfg Features

Perform the related activity using the electronic activities.

.

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Spot Welding Applications

Creating and Editing a Weld Path

In this topic, we will make some changes to the weld path associated to the
weld operation.
It contains the following subtopics:
• Verifying the Weld Location Orientation

• Activity: Adjusting a Weld Path

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 Spot Welding Applications

Verifying the Weld Location Orientation

When projecting weld locations, a preliminary orientation of the weld location

is created, so the next step in the process is to check the orientation of the
locations. We start by taking any weld gun to further refine the weld location
orientation (i.e. approach vector and perpendicular vector). At this stage it is
not necessary for the gun to be attached to a robot.
Weld location orientation refinement tools covered in this topic:

• Weld —> Rotate Locations — enables you to rotate a weld location

or other Mfg feature around its axes (usually around the Perpendicular
axis). The Mfg feature’s axes and their limitations are defined in the
Options dialog.

• Weld —> Align Locations — enables you to align the orientation of

several weld locations to another reference weld location while keeping
the Perpendicular axes normal to the surface. Alignment is useful in order
to determine an uniform welding approach direction for all the locations.

Weld location orientation refinement tools covered in later topics:

• Weld —> Flip Locations —> Flip Locations on Surface

• Weld —> Pie Chart

• Weld —> Automatic Approach Angle

• And more …

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Spot Welding Applications

Activity: Adjusting a Weld Path

Perform the related activity using the electronic activities.

.

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 Spot Welding Applications

Multi Sections
In this topic, we will describe the Weld —> Multi Section tool.
It contains the following subtopics:
• Steps for Creating Multi Sections

• Activity: Gun Shank Validation

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Spot Welding Applications

Steps for Creating Multi Sections

• Create and place a cutting box on weld location(s).

• Create multi-sections of the workpiece to evaluate the suitability of a gun.

• Edit multi-sections (adjust section clipping).

• Select gun to be placed on sections and evaluate gun design (measure

required throat depth and throat height to weld all sections in the multi
section).

• Adjust locations in Multi Section window as desired.

• Based on gun overlay, modify the shank (export cross section and gun
overlay to CAD system) OR choose another gun that is appropriate for
this particular process using either:

o Tools —> eMServer —> Power Bar

o Weld —> Geometric Gun Search

• Close multi-section window and store as object.

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 Spot Welding Applications

Activity: Gun Shank Validation

Perform the related activity using the electronic activities.

.

Process Simulate on eMS Basic Robotic Simulation Student Guide 12-29

Spot Welding Applications

Weld Distribution Center (WDC)

This topic describes how to use the Weld Distribution Center (WDC).
There are several ways to assign welds to weld operations:
• Make the assignment in an external system and import into Process
Designer (via CC or XML)

• Use the Weld —> Weld Distribution Center in Process Simulate

(covered here)

It contains the following subtopics:

• WDC Overview

• WDC Primary Functionality

• WDC Settings

• Activity: WDC and AAA

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 Spot Welding Applications

WDC Overview

The Weld Distribution Center (WDC) is a tool for high level distribution
of weld points in the station. The WDC is an environment that provides
information about the weld points and the ability of the robot and guns in the
station to weld them.
WDC provides a Robot, Gun capability matrix allowing users to determine
which robot and gun in the station are capable of welding any weld point.
To use the WDC, select the relevant weld points, weld operations, robots or
station and view their status. For each weld point, the WDC displays:
• WP name

• WP attributes – the attributes columns can be controlled by the user

according to the existing customization

• For each robot:

o Reachability status – reach, partial reach or no reach

o Collision status – check for collisions in the robot reach position

A main feature of the WDC is the ability to distribute weld points to an

operation in the station while balancing the number of weld points for robot /
operation in the context of the cycle time.
Users distribute weld points by selecting the check box in the matrix that
represents the connection between the weld point and the operation. The
system then implements distribution "online" and updates other viewers such
as the Operation Tree and Relation Viewer.
During weld point distribution the application provides immediate feedback
regarding:
• WP balance – number of weld points in each operation

• Operation cycle time (actual time) – total cycle time of the operation. The
cycle time is composed of the weld point time values:
o Actual time = Number of WP X (Weld Point Welding time+ Weld Point
Motion time + Weld Point Holding Time)

o Cases of actual time exceeding operation planned time are marked in

red

o When no time values are defined in the system for each weld point,
users can set a default time for all the weld points using the Settings
option

• Verified time – operation duration as calculated after simulation

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WDC Primary Functionality

These options are found on the Weld Distribution Center toolbar:

• Automatic Approach Angle

• Add WP to the WDC

• Remove WP from the WDC

• Check for collision and reachability

• Automatically distribute WP

• Open Pie chart

• Settings

• Configure Attributes List — Define WP attributes shown in WDC

• Jump robot to WP

• Filter by WP type or assigned

• Export WDC to Excel

WDC main window:

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WDC Settings

WDC Settings window:

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 Spot Welding Applications

Activity: Using Weld Distribution Center (with Automatic Approach Angle)

Perform the related activity using the electronic activities.

.

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Spot Welding Applications

Process Methodology, revisited

This topic describes the process methodology used in this topic.
It contains the following subtopics:
• Robotic Principles

• The Process: From Least Constraints to Most Constraints

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 Spot Welding Applications

Robotic Principles

Robot Program:
When using a teach pendant, the robot is moved to a position and the joint
angles are recorded.
Robot Program consists of ...
A SEQUENCE of poses consisting of JOINT ANGLES with associated
INSTRUCTIONS
Process Simulate Program:
Process Simulate uses Inverse kinematics to determine the joint values
needed to reach a given target location.
Process Simulate Program consists of ...
A PATH that consists of TARGET LOCATIONS (Position and Orientation)
with associated ATTRIBUTES
With this definition of a program, the process in Process Simulate is
independent of the robot and the tool. Later, the Process Simulate program
can be downloaded to robot program, so that it can control the robot. This
gives the flexibility in Process Simulate to select a different robot at any time
before we download.

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The Process: From Least Constraints to Most Constraints

In Process Simulate, we start with the simplest situation: a part and a path.
Then we slowly add one more piece to the Scenario (study)–such as weld
guns, robots, fixtures, etc...–until the path is perfected. Here is the process
we follow:
1. Define the guns, if they are not already

2. Place workpiece in Scenario (study).

3. Define or import work points.

4. Project target locations on the work piece.

5. Check orientation of the target locations using a first approximation gun.

6. Create first approximation sequence of weld path.

7. Perform a first run along the path.

8. Test reachability of robot.

9. Check for collisions.

10. Adjust path.

11. Optimize path cycle time.

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Overview of Gripper Creation (Optional)

This topic provides an overview of how to define poses for kinematic devices.
This topic is covered earlier in this course.

It contains the following subtopics:

• Discussion of Steps to Add Poses to an Object

• Define an object As a Gripper (Discussion Only)

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Spot Welding Applications

Discussion of Steps to Add Poses to an Object

• Open the object for modeling

• (kinematics should be already defined)

• Joint jog the mechanism into the desired position or approximately into
position

• Edit the poses for the current mechanism

• Create a new pose

• Use the current joint values or enter new ones

• Accept the values entered for this pose

• Define the rest of the poses for this mechanism

• Save the object

What Poses Need to be Defined?

For grippers, the OPEN and CLOSE poses must be defined (Pose names are
case-sensitive).

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Define an Object As a Gripper (Discussion Only)

This topic, excerpted from our earlier discussion , describes the procedure
for defining an object as a gripper:
1. Follow the same process learned to define an object as a pneumatic or
servo gun except:
• In the Tool Definition window, click Gripper (instead of Gun) to
constitute the device as a gripper.

2. The Offset is the distance from the TCP Frame where other objects will
attach to the gripping entities at the pick location of a pick and place
operation.

3. Save and end modeling the object (the same as pneumatic or servo guns).

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Scenario Setup
This topic describes how to set up the Scenario.
It contains the following subtopics:
• Setting up a Mounted Workpiece Scenario (study)

• Mount Tool

• Activity: Putting the Gripper on the Robot (for Ped. Welding)

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Setting up the Scenario (study)

• Get and place the robot

• Get the gripper

• Mount it on the robot

• Get the workpiece

• Place it on the gripper

• Attach it to the gripper

The gripper should be mounted to the robot. The part and any
spacers should then be attached to the gripper.

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Mount Tool

The Kinematics —> Mount Tool command:

• Relocates the tool from a frame on the tool (i.e. self origin) to a frame on
the robot (i.e. the TOOLFRAME)

• It attaches the gun to the TOOLFRAME of the robot

• It moves the TCPF of the robot to predefined position and orientation

on the mounted tool.
When RRS and OLP is performed, it is possible to set the TCPF to
several positions as defined in the Teach Pendant (non-default teach
pendant) or Robot Properties. More on this topic in the WKP315S
Process Simulate on eMS Robotics Advanced.

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Activity: Putting the Gripper on the Robot (for Ped. Welding)

Perform the related activity using the electronic activities.

.

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Spot Welding Applications

Material Handling (Pick and Place) Operations

This topic describes how to maneuver the part in and out of the fixture.
We will create pick and place operations which contain special via locations
for picking up and dropping off the part.
It contains the following subtopics:
• Pick and Place Basics

• Activity: Get/Put the Part in the Fixture

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Pick and Place Basics

To create a new Pick and Place Operation:

• Select Operations -> New Operation —> New Pick and Place Operation
.

• Select the Pick and Place poses

• Select the Pick and Place TCP positions.

Any of the techniques described before for editing paths of via
locations can be used with this path type as well. A material
modeling path can also be created using a Weld Operation (which
only contains via locations), if you don’t want to use the special pick
and place behavior.

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Spot Welding Applications

Activity: Get/Put the Part in the Fixture

Perform the related activity using the electronic activities.

.

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Creating a Rough Mounted Workpiece (Pedestal Welding) Path

This topic describes how to create a rough mounted workpiece (external TCP
or pedestal welding ) path.

It contains the following subtopics:

• Introduction to Pedestal Welding

• External TCP Usage Differences

• Setting up a Mounted Workpiece Path

• Reach Test

• Jumping to a Location Basics

• Activity: Creating a Rough Mounted Workpiece Path

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Introduction to Pedestal Welding

Pedestal Welding: In this use case, the workpiece is attached to a gripper

mounted on the robot. The welding is performed on a weld gun mounted to a
pedestal. It is also known as ped. welding.
Different representations for compound weld operations (Changed through
Operation Properties):
• Pedestal Welding (External TCP)

• Gun on Robot Welding

External TCP Support:

• Simulation support

• Operations —> New Operations —> New Weld Operation

• Operations —> Operation Properties

• Weld —> Multi Sections

• Weld —> Pie Chart

• Kinematics —> Reach Test

• Kinematics —> Robot Smart Place

• eMServer Selective Update

• Etc...

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 Spot Welding Applications

External TCP Usage Differences

In order to define a weld operation as a pedestal weld, the External TCP

checkbox should be checked. It can be checked when the weld operation
is created or it can be set by right clicking the weld operation, selecting
Operation Properties , clicking the Process tab, then clicking External
TCP.
With External TCP weld operations, the weld gun is NOT mounted to the
robot, but it is specified in the Gun prompt on the Operation Properties
Process tab. Typically a gripper is mounted to the robot, which is used to
pick up the parts and move them to the pedestal weldgun.

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Setting up a Mounted Workpiece Path

• Use the Scenario (study) from the last topic

• Create spot mfg features (welds) on the workpiece

• Project target locations on the workpiece at the work points

• Create a path through all the locations

• Get the external (ped) welder and orient it

• Associate the locations with the TCP frame of the external welder by
checking the External TCP checkbox on the Operations Properties window

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Reach Test

Kinematics —> Reach Test enables you to test whether a robot can reach
all selected locations, and to optimize the Scenario (study) layout.

You can jump to location by double-clicking a weld location in the Reach

Test.

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Spot Welding Applications

Jumping to a Location Basics

There are several ways to get a robot to a location we will only discuss one
method for now. The others will be discussed later in this course:

• Kinematics —> Jump to Location

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Activity: Creating a Rough Mounted Workpiece Path

Perform the related activity using the electronic activities.

.

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Spot Welding Applications

Orienting Workpiece Locations

This topic describes how to orient the locations on a gripped part.
It contains the following subtopics:
• Steps to Orienting the Locations

• Pie Chart

• Activity: Orient the Locations

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Steps to Orienting the Locations

• Adjust the orientation of one of the locations, as a reference location using

the next two steps

• Define a location to check.

• Then modify the location orientation until it is reachable.

• Align the rest of the locations to match the reference location

• Define and check the path so that all locations are reachable

• Spot simulate the path

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Pie Chart

Weld —> Pie Chart — enables you to determine the approach vector for
a weld gun to a selected weld location. It provides an easy method for
determining how a robot with a weld gun should approach a weld location
in order to perform welding — the system calculates the approach for the
robot and its mounted gun. If a robot has not been assigned, the Pie Chart
option enables you to determine the gun collision status. You can also use Pie
Chart to create a collision set.

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Activity: Orient the Locations

Perform the related activity using the electronic activities.

.

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Spot Welding Applications

Introduction to Weld Gun Search

This topic describes how to use the Geometric Gun Search tool.
It contains the following subtopics:
• Geometric Gun Search Basics

• Activity: Weld Gun Search

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Geometric Gun Search Basics

It is a step-by-step wizard that guides the user to find the optimum gun for
welding.
• Load the desired data in Process Simulate.

• Open the Geometric Gun Search window.

• Select the weld path.

• Select the desired guns to be checked. (i.e. Use weld guns from the eMS
project gun library).

• Check if the selected guns collide.

Parts or tooling can be selected for checking the guns against. Gun
poses that will be used at each location can be chosen.

• Define the misc. options such as flip gun, angle of rotation, gun poses,
number of steps, etc....

• Display result table. It displays a comparison between the tested guns

and all the spots in the selected path.

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Spot Welding Applications

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 Spot Welding Applications

Activity: Weld Gun Search

Perform the related activity using the electronic activities.

.

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Spot Welding Applications

Servo Guns
This topic describes how to use servo guns. In Process Simulate a pneumatic
gun’s weld poses must be defined before it is used (i.e. CLOSED, OPEN,
SEMIOPEN). Whereas a servo gun’s weld poses are defined as an attribute
on the target locations
A servo gun is an electrical spot-welding gun controlled by a servomotor
and an encoder. A servo gun usually has two arms: the first, the
dynamic or active arm, also designated main joint, is controlled by an
electric motor; the second, the static or passive arm, also designated
balance joint, is actuated either pneumatically, or mechanically with a
spring-return device.
Servo guns differ from traditional pneumatic guns in that whereas the
pneumatic guns have three poses, open, semiopen and closed, servo
guns are continuous and can move their joint to any desired value
within its limits. Thus the robot can open and close the servo gun
during motion, thereby reducing cycle time.

Using servo guns has an affect on the Gun Define, Joint Jog, Default
Controller, Sequence Editor, and the resulting simulation.
It contains the following subtopics:
• Servo Gun Usage

• Servo Gun Definitions

• Define an Object As a Servo Gun (Discussion Only)

• Instructor Demo: Simulating Robots with Servo Guns

• Activity: Working with Servo Guns

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Servo Gun Usage

When welding is complete, the servo gun opens in either of two different ways:
• The passive arm retracts to its open position, and the active arm moves
to a new value.

• The passive arm retracts to its open position, and the active arm moves to
its position before the welding operation, but using a different arrival-zone
value; thus the robot starts moving to a new location while the gun is still
moving. Kuka robots use this method.

For motion to welding locations, the robot:

1. Moves to the compound welding location.

2. Moves the servo gun to its CLOSE pose.

3. Simultaneously moves the passive servo-gun joint to its OPEN pose, and
moves the active servo-gun joint to its DEPART attribute value if any.

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Servo Gun Definitions

• Active arm - the active arm is defined as a regular external axis of the
robot. Any function, by which the controller controls an external axis, can
therefore control also the servo gun.

• Passive arm - movement of the passive arm is limited; it is used for

balance against the active arm.

• Gun poses - The servo-gun model must have a CLOSE state (pose).
The commands in the Process Simulate Gun Search toolbox require the
CLOSE state, and may also use optional OPEN and SEMIOPEN poses.

• Mounting Tool – Mount places the servo gun on the robot and attaches
it to the robot, and also constitutes the active arm as an external axis
of the robot.

• Creating and updating locations - The locations for servo-gun simulations

must have external axis values in order to move the active arm together
with the robot. To Set External Axis command is used to add servo gun’s
Active Arm joint value to the location.

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Define an Object As a Servo Gun (Discussion Only)

This topic, excerpted from our earlier discussion , describes the procedure
for defining an object as a gripper:
Before defining a servo gun, ensure that:
• the gun is currently being modeled.

• The Modeling and Kinematics commands have been issued as required to

define that object as a kinematic device.

• At least one pose of the device has been defined as CLOSE.

• A tool center-point frame (TCPF) has been defined for the object.

1. Follow the same process learned to define an object as a gun except:

• In the Tool Definition window, click Servo Gun (instead of Gun) to
constitute the device as a servo gun.

2. Save and end modeling the object (the same as pneumatic guns).

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Spot Welding Applications

Instructor Demo: Simulating Robots with Servo Guns

Perform the related activity using the electronic activities.

.

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 Spot Welding Applications

Activity: Working with Servo Guns

Perform the related activity using the electronic activities.

.

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Spot Welding Applications

Summary
Subjects learned in this topic:
• The basic terms and processes of spot welding

• Basic Process Simulate Robotics path development process.

• Some background information regarding manufacturing feature

representation.

• How to project welds to create weld locations.

• How to make some changes to the weld path associated to the weld
operation.

• The Weld —> Multi Section tool

• How to use the Weld Distribution Center (WDC)

• The process methodology used in this topic

• Overview of how to define poses for kinematic devices.

• How to set up the Scenario.

• How to maneuver the part in and out of the fixture.

• How to create a rough mounted workpiece (external TCP or pedestal

welding ) path.

• How to orient the locations on a gripped part.

• How to use the Geometric Gun Search tool.

• How to use servo guns.

Instructor Note:
Summary instructor notes.

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Lesson

13 Material Handling Applications

Purpose
To provide an introduction to Process Simulate for material handling
applications (i.e. Assembly, Packing/Palletizing, Part Transfer).

Objectives
After you complete this topic, you should be familiar with:
• Overview of how to define poses for kinematic devices.

• How to set up the Scenario

• How to do palletizing

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Material Handling Applications

Overview of Gripper Creation (Optional)

This topic provides an overview of how to define poses for kinematic devices.
This topic is covered earlier in this course.

It contains the following subtopics:

• Discussion of Steps to Add Poses to an Object

• Define an object As a Gripper (Discussion Only)

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 Material Handling Applications

Discussion of Steps to Add Poses to an Object

• Open the object for modeling

• (kinematics should be already defined)

• Joint jog the mechanism into the desired position or approximately into
position

• Edit the poses for the current mechanism

• Create a new pose

• Use the current joint values or enter new ones

• Accept the values entered for this pose

• Define the rest of the poses for this mechanism

• Save the object

What Poses Need to be Defined?

For grippers, the OPEN and CLOSE poses must be defined (Pose names are
case-sensitive).

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Material Handling Applications

Define an Object As a Gripper (Discussion Only)

This topic, excerpted from our earlier discussion , describes the procedure
for defining an object as a gripper:
1. Follow the same process learned to define an object as a pneumatic or
servo gun except:
• In the Tool Definition window, click Gripper (instead of Gun) to
constitute the device as a gripper.

2. The Offset is the distance from the TCP Frame where other objects will
attach to the gripping entities at the pick location of a pick and place
operation.

3. Save and end modeling the object (the same as pneumatic or servo guns).

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Material Handling Scenario Setup

This topic describes how to set up the Scenario.
It contains the following subtopics:
• Setting up a Material Handling Scenario (study)

• Instructor Demo: Material Handling Example

• Activity: Pick and Place (Material Handling) Setup

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Material Handling Applications

Setting up the Material Handling Scenario (study)

• Get and place the robot

• Get the gripper

• Mount it on the robot

• Get and place conveyors, rails, and containers

• Get and place the workpieces

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 Material Handling Applications

Instructor Demo: Material Handling Example

Perform the related activity using the electronic activities.

.

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Material Handling Applications

Activity: Pick and Place (Material Handling) Setup

Perform the related activity using the electronic activities.

.

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 Material Handling Applications

Material Handling (Pick and Place) Operations

This topic describes how to create pick and place operations to do material
handling. In this topic, we will perform palletizing activities as an example.
We will create pick and place operations which contain special via locations
for picking up and dropping off the part.
It contains the following subtopics:
• Pick and Place Basics

• Activity: Create the Basic (PNP) Process

• Activity: Stacking Boxes

• Activity: Doing the Second Pass (Optional Activity)

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Material Handling Applications

Pick and Place Basics

To create a new Pick and Place Operation:

• Select Operations -> New Operation —> New Pick and Place Operation
.

• Select the Pick and Place poses

• Select the Pick and Place TCP positions.

Any of the techniques described before for editing paths of via
locations can be used with this path type as well. A material
handling path can also be created using a Weld Operation (which
only contains via locations), if you don’t want to use the special pick
and place behavior.

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 Material Handling Applications

Activity: Create the Basic (PNP) Process

Perform the related activity using the electronic activities.

.

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Material Handling Applications

Activity: Stacking Boxes

Perform the related activity using the electronic activities.

.

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 Material Handling Applications

Activity: Doing the Second Pass (Optional Activity)

Perform the related activity using the electronic activities.

.

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Material Handling Applications

Summary
Subjects learned in this topic:
• Overview of how to define poses for kinematic devices.

• How to set up the Scenario

• How to do palletizing

Instructor Note:
Summary instructor notes.

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Lesson

14 Continuous Applications

Purpose
To provide an introduction to Process Simulate.

Objectives
After you complete this topic, you should be familiar with:
• Some background information regarding manufacturing feature
representation.

• How to project continuous MFG features to create continuous mfg robotic

paths.

• How to use continuous MFGs.

• Make some changes to the weld path associated to the weld operation.

• Making changes to the path associated to the continuous mfg operation.

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Continuous Applications

Overview of Continuous Robotic Applications

This topic describes various continuous robotic applications.
It contains the following subtopics:
• Arc Weld Basics

• Painting Basics

• More Continuous Robotic Applications

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 Continuous Applications

Arc Weld Basics

One application is to create robotic gas metal arc welding (GMAW a.k.a.
Metal Inert Gas a.k.a. MIG) sessions using the Robcad Arc.
Arc Welding Basics (1):

1. Direction of travel

2. Contact tube/tip and Shield gas nozzle

3. Electrode

4. Shielding gas
• Protects against dross and porosity (Quality problems)

5. Molten weld metal

6. Solidified weld metal

7. Workpiece

Arc Welding Basics (2)

• An electric arc is established between the workpiece and a consumable
electrode

• The arc continuously melts the electrode as it is automatically fed into

the weld puddle
o Feed speed dependant on wire diameter, welding current , stick-out,
and torch travel speed

• The weld metal is shielded from the atmosphere by a flowing gas mixture

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Continuous Applications

• Just need to guide the torch position and orientation along the weld seam

Arc Welding Basics (3)

• Stick-out distance
o A.k.a. wire electrode extension

o Distance from contact tip to end of electrode

• Tip-to-Work distance
o Distance from contact tip to workpiece

o Tip-to-work distance = stick-out + arc length

o Tip-to-work distance should be kept consistent to avoid overheating

and wasting shield gas

• Torch orientation
o Should bisect the angle between the workpieces

o Travel angle should be approximately vertical (shield gas has an

effect; i.e. CO2 tends to push instead of drag)

Seam Creation Basics

Seams
• Seam — arc weld path of weld locs with associated via locs. Created weld
locs follow the curve of the Continuous Mfg Feature with a linear motion
type (except arcs which use circular motion type)

• Continuous Feature Operation — can contain one or many seams

Welding is performed at the TCP of the torch

• Distance to TCP – Stick-Out distance

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• Torch Offset – additional distance (i.e. to modify penetration, arc length,

prevent burnthrough on varying thickness workpieces, etc…)

The TCP is usually placed at the stick-out distance. The arc length,
which is approx the typical OLP calibrated tolerance (1 mm), can
be considered using a torch offset, by using “auto seam tracking”
(controller specific) or touch sensing (a.k.a. a search).

Bisector Angle

• Measured from bisector to side wall

• Default is 0 degrees (on the bisector)

• i.e. bisector angle of 0 degrees for a fillet weld

• i.e. bisector angle of 5 degrees for a beveled butt joint

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Bisector – bisects the angle between the workpieces

Travel Angle
• Measured along welding direction

• A.k.a. Lead angle

• Default is 90 degrees, but is not typical

• Drag
o i.e. travel angle of 80 degrees

o Less than 65 degrees causes excess spatter

o Backhand welding

o For deeper penetration (and wider bead width) or root pass on

multi-layer welds

• Push
o i.e. travel angle of 100 degrees

o Forehand welding

o Do 95% of the time. Normal (standard) and multi-layer welds

(excluding the root pass) have a slight push

o Better for thin parts and less penetration

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Seam Orientation
• Most welding is done with the base wall flat on the ground (Horizontal or
flat seams). This produces the best welds.

• In rare cases welding is done with the part at 10 degree angle down hill
for maximum speed. This is known as a gravity weld.

• For welding vertical seams:

o Vertical up (welding from bottom to top)

o Vertical down (welding from top to bottom)

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Painting Basics

The contemporary process of vehicular spray painting is a result of many

years of development in an effort to improve quality while reducing time
and costs. The process of painting vehicle bodies currently uses a painting
line which receives the body after the primer coats have been applied. A
representative process comprises five stages:
1. Preparation - dust is removed before applying the final color.

2. Interior-paint booth - the final base color is sprayed onto inner portions
of the body where access is relatively difficult. This stage benefits greatly
from the use of one or more robots.

3. Exterior-paint booth - the final base color is sprayed onto exterior of

the body where relatively easy access renders practical use of specialized
equipment.

4. Manual touchup - additional final base color is sprayed manually onto

portions of the vehicle not adequately covered in the base booth.

5. Oven drying - the final base color is baked dry and hard.

These stages may be repeated for additional coats of paint such as the
application of clear enamel over the base coat. In addition, completely
different spraying processes may be used for spare parts, spray gluing,
and underbody and other sealing; these processes usually differ from the
processes for painting vehicle bodies.

The Robotic Paint Booth

The painting operations which occur in the interior-paint booth best lend
themselves to robotic applications; indeed, robots have been used for many
years in vehicular spray-paint booths in order to improve the quality and
consistency of the paint process compared to manual spray-painting methods.
Advantages of using robots include:
• Accuracy and repeatability are easier to achieve

• Robots are not affected by painting hazards that are problematic for
humans

• Long-arm robots easily cover large vehicles, such as trucks or vans, which
are difficult to reach manually.

• Robots perform difficult and monotonous jobs without tiring or

complaining.

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A modern paint booth is usually constructed as a clean room, and includes a

conveyor, the vehicle being painted, one or more manipulators to open and
close doors and lids, at least one robot, a controller for the robot, a paint
gun with its associated hoses, compressors and other equipment, and the
paint-gun controller.

Painting Equipment
Of the items included in a paint booth, three constitute the painting
equipment actually involved in the programmed, automated painting process:
• The robot controller; it usually executes the robot program and initiates
signals which activate the paint controller.

• The paint controller; it controls the opening and closing of the spray
gun. It also produces the spray fan and determines the shape of the fan,
the rate and amount of paint being used, and the size of the droplets
comprising the paint spray.

• The spray gun; it is the device which receives the signals from the paint
controller in order to perform the painting process.

Paint-Spray Composition
Four items of equipment produce the paint as sprayed on the vehicle:
• A fluid pump which pumps the paint to the spray gun.

• An atomizing-air pump which pumps pressurized air through the main

spray-gun nozzle to break up the sprayed paint into tiny droplets the
size of which is carefully controlled.

• A horn-air pump which drives pressurized air toward the sides of the
paint spray as it exits from the gun, controlling the shape of the paint fan.
If the horn-air pressure is low, the fan is short and wide; if the pressure is
high, the fan is long and narrow.

• A paint gun which includes the main nozzle from which the paint exits
together with the atomizing air, and various secondary nozzles which
introduce horn air to control the shape of the paint fan. The paint thus
exits in the shape of a fan from the main nozzle of the paint gun.

Paint-Spray Control
The atomizing- and horn-air pressures and the various paint-flow parameters
are usually controlled by the robot program, using data recorded in a
paint-parameters table residing either in the robot controller or in the paint
controller. Individual data are recorded for each type of paint or color which
the application uses. The robot controller communicates the relevant paint

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parameters to the paint controller either by sending the parameters or by

sending a paint-parameters code constituting a key to a particular paint
and its associated parameter values.
In addition to controlling the spray-fan values, the robot controller needs
also to communicate instructions to open and close a spray gun, i.e., to start
and stop painting.
Activating the air pressures and the gun nozzle occupies time. The delay
from the time the paint controller receives the command until the command
takes effect, is measured in milliseconds. When the delay pertains to a spray
gun, it is designated gun delay. The delay for opening a gun may differ from
the delay for closing the gun.
Either the robot controller can compensate for the delay by sending
the opening and closing signals slightly sooner, or the programmer can
compensate for the delay by inserting instructions sooner in the program.

Painting-Program Goals
A painting program for a production robot needs to achieve five goals:
1. Evenly cover the entire surface with paint within a specified range of
thicknesses.

2. Minimize the cycle time required to execute the program.

3. Minimize the amount of material used in order to achieve the required

thickness, i.e., minimize overspray and other waste.

4. Rapidly achieve production quality in order to minimize down time and

the use of scrap vehicle bodies.

5. Achieve a maintainable program which minimizes the number of paint

brushes, i.e., sets of paint parameters. Since each set of paint parameters
is duplicated for each different paint material, using many sets makes the
program difficult to calibrate with tests from actual production samples.

Producing the Program

Producing a painting program for a production robot to achieve the goals
listed above, usually entails the steps listed below:
1. Analyze the target area assigned to a specific robot, and determine the
paths through which the robot should move in order adequately to cover
the area

2. Determine the order in which the various paths, including both the
painting and non-painting portions, should be joined

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3. Teach the combined paths to the robot and solve any reach and collision
problems that may occur in the process.

4. Assign speed values to the motion program

5. Perform a dry run: run the robot through the program and solve dynamic
reach and collision problems if they occur.

6. Determine the points where a spray gun should open and the points where
a gun should close, and verify that the program can still be executed.

7. Assign paint parameters to each painting portion of the path, according

to coverage and thickness requirements. Paint parameters are tested on
the actual production line to determine available sets of parameters that
provide the desired nominal width and thickness at a specified speed. The
list of these sets is then delivered to the programmer.
• The various parameters used in a painting program are not
independent. For example, changing the speed because of motion
problems affects the thickness; changing the distance from the surface
to prevent a collision affects the coverage and the thickness.

8. Execute a preliminary wet run.

9. Check coverage and thickness.

10. If improvements are needed, edit the program and reteach the robot. Dry
and wet runs can be repeated until complete satisfaction is achieved.

Painting-Program Problems
programming them. Up to the present, programming painting robots on line
has been more of an art than a science, requiring long initial programming
efforts and producing cumbersome robot programs that are hard to maintain.
In particular, problems arise due to:
• The complexity of the workpiece.

• Difficulties associated with reachability and collisions.

• Runners occurring at edges and in corners.

As a result, producing a workable program is a trial-and-error process usually

requiring several weeks during which the painting line is shut down.

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More Continuous Robotic Applications

• Laser Cutting — (According to www.wikipedia.org) uses a laser to cut

materials, and is typically used for industrial manufacturing applications.
Laser cutting works by directing the output of a high power laser, by
computer, at the material to be cut. The material then either melts,
burns, vaporizes away, or is blown away by a jet of gas, leaving an edge
with a high quality surface finish. Industrial laser cutters are used to cut
flat-sheet material as well as structural and piping materials.

• Gluing/Dispensing — For example, a bead of glue is applied to the

part from a dispenser. There are two common scenarios: the dispenser
is mounted on the robot, or the robot grips the part and moves it along
an external glue dispenser.

• Grinding/Deburring/Material Removal/Polishing — For

gridding/deburring, various tools are used to smooth the edges of
metal parts. There are two common scenarios: the tool is mounted on
the robot, or the robot grips the part and moves it along an external
grinding/deburring machines. The first scenario may also include a tool
changer allowing the robot to switch the mounted tool between various
grinding and deburring tools.

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Continuous MFG Representation

In this topic, we will discuss some background information regarding
manufacturing feature representation.
It contains the following subtopics:
• Manufacturing Feature Types

• Viewing Manufacturing Features

• Sources for Manufacturing Features

• Sources for Basic Manufacturing Feature Orientation

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Manufacturing Feature Types

There are several types of Manufacturing Features. However, only on these

types will be discussed in this course:
• Weld point – Used to represent spot welds. Does not have any associated
geometry. This subject was covered earlier in this course.

• Continuous Mfg – Used to represent arc weld seams. It can

also be used to represent other continuous processes such as Arc
welding, Gluing/Dispensing, Laser cutting, Painting, Material
Removal/Grinding/Deburring/Polishing, etc… Has geometry (i.e. a curve
or line) associated to it.

Another Manufacturing Feature type, PLP, will not be discussed in

this course. It is used to represent the point where the part is being
constrained (i.e. clamped).

These Manufacturing Feature types represent a theoretical position (without

orientation) of the robot TCP on the part. Each Manufacturing Feature can
also contain several attributes.

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Viewing Manufacturing Features

Where to Look for Mfg Features:

• Operations Tree — Mfg Features are shown here as a child of the
simulative operation they are related to (until they projected to create the
location operations)

• Graphic Viewer — Mfg Features are shown here until they are projected
to create locations (then they are blanked by default)

• Mfg Viewer — Mfg Features are always shown here.

Mfg Viewer:
This viewer contains a filterable table of Mfg features. It contains various
columns of attributes that can be added and other functionalities including:
• Find by Caption — Find a Mfg Feature based on its caption

• Unassign — Unassign a Mfg Feature from a part

• Customize — Enables you to select the MFG attributes that are

displayed in the MFG Viewer.

• Filter by Type — Filters the display of the MFG Viewer based on

the Mfg Feature type.

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Sources for Manufacturing Features

Manufacturing features are always tied to one or more parts. In order
to “see” a Manufacturing feature in Process Simulate in must be created
and associated to a part that is either associated to the study directly or
indirectly (indirectly means it’s associated to a part that is associated to
an operation associated to the study).

For Continuous Manufacturing Features:

• Manufacturing Feature Created in Process Designer or Process Simulate
o In the Navigation Tree, right click a Mfg Feature Library and select
New . From the New window, select Continuous Manufacturing
Feature.
Associate curves or line objects (.COJT) created in Process
Simulate or imported into Process Designer using the Physical tab
of the Properties window of an existing Continuous Manufacturing
Feature.

• Associate curves or line objects (.COJT) created in Process Simulate or

imported into Process Designer using Weld —> Continuous —> Create
Continuous Mfg from Curve .

By default Mfg Features show in the Graphic Viewer as a red square and are
also displayed in the Mfg Feature viewer.

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Sources for Basic Manufacturing Feature Orientation

For Continuous Manufacturing Features:

• Weld —> Continuous —> Project Continuous Mfg Features —

Creates a Continuous Robotic Operation containing a sequence of location
operations.
We will discuss Continuous Mfg Features in more detail in a later
topic in this course.

Using these two commands produces one or many location operation for each
Manufacturing feature. The location operation contains the position and
orientation of the robot TCP at the manufacturing feature. The orientation of
the location operation can be further refined using various tools in Process
Simulate which will be described later in class.

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Projecting Continuous Mfg Features

This topic describes how to project continuous MFG features to create
continuous MFG robotic paths.
A location in Process Simulate is unique type of frame that contains the
position and orientation of the TCP frame at a point. Locations are generated
with their origins placed according to where the projection of the related
curve intersects a surface or solid it is projected onto. The locations guide the
tool center point of the robot approach vector and a vector perpendicular
to the workpiece.
Locations also contain process information specific to spot welding such as:
Gun state, Location type, Speed, etc... for each location.
It contains the following subtopics:
• Continuous Location Constraints

• Projecting Weld Locations

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Continuous Location Constraints

Weld locations must be on the surface and one axis must be perpendicular to
the surface.
A continuous MFG feature location’s orientation is very important.
• Typically one axis is to be normal to the surface being worked on. This
Normal axis set by default to Z.

• Another axis indicates the direction of Movement Vector of the continuous

mfg. This axis is set by default to X.

Default approach and perpendicular axis are defined and can be

modified using Tools -> Options and choosing the Continuous tab.

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Projecting Continuous Mfg Features

Weld —> Continuous —> Project Continuous Mfg Features command

enables you to project a set of continuous Mfgs onto the parts to which they
are assigned. Projecting the Mfgs generates a robotic seam operation and
a seam location for each Mfg. The projected seam location approximates
the shape of the part in accordance with the maximal segment length and
maximal tolerance parameters.

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• Before executing Project Continuous Mfgs, you specify a continuous robot

compound operation. The seam operations that the command generates
appear in the Operation Tree as children of the specified robot operation.

• Check Project on approximation only.

Only JTs in the XTBRep format support projecting weld points on
exact geometry. If the part exact geometry is not available in the
JT file (i.e., it is a location that did not retrieve the exact geometry),
users are asked whether to project based on an approximation
or skip the projection for the weld points which failed for exact
projection.

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Continuous MFGs and Continuous Feature Operations

This topic describes how to use continuous MFGs. These objects are
used to make continuous feature operations which are used to represent
Arc welding, Gluing/Dispensing, Laser cutting, Painting, or Material
Removal/Grinding/Deburring/Polishing processes.
Related commands:

• Weld —> Continuous —> Project Continuous Mfg Features

• Operation —> New Operation—> New Continuous Feature Operation

It contains the following subtopics:

• Basic Usage

• Activity: Using Continuous Feature Operations

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Basic Usage of Continuous Mfg Features and Operations

In Process Designer (or in a Navigation Tree in Process Simulate):

• Create new Continuous Mfg object in an MfgFeatureLibrary and connect
it to a 3D representation of a curve (a.k.a. .COJT folder containing a
.JT file).

• Assign parts for the welding process to the Continuous Mfg.

• Create a new Continuous Feature Operation.

Two methods to create a Continuous Feature Operation:
o Process Designer or Process Simulate method: From the
Navigation Tree window, right click on the parent operation and
select New . Check ContinuousWeldOperation. Click [OK].

o Process Simulate only method: From the Operation Tree,

select the desired parent operation. Select Operation -> New
Operation -> New Continuous Feature Operation .

• Assign the Continuous Mfg to the Continuous Robotic Operation.

In Process Simulate:
• Create the continuous seam and continuous seam locations.

• Assign the desired robot and tool to the Continuous Robotic Operation.

• Select Weld —> Continuous —> Project Continuous Mfg Features

• Check and modify locations to insure robot reachability.

• Set motion and process parameters.

• Simulate and analyze the results.

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Activity: Using Continuous Feature Operations

Perform the related activity using the electronic activities.

.

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More Continuous Mfg Feature Applications (Arc weld, Paint, and

Debur)
This topic describes other continuous application tools
It contains the following subtopics:
• Additional General Continuous Mfg Feature Tools

• Additional Arc weld Tools

• Additional Paint Tools

• Additional Operation Menu Tools

• Activity: Creating Arc MFGs for the Whitehouse part

• Activity: Creating Debur MFGs for the Whitehouse part

• Activity: Creating Paint MFGs for the Whitehouse part

• Activity: Creating Arc Seams for the Whitehouse part (using Project Arc
Seam)

• Activity: Creating Deburring Paths for the Whitehouse part (using Project
Cont. Mfg Features)

• Activity: Creating Paint Paths for the Whitehouse part (using Project
Cont. Mfg Features)

• Activity: Modifying Arc weld Operations and Seams

• Activity: Modifying Debur Operations and Seams

• Activity: Modifying Paint Operations and Seams

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Additional General Continuous Mfg Feature Tools

Additional Weld Menu Tools:

• Weld —> Continuous —> Insert Location Inside Seam — enables you
to add seam locations to seam operations. It is enabled when the selection
is empty or when a continuous location is selected. This command is
useful for fine-tuning paths and debugging.

• Weld —> Continuous—> Split Seam Operation — enables you

to split a robotic seam operation into two separate operations. If, for
example, there are reachability or accessibility issues for an operation’s
assigned robot, you can split the problematic operation into two separate
operations and assign each operation to a different robot. You can only
split operations containing three or more locations.

• Weld —> Continuous—> Create Continuous Mfg from Curve —

enables you to create a continuous Mfg from any curve in the current
project. You can either use an existing curve, create a new curve, or
import a curve into the project from an external CAD program. After
creating a continuous Mfg, you can Project Continuous Mfgs on to parts.

• Weld —> Continuous—> Indicate Seam Start — enables you to create

a continuous Mfg from any curve in the current project. You can either
use an existing curve, create a new curve, or import a curve into the
project from an external CAD program. After creating a continuous Mfg,
you can Project Continuous Mfgs on to parts.

• Weld —> Continuous—> Emphasize Continuous Mfg — enables you

to highlight Mfgs for easy viewing in the Graphic Viewer.

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Additional Arc weld Tools

Arc weld Specific Tools:

• Weld —> Continuous—> Project Arc Seam — takes a MFG feature

as input. It allows selection of a base wall part, a side wall part, and
various torch alignment parameters. The path that is produced should
require far fewer modifications than an arc weld path created with Project
Continuous Mfg Features .

• Weld —> Continuous—> Torch Alignment — allows modifying the

various torch alignment parameters for a single location or for an entire
arc seam.
Torch alignment parameters include: Travel Angle, Work angle,
Spin angle, Base wall offset, Side wall offset, and Seam offset.

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Additional Paint Tools

Paint Specific Tools that are not on the standard window layout
these tools can be added to menu using Tools —> Customize. The robot
tracking commands are on the Advanced Simulation window layout
under Robotics.

• Create Paint Trigger — enables you to create a trigger which specifies

where a Paint gun begins or ends its painting operation.

o Type is either: Open Paint Gun, Change Brush, or Close Paint Gun.

• Edit Paint Trigger — enables you to edit existing paint triggers. For
example, you can select a different parent location for the paint trigger
or edit its name.

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• Robot Tracking Mode On/Off — Turns robot tracking mode on or off.

You can define a robot line tracking mechanism to enable simulated
robots to track objects moving on a conveyor. This can be used, for
example, when simulating the painting of parts. For event-based
simulations only. Not covered in this course.

• Robot Tracking Viewer — enables you to define robot-frame tracking

sets. After enabling robot tracking mode, Process Simulate reports when
the robot is able to reach the frame during a simulation and when it
cannot. Additionally, in the Graphic Viewer, you can see the robot jump
to the frame. For example, if a robot paints a car door while another
robot is opening the same door, you can use the Robot Tracking Viewer
to verify that the painting robot is able to reach a selected frame on the
door at all times during the door opening operation. The Robot Tracking
Viewer also automatically displays the object to which the reference frame
is attached. Tracking sets are considered engineering data and Process
Simulate saves them for future sessions.

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Additional Operation Menu Tools

Additional Operation Menu Tool:

• Operation —> Path Editing —> Multiple Locations Manipulation —

enables you to split a robotic seam operation into two separate operations.
If, for example, there are reachability or accessibility issues for an
operation’s assigned robot, you can split the problematic operation into
two separate operations and assign each operation to a different robot.
You can only split operations containing three or more locations.

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Activity: Creating Arc MFGs for the Whitehouse part

Perform the related activity using the electronic activities.

.

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Activity: Creating Debur MFGs for the Whitehouse part

Perform the related activity using the electronic activities.

.

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Activity: Creating Paint MFGs for the Whitehouse part

Perform the related activity using the electronic activities.

.

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Activity: Creating Arc Seams for the Whitehouse part (using Project Arc
Seam)

Perform the related activity using the electronic activities.

.

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Activity: Creating Paint Paths for the Whitehouse part (using Project Cont.
Mfg Features)

Perform the related activity using the electronic activities.

.

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Activity: Creating Deburring Paths for the Whitehouse part (using Project
Cont. Mfg Features)

Perform the related activity using the electronic activities.

.

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Activity: Modifying Arc weld Operations and Seams

Perform the related activity using the electronic activities.

.

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Activity: Modifying Debur Operations and Seams

Perform the related activity using the electronic activities.

.

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Activity: Modifying Paint Operations and Seams

Perform the related activity using the electronic activities.

.

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Summary
Subjects learned in this topic:
• Some background information regarding manufacturing feature
representation.

• How to project continuous MFG features to create continuous mfg robotic

paths.

• How to use continuous MFGs.

• Make some changes to the weld path associated to the weld operation.

• Making changes to the path associated to the continuous mfg operation.

Instructor Note:
Summary instructor notes.

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Lesson

15 Final Steps for Robotic Path

Development

Purpose
To provide an introduction to Process Simulate.

Objectives
After you complete this topic, you should be familiar with:
• how to use several techniques to test the robot’s ability to reach locations
in its path.

• reviews Process Simulate collision detection tools that were covered in

detail in the WKP100S Process Simulate on eMS Basics course. Dynamic
and static collision detection will be discussed.

• Tools that can be used to modify paths so that collisions are avoided.

• Various buttons found on the Path toolbar and Operations menu that
can be used to create via locations.

• Several tools that can be used to modify a location in a path.

• Several tools that can be used to modify a path.

• Additional path (weld operation) creation tools.

• Several techniques to edit location attributes and provides some basic

examples of locations attributes from the Process Simulate default
controller.

• How to do signal I/O (without the Cyclic Event Evaluator).

• How to do multiple robot work balancing using location attributes and

Interference Zone.

• How to create swept volumes of an object moving along its path.

• What hard and soft joint limits are and how to set kinematic soft limits.

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• Adding some events to our simulation.

• How to use setup and use external axis (joint). For example, a robot on a
rail (7th axis) or gantry is considered an external axis (joint) or a robot on
a multi axis gantry system.

• Creating a Sequence of Simulative Operations.

• Procedure required to create a compound operation in Process Simulate.

• How to create a basic sequence.

• How to use the PLP and rough volumes

• Some other Robotics features.

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Test Robot’s Reachability to the Locations

This topic describes how to use several techniques to test the robot’s ability to
reach locations in its path.
It contains the following subtopics:
• Robotic Reach Basics

• Smart Place

• Smart Place Modes

• Robotics Viewer

• Jumping and Moving to a Location

• TCP Tracker

• Activity: Testing Reachability (Method 2)

• Activity: See Robot Reaching Locations

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Robotic Reach Basics

Another constraint we will add to the process creation is the reachability

of the robot. These steps must be done before you can test the robot’s
reachability:
• Bring robot into the Scenario (study).

• Mount gun to robot (and define TCPF).

The following methods allow you to check the reachability of a robot to

locations.

• Method 1: Kinematics —> Reach Test (Interactive method)

• Method 2: Kinematics —> Robot Smart Place – Static (Jumps to

the locations)
Smart Place Fixture Placement only works with Weld Operations.

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Reach Test

Kinematics —> Reach Test enables you to test whether a robot can reach
all selected locations, and to optimize the Scenario (study) layout.

You can jump to location by double-clicking a weld location in the Reach

Test.

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Robot Smart Place

Smart Place Fixture Placement only works with Weld Operations.

Kinematics —> Robot Smart Place calculates placements within a

specified search domain for a robot from which it can superimpose its TCPF on
specified locations. Each such calculated placement for the robot is a solution.
• This command creates grid points representing all possible solutions at
the intervals specified.

• Proximity specifies how closely joints may approach their limits for
auto-placement solution to be reported as acceptable. The proximity value
is specified as a percentage of the total joint travel.

• The tested grid points are colored to indicate the degree of success.

• The robot Smart Place command enables you to find optimal locations for
robots and fixtures.

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Final Steps for Robotic Path Development

Smart Place Modes

It can work in one of the following two modes:

• Robot Placement – Enables you to determine the range of points from
which a robot can reach a selected group of weld and via locations, either
fully, partially, or with a collision. This enables you to position robots
optimally. :

• Fixture Placement – Enables you to determine the range of points from

which a selected group of robots can reach selected fixtures (parts and
resources), either fully, partially, or with collision, while performing their
associated operations. This enables you to position fixtures optimally
while maintaining robot reachability.
Smart Place Fixture Placement only works with Weld Operations.

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Robot Viewer

The Robotics —> Robot Viewer .

Panels:
• Joint Monitor — SeeWKP315S Process Simulate on eMS Robotics
Advanced for more information

• Joint Status — covered here

• Digital Signals — See WKP215S Process Simulate on eMS Cyclic Event

Evaluator (CEE) for more information.

• Analog Signals — See WKP215S Process Simulate on eMS Cyclic Event

Evaluator (CEE) for more information.

• TCPF Speed Monitor — SeeWKP315S Process Simulate on eMS Robotics

Advanced for more information

• Joint Speed and Acceleration — SeeWKP315S Process Simulate on eMS

Robotics Advanced for more information

Basic Usage:
In the Robot Viewer, select the down arrow to the right of the Panels button
and uncheck everything except Joint Status.

Click Settings to choose either Joint Values or Limits Percentages.

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Jumping and Moving to a Location

There are several ways to get a robot to a location:

• Sequence Editor simulation controls

• Kinematics —> Jump to Location

• Kinematics —> Jump Assigned Robot

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TCP Tracker

The TCP Tracker command records the motion of the robot TCP as a curve
and stores it as a TCP track object.

Usage:
• Select a robot with a preexisting path/robotic simulative operation.

• Select Robotics —> TCP Tracker .

• From he TCP Tracker window, select the desired track color.

• Play the simulation.

• Turn off the TCP Tracker by click Stop in the TCP Tracker window.

• Delete or black the track lines.

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Activity: Testing Reachability (Method 2)

Perform the related activity using the electronic activities.

.

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Activity: See Robot Reaching Locations

Perform the related activity using the electronic activities.

.

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Final Steps for Robotic Path Development

Dynamic and Static Collision Detection

This topic reviews Process Simulate collision detection tools that were covered
in detail in the WKP100S Process Simulate on eMS Basics course.
It contains the following subtopics:
• Collision Basics

• Collision Viewer

• Dynamic Collision Report

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Collision Basics

These tools can temporally change the colors of objects in the Graphic Viewer
and the Collision Viewer.
There are three levels of detection granularity:
• Near Miss – Objects are highlighted in yellow if they come within a
predefined clearance envelope of each other

• Collision Contact – Objects can optionally be highlighted in red if they

are touching each other (or orange if near miss detection is activated).

• Collision Penetration – Objects are highlighted in red if they exceed the

allowed penetration depth with each other.

Collision detection types:

• Dynamic collisions – Collisions that occur during a simulation or while
objects are being placed.

• Static collisions – Collisions that are occurring without moving the

objects.

Collision options:
When a collision occurs the object’s color is always changed to red in the
Graphic Viewer and the Collision Viewer. Optionally a simulation can be
stopped when a collision is detected and/or a sound is played at regular
intervals while in a collision state.

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Collision Viewer
The Collision Viewer displays all current occurring collisions, near misses
and contacts. It enables you to define, detect and view collisions in the data
currently displayed in the Graphic Viewer, as well as view collision reports.
The Collision Viewer is composed of two panes. The left pane can be closed or
opened by clicking Show/Hide Collision Sets .
To open the Collision Viewer:
• From the View menu, select Viewers, and then Collision Viewer.

To close the Collision Viewer:

• Click Close in the right-hand corner of the window.

Review of Collision Viewer Toolbar:

• New Collision Set

• Remove Collision Set

• Edit Collision Set

• Fast Collision Set

• Emphasize Collision Set

• Show/Hide Collision Sets

• Collision Options

• Collision Mode On/Off

• Freeze Viewer

• Show/Hide Colliding Contour

• Show Colliding Pair

• Export to Excel

• Show/Hide Contour View

• Filter Collision Results

• Collision Depth

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• Color Colliding Objects

• Zoom To Selected

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Dynamic Collision Report

The Dynamic Collision Report records all the collisions that occur during
simulation of the current operation, according to the active collision set in the
Collision Viewer. It enables you to do all of the following:
• Jump directly to the time of a specific collision.

• Save the information in the Dynamic Collision Report in an Excel file

for collaboration with other users.

• View a detailed report for the colliding objects in the active collision set or
for selected collision pairs in the Dynamic Collision Report.

• Use the Dynamic Collision Report to display all the collisions in a

simulation of an operation in conjunction with the Sequence Editor and
Collision Viewer to display all the current collisions.

Basic Usage:
• Setup collision and near miss checking.

• From the Sequence Editor, set a current operation and click Dynamic
Collision Report .

• In the Dynamic Collision Report window, click Start Generating Report

. Process Simulate runs a simulation of the current operation and
populates the Dynamic Collision Report window.

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Introduction to Path Modification

This topic describes tools that can be used to modify paths so that collisions
are avoided.
It contains the following subtopics:
• Path Modification Basics

• Activity: Adding Start / End Vias and Approach / Retract Locations in

the Path

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Path Modification Basics

In this topic, we will create via locations in order to clear clamps and create
pounce/clear locations. We will modify the path to avoid the collisions found
in the previous topic.
These commands are found in the “Operations —> Path Editing”
menu:

• Manipulate a location – Allows manipulating a via location with a

Manipulator Frame and the object placed at the location. Must have a
location selected first. (Most frequently used location modification tool)

• Add Location After - A new location is added to the path after the
selected location. The flow object and Manipulator Frame are placed at
the new location (superimposed on the selected location) allowing you
to place the new location.

• Add Location Before - A new location is added to the path before the
selected location. The flow object and Manipulator Frame are placed at
the new location (superimposed on the selected location) allowing you
to place the new location.

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Activity: Adding Start / End Vias and Approach / Retract Locations in the
Path

Perform the related activity using the electronic activities.

.

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Via Location Creation Tools

This topic describes various buttons found on the Path toolbar and Operations
menu that can be used to create via locations.
It contains the following subtopics:
• Location Creation Basics

• Activity: Creating Collisions Lists

• Activity: Using Add Location By Pick

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Location Creation Basics

If the Path toolbar is not shown, right click on the toolbar area, and
select Path from the popup menu.

Selecting a path in the Graphic Viewer, or location operation on the

Operations Viewer, makes certain options available on the Operations —>
Path Editing menu or Path toolbar.
Use these tools to add another location to a path:

• Add Location By Pick - Add a location using the mouse. Must have a
path/operation selected first. (Most frequently used location creation tool).

• Add Current Location - Add a location at the current position of the

associated object. Must have the operation set as the current operation.

Use these tools to add another location based on an existing location

in a path:

• Add Location After - A new location is added to the path after the
selected location. The flow object and Manipulator Frame are placed at
the new location (superimposed on the selected location) allowing you
to place the new location.

• Add Location Before - A new location is added to the path before the
selected location. The flow object and Manipulator Frame are placed at
the new location (superimposed on the selected location) allowing you
to place the new location.

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Activity: Creating Collisions Lists

Perform the related activity using the electronic activities.

.

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Activity: Using Add Location By Pick

Perform the related activity using the electronic activities.

.

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Location Modification Tools

This topic describes several tools that can be used to modify a location in
a path.
It contains the following subtopics:
• Location Modification Basics

• Automatic Approach Angle

• Modifying Locations Using the Path Editor

• Path Segment Simulation

• Activity: Using Manipulate Location and Rotate Weld Locations

• Activity: Using the Automatic Approach Angle window

• Activity: Modify Locations According to Robot Reach (Pie Chart)

• Activity: Simulating a Segment of a Path

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Location Modification Basics

Use these tools to modify an existing location in a path:

• Operations —> Path Editing —> Manipulate a location – Allows

manipulating a via location with a Manipulator Frame and the gun placed
at the location. Must have a location selected first. (Frequently used
location modification tool)

• Weld —> Rotate Locations - Allows manipulating a weld location

with a Manipulator Frame and the gun placed at the location. Must have
a location selected first. (Frequently used location modification tool)

• Weld —> Pie Chart - Allows manipulating a weld while considering

the robot reachability.

• Path Editor.

• Like any other entity, a location can also be manipulated with these
commands from the Tools —> Placement menu: Placement Manipulator
and Relocate .

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Automatic Approach Angle

The Automatic Approach Angle command can be used to rotate several

weld locations to a collision free approach angle, if one exists.
Automatic Approach Angle functionality:
• Robot — Ability to select robot; the mounted Gun is automatically
selected as well

• Pose — Define the pose for collision analysis

• Locations list — Add and remove weld locations to the list of locations

• Apply – rotate all locations to the optimized approach angle

• View a location’s status using the Pie Chart

• Flip a location’s perpendicular by 180 degrees

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Modifying Locations Using the Path Editor

The Paths Editor can be used to change the position and orientation of the
locations directly.

Add a path: select it and clickAdd Operation to Editor

Remove a path: select it and clickRemove Item from Editor
Specifying which columns are shown in the Path Editor

• On the Path Editor, click Customize Columns .

• In the Customize Columns window in the Available columns list, expand

into the desired group of attributes.

• Select the desired attributes.

This list of attributes can be saved and loaded for later use using
these buttons: and .

• Click [OK].

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Path Segment Simulation

You may wish to concentrate on a specific segment of an operation, for

example to optimize or debug it. In this case, it is time-consuming and
superfluous to simulate the operation from the start each time. You can define
the locations of interest as an operation segment. From the Path Editor,
select the sequential locations, and then click Path Segment Simulate .
When Process Simulate simulates a segment, the simulation runs from the
first of the selected locations and finishes at the last selected location.
Notes: :
• Changing the first or last segment locations or deleting them makes the
segment inactive.

• After using the Add Operation to Editor or Remove Item from Editor
commands makes the segment inactive.

• A segment must contain at least one location.

• The locations in a segment must be continuous.

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Activity: Simulating a Segment of a Path

Perform the related activity using the electronic activities.

.

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Activity: Using Manipulate Location and Rotate Weld Locations

Perform the related activity using the electronic activities.

.

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Activity: Using the Automatic Approach Angle window

Perform the related activity using the electronic activities.

.

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Activity: Modify Locations According to Robot Reach (Pie Chart)

Perform the related activity using the electronic activities.

.

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Path Modification Tools

This topic describes several tools that can be used to modify a path.
It contains the following subtopics:
• Process Simulate Support

• Path Modification Basics

• Automatic Path Planner (APP) for Robotic Paths

• Mirror

• Modifying Paths Using Operation Properties

• Activity: Using Copy Location Orientation

• Activity: Using Interpolate Locations Orientation

• Activity: Mini Putting It All Together

• Activity: Using Reverse Operation

• Activity: Reordering Locations

• Activity: Using Automatic Path Planner for Robot Paths

• Activity: Using Mirror

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Process Simulate Support

PS on
PS on eMS PS on
Teamcenter PS on eMS
Can be done: Robotic Teamcenter
Robotic Flow Paths
Paths Flow Paths
Paths
Create Swept
No Yes Yes Yes
Volume
Use Automatic
No Yes Yes Yes
Path Planner
Create Mirror
No Yes No Yes
Operation

The Mirror command can only be run with Weld Operations. It does not
work with Pick and Place Operations.

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Path Modification Tools Basics

Use these tools to modify an existing path:

• Operations —> Path Editing —> Shift Location Back - Shift location
by one position towards the front of the path. Must have a location
selected first. (Least used location creation tool).

• Operations —> Path Editing —> Shift Location Forward - Shift

location by one position towards the end of the path. Must have a location
selected first. (Least used location creation tool).

• Operations —> Reverse Operation – Changes the order of the

locations in the path to be the reverse. Must have a path/operation
selected first.

• Operations —> Mirror – Creates a second path whose weld locations

are reflected about a plane.

• Operations —>Path Editing —> Multiple Locations Manipulate – Use

to modify locations of continuous feature operations by offsetting the path
from the surface edge it was created from (i.e. for tool compensation).

• Operations —> Path Editing —> Copy Location Orientation – Changes

the orientation of the selected locations to match a reference location.
Uses one reference location and several target locations (For via locations)

• Operations —> Path Editing —> Interpolate Locations Orientation —

Changes the orientation of the selected locations by interpolating their
approach vectors between reference locations. Uses two reference location
and several target locations (For via locations)

• Operations —> Operation Properties – Allows displaying and

modifying various properties of an operation

• Reorder by Links – changes the hierarchy (a.k.a. display order in the

tree) of operations to match the sequence of operations. (Found by right
clicking in the Sequence Editor).

• Weld —> Flip Locations —> Flip Locations on Surface

• Weld —> Align Locations (For weld locations)

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• Weld —> Duplicate Weld Operation – Creates a new weld operation

with a similar weld definition to the previous one. Covered in a later topic.

• Sequence Editor — Drag and drop the operations into the desired order.

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Automatic Path Planner (APP) for Robot Paths

The Operations —> Automatic Path Planner (APP) in Process Simulate

enables users to generate collision paths. The Automatic Path Planner
algorithm works by dividing operations into pairs of locations. For each pair,
it first plans a collision-free path and then optimizes the planned path to be a
smooth, collision-free path.
The input to the APP is a simulative operation or a segment of a simulative
operation (object flow or robotic). The Output of the APP is a collision free
operation.
Automatic Path Planner may add or delete via locations while
calculating collision-free operation paths.

Automatic Path Planner may add or delete via locations while

calculating collision-free operation paths.

Setting the basic parameters:

• Fixed — Check this box to designate a location as mandatory. While
calculating a collision-free path, Automatic Path Planner deletes the
optional via locations (and replaces them with new via locations) but
retains mandatory ones.

• Paths & Locations - List of sequential location from the same operation.

• Set Segments — By default, Automatic Path Planner runs on complete

operations. However, you can select specific segments (sets of two or
more locations) on which to run Automatic Path Planner, if, for example,
you wish to investigate a specific part of a path. In the Automatic Path
Planner window select and right click the desired locations.

Setting the advanced parameters:

• Calculation - The number of path optimization iterations that Automatic
Path Planner performs. Setting the slider for higher precision causes
Automatic Path Planner to run more iterations and more time is required
to complete its calculations.

• Clearance - The allowed distance between the moving object and the
colliding objects. Derived from the Near Miss value of the active collision
list.

• Dynamic Penetration — The number of path optimization iterations that

Automatic Path Planner performs. Setting the slider for higher precision
causes Automatic Path Planner to run more iterations and more time is
required to complete its calculations.

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• Ignore colliding fixed locations — If a segment is invalid due to a

collision, Automatic Path Planner calculates a path that includes the
colliding locations. For colliding locations, the algorithm finds the closest
collision-free location and calculates a path from that collision-free
location.
All the Automatic Path Planner options are saved for the next
session of Process Simulate.

How it works:
The APP goes through two iterations. The first iteration identifies problem
areas in the path. The second iteration deletes the optional locations and
fixes the path (adding locations as needed).
Tips and techniques:
• The APP module utilizes a third party algorithm (KINEO). There is a
specific package license that needs to be installed in order to allow the use
of the APP module.

• The APP will not fix existing flow operation locations that are in a
collision status.

• Since the last location is usually in collision (assembly position) the APP
should be executed with an additional via location that is free of collision.

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Automatic Path Planner (APP) Robot Settings

Robotics Specific Settings

Optimization is an iterative process and may be performed for robotic
operations either by:
• Cycle time — Finding the shortest path

• Joint Travel (Calculating the quickest path) – Automatic Path Planner

assigns zones of varying size to the locations in the path and then runs
a simulation (in the background). The robot is required to pass through
the location zones but is not necessarily expected to arrive at the exact
location. Automatic Path Planner receives collision feedback from the
simulation. If there are collisions, Automatic Path Planner allocates
smaller zones and if not, it allocates larger zones.

• Robot Settings
o Joint Weights - This causes Automatic Path Planner to allocate higher
priority to moving joints with a higher relative weight. For example,
when a workflow necessitates accessing weld points in a crowded
environment, you can assign a higher relative weight to a robot joint
that rotates the weld gun. This causes the Automatic Path Planner
to select it over a joint with a lower relative weight that moves the
robot arm. The resulting path is more likely to avoid collisions in a
restricted area.

o Zones — you can specify which zones (accuracy) to use. They should
be listed from smallest to largest.
Since simulations execute in the background, the duration of
Cycle Time Optimization is typically longer compared to Joint
Travel Optimization.

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Mirror

The Mirror toolbar provides the ability to mirror existing operation and
compound operations including their hierarchy.
• Twin objects (station, lines…) can not be mirrored. Search for mirrored
weld points in the eMS database and connect them to the generated
operation

• Search for mirrored resources (robot, guns…) and connect them to the
generated operation

• Ability to create new resources in their mirrored location

Mirror toolbar functionality:

• Define Mirror Plane - Create mirror plane and locate it

• Find Mirror WPs in Database - Search for Mirror WP in the Database

and load them to the Scenario (study)

• Auto Mirror - search and connect all mirrored objects

• Find Mirror Objects - Search for Mirror object according to the

current selection

• Create New Mirrored Objects - Create new resources / WP in the

mirrored location

• Clear - Clear existing search results

• Clear All - Clear all

• Display - Display selected object

• Emphasize - Emphasize selected pair (i.e. source object and mirror

object)

• Options - Define tolerance search

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Modifying Paths Using Operation Properties

From either the Sequence Editor or the Operations Tree right click the flow
operation (path) and select Operation Properties .
The General tab of the Properties window can be used to change the Name of
the operation and enter a Comment.

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Activity: Using Copy Location Orientation

Perform the related activity using the electronic activities.

.

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Activity: Using Interpolate Locations Orientation

Perform the related activity using the electronic activities.

.

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Activity: Mini Putting It All Together

Perform the related activity using the electronic activities.

.

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Activity: Using Reverse Operation

Perform the related activity using the electronic activities.

.

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Activity: Reordering Locations

Perform the related activity using the electronic activities.

.

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Activity: Using Automatic Path Planner for Robot Paths

Perform the related activity using the electronic activities.

.

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Activity: Using Mirror

Perform the related activity using the electronic activities.

.

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Additional Path Creation Tools

In this topic, we will discuss additional path (weld operation) creation tools.
There are several ways to create a new (path) weld operation, including:
• Create a new weld operation in directly.

o Select Operation -> New Operation —> New Weld Operation .

• Duplicate an existing weld operation.

o Select Weld -> Duplicate Weld Operation .

It contains the following subtopics:

• Duplicate Weld Operation

• Instructor Demo: Using Duplicate Weld Operation

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Duplicate Weld Operation

The Duplicate Weld Operation command enables you to create a new

weld operation by applying an existing weld operation definition to new weld
points. This command is useful for creating a new operation that is similar to
a previously-defined operation. The positions of the new weld points must
correspond to the weld points defined in the existing weld operation.

For example, if you have defined an operation for welding a car door, you can
use this command to create a new operation for welding a different type of
car door.

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Instructor Demo: Using Duplicate Weld Operation

Perform the related activity using the electronic activities.

.

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Editing Location Attributes

This topic describes several techniques to edit location attributes and provides
some basic examples of locations attributes from the Process Simulate default
controller.
We will set the motion type, zone, speed, and wait time. There are two tools
to edit location attributes:
• Path Editor

• Robotics -> Teach Pendant

It contains the following subtopics:

• Basic Location Attributes

• Teach Pendant

• Custom columns in the Path Editor

• Activity: Editing Location Attributes

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Basic Location Attributes

• Motion Type – Describes how a robot will move in between locations.

o Joint – typically causes the robot to move in an arc between locations

o Linear – causes the robot to move straight between the locations.

• Zone – Describes how the robot will approach/arrive at a location.

o Fine – causes the robot to slow and “arrive” at the location

o No Decel – cause the robot to not slow and “approach” the location
(However, arrival is not a requirement).

• Speed
o Joint Speed measured as a percentage of the max speed.

o Linear Speed measured in mm/sec.

• Wait Time – measured in seconds.

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Teach Pendant

The Teach Pendant can be used to view and edit the attributes of a path,
one location at a time.

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Custom columns in the Paths Editor

The Path Editor can be used to view and edit same attribute of several
locations simultaneously.

Custom columns in the Paths Editor:

• On the Path Editor, click Customize Columns .

• In the Customize Columns window in the Available columns list, expand

into the desired group of attributes.

• Select desired attributes.

This list of attributes can be saved and loaded for later use using
these buttons: and .

For each robot controller (i.e. ABB, Fanuc, Kuka, etc ...) there a
sample .XML file that can be loaded located under its install folder
(i.e. .\Tecnomatix\eMPower\Robotics\OLP\ ...).

• Click [OK].

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Activity: Editing Location Attributes

Perform the related activity using the electronic activities.

.

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Signal (I/O) Definition & Simulation

This topic describes how to do signal I/O (without the Cyclic Event Evaluator).
It contains the following subtopics:
• Steps for Driving Devices

• Activity: Driving Devices

• Activity: Waiting Until a Device is Driven to Move

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Steps for Driving Devices

• Define some poses for the destination mechanism, if not already defined

• Enter the Teach Pendant

• Pick the weld path to send the signals from

• Enter the device to drive and a state to drive it to

Press the [Shift] key and pick the object at the same time. The
object’s self-origin frame will be displayed. Pick it again with the
[Shift] key depressed to turn it off (or select another object.

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Activity: Driving Devices and Waiting Until a Device is Driven to Move

Perform the related activity using the electronic activities.

.

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Multiple Robot Simulation & Work Balance

This topic describes how to do multiple robot work balancing using location
attributes and Interference Zone.
It contains the following subtopics:
• Steps for Sending Signals to Robots

• Activity: Adding a Second Robot

• Activity: Two Robot Simulation

• Activity: Setting Up Robot Signals using the Teach Pendant

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Steps for Sending Signals to Robots

• (Create simulative operations for two robots in the current Scenario

(study))

• Pick the weld path to send the signals from

• Enter the Teach Pendant window

• Enter the robot and signal to send to that robot

• Pick the weld path to receive the signal

• Enter the Teach Pendant window

• Enter the signal to wait for

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Activity: Adding a Second Robot

Perform the related activity using the electronic activities.

.

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Activity: Two Robot Simulation

Perform the related activity using the electronic activities.

.

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Activity: Setting Up Robot Signals using the Teach Pendant

Perform the related activity using the electronic activities.

.

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Working with Hard and Soft Limits

This topic describes what hard and soft joint limits are and how to set
kinematic soft limits.
It contains the following subtopics:
• Hard limits

• Soft limits

• Activity: Avoiding Collisions with Stationary Objects

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Hard limits

• Set the range from infinite motion to the correct range for that robot

• Set by the manufacturer of the robot

• Controlled by the .e file or other kinematic joint limits

• Defined when the kinematics for the object is modeled in Process Simulate.

• Defined for the robot prototype (while modeling the robot, use the
Kinematic Editor).

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Soft limits

• Farther restrict the hard limit range of motion

• Used to avoid robot collisions with stationary objects in the Scenario

(study)

• Set for a certain robot instance

• The default soft limits are the same as the hard limits

• Set soft limits using Kinematics —> Joint Jog .

• To remove soft limitsReset All Soft Limits

In Process Simulate, hard limits are what is set during modeling of the
prototype, whereas soft limits are set on an instance of the robot in
the scenario (study).

On most 6 axis robots, J3 (dependant on J2) has variable joint limit and
cannot have soft limits applied to it).

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Activity: Avoiding Collisions with Stationary Objects

Perform the related activity using the electronic activities.

.

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Robotic Swept Volumes and Interference Zones

This topic describes how to create swept volumes of a robot moving along
its path.
It contains the following subtopics:
• Swept Volume Basics

• Process Simulate Swept Volumes

• Process Simulate Interference Volumes

• Process Simulate Inference Zones

• Activity: Using Swept Volumes

• Activity: Using Inference Zones

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Swept Volume Basics

In general, there are several different types of swept volumes that could be
created or considered:
• Robot Operating Space – 3D volume of a robot running along a path. This
can be created in Process Simulate.

• Robot Restricted Space – (in case the robot goes wild) Maximum
movement of a robot, including soft limits. This cannot be created in
Process Simulate.

• Robot Safety Space

o New standard definition: a clearance envelope around the operating
spaces of all involved robots. This can be created in Process Simulate.

o Old standard definition: a clearance envelope around the restricted

space of all involved robots. This cannot be created in Process
Simulate.
The creation of a swept volume in Robcad has a 15 mm (cube)
tolerance. The creation of a swept volume in Process Simulate
has a tighter tolerance and uses a different algorithm to
generate them.

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Process Simulate Swept Volumes

• The Operations —> Swept Volume command creates an object to

represent the robot operating space.

• The swept volume can be used to help position robots in optimal locations,
especially when robots participate in a single process and work on the
same parts.

• Users can list multiple simulative operations in this command to produce

multiple swept volume objects.

• Can consider simulation events

• Can support both time-based and event-based simulation

• The resulting objects are shown in the Volumes folder of the Object Tree.

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Process Simulate Interference Volumes

An Interference Volume is the common volume of two intersecting Swept

Volumes.
You cannot make an interference volume of another interference
volume.

Capabilities
• Represents the interference volume using a physical 3D volume.

• The interference volume is a persistent object stored as a JT file.

• The Relation Viewer displays the relation between the origin operations
and the interference volume.

• Viewing and examining this object simplifies complex objects violation

scenarios, enhances the collision detection capabilities and enables a
faster solution of the problem.

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Process Simulate Inference Zones

The Interference Zone command can only be run with Weld Operations
and cannot be run with Pick and Place Operations.

• To open the command, select Robotics —> Interference Zone .

• An interference zone is the zone common to a weld operation and the

swept volume previously created from another robotic operation. This
command can be used to analyze the robot safety space for an area of a
manufacturing facility.

• The command creates the interference zone by simulating a robotic

operation and comparing it with a swept volume object.

• Where the simulation results in a collision between the swept volume

object and the robotic operation, the command creates interference zones.

• The interference zone can be used to detect and visualize collisions that
may occur during the execution of robotic operations.

• The interference zone is detected when any object attached to the robot
collides with the swept volume or any attached object which is visible.

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Activity: Using Swept Volumes

Perform the related activity using the electronic activities.

.

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Activity: Using Inference Zones

Perform the related activity using the electronic activities.

.

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Adding Events to a Sequence of Simulative Operations

In this topic, we will add some events to our simulation.
It contains the following subtopics:
• Introduction to Events

• Additional Event Types

• Event Basics

• The Attach Command versus the Attach Event

• Emphasize Events versus Emphasize Presentation Modes

• Activity: Add an Emphasize Event

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Introduction to Events

Events can be added to operations and simulative operations. They are a

way to make something happen at a specific time during the simulation.
Sometimes events just add a more polished look to the simulation, and other
times they are critical to creating an accurate simulation.
Actions performed by events during a simulation override similar
actions performed by a presentation mode.

There are several different types of events in Process Simulate:

• Attach Event - Attaches several objects to another object.

• Detach Event - Breaks the attachment.

• Display Event - Shows a blanked object during a simulation.

• Blank Event - Hides a displayed object during a simulation.

• View Point Event – Stores and applies the current viewpoint during a
simulation.

• Emphasize Event – Used to color specific objects or change their

transparency during simulation.

• De-emphasize Event – Used to undo the affects of the Emphasize Event.

• Pause Event – Temporarily stop the simulation. This type of event can be
enabled or disabled.

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• Activate Collision Sets Event — starts collision checking based on the

specified collision sets.

• Deactivate Collision Sets Event — stops collision checking based on the

specified collision sets.

• Human Event — This event type is discussed in the Process Simulate

Human training course.

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Additional Event Types

Additional event types that not shown on the Sequence Editor right
click by default:

These can be added to the right click using Tools -> Customize.
• Snapshot Event – Applies the viewpoint of a snapshot during a simulation
(but nothing else from the snapshot).

• Add to Group Event - Adds objects to a group.

• Remove from Group Event - Removes objects from a group

• Signal Event – Covered in the WKP215S Process Simulate on eMS CEE

• Human Event – Covered in the WKP206S Process Simulate on eMS

Human.

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Event Basics

To create an event:
Events are created by right clicking the desired operation in the Gantt chart
displayed in the Sequence Editor and selecting the desired event type.
To edit an event:
Existing events are shown as red dots in the Gantt chart.

There are several things that can be done with an event:

• Drag the red dot on the Gantt chart to change the time when it occurs.

• Right click on the red dot on the Gantt chart and select Edit Event .
Change its parameters and Click [OK].

• Right click on the red dot on the Gantt chart and select Create Opposite
Event (i.e. Blank / Display; Attach / Detach).

• Right click on the red dot on the Gantt chart and select Copy .

• Right click on the red dot on the Gantt chart and select Delete .

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The Attach Command versus the Attach Event

The Attach Command

• The Attach command is found by selecting Modeling -> Attach . This

command is independent of a sequence of operation. The only way to
break this attachment is to use Modeling -> Detach .

You can see if an object is attached to another object by selecting the

object and opening the Modeling menu. If the Attach option is
disabled, the object is already attached to an object and you can
detach it if required. If the Detach option is disabled, the object
is not attached to another object and you can attach it if required.

Specify the type of attachment, as follows:

• One Way: The attached objects can be moved independently of the object
to which they are attached. If you move the object to which the objects are
attached, all the objects move together.

• Two Way: If you move the attached objects or the object to which the
objects are attached, all the objects move together.

The Attach Event

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This event works just like the command, but it is performed during a
simulation.

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Instructor Demo: Adding an Attach Event

Perform the related activity using the electronic activities.

.

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Activity: Adding a View Point Event

Perform the related activity using the electronic activities.

.

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Activity: Add a Pause Event

Perform the related activity using the electronic activities.

.

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Activity: Coloring Events by Type

Perform the related activity using the electronic activities.

.

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7th Axis and More (External Axis Usage)

This topic describes how to use setup and use external axis (joint). For
example, a robot on a rail (7th axis) or gantry is considered an external axis
(joint) or a robot on a multi axis gantry system.
Related commands:

• Kinematics —> Set External Axes Values

• Kinematics —> Clear External Axes Values

• Robotics —> Robot Properties

It contains the following subtopics:

• External Axes Basics

• External Axes Usage

• Instructor Demo: Working with a 7th Axis

• Activity: Working with a 7th Axis

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External Axis Basics

In Process Simulate Rails, Gantries and Positioners are types of external

joints.
• Rail – It is a separate .COJT that consists of a single linear joint. A robot
is Attached to the child link of j1 (in the study, not in modeling).

• Gantry – It is a separate .COJT that consists of three linear joints. A

robot is Attached to the child link of j3 (in the Scenario (study), not in
modeling).

• Positioner – It is a separate .COJT that consists of 2 rotational joints.

The part is Attached to the child link of j2 (in the Scenario (study), not
in modeling).

• Other kinematic devices can be used as externals as well, these three

are provided as typical examples.

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External Axes Usage

Set External Axes Values lets you to store the current values of external axes
(such as rails, servo guns and so on) that were defined in Robot Properties at a
selected location. When the robot reaches this location, the external axes will
be positioned at the stored values.
To set the external axes values:
1. Select one or more robotic locations or an operation from the Operations
Tree or the Graphic Viewer, and then click Set External Axes Values .

2. In the Set External Axes Values window, select the external axes whose
values you want to save

3. Click [OK]. The current values of the robot’s external axes are stored at
the location. When the robot reaches this location, the external axes will
be positioned according to these values.
In the Path Editor, the External Axes column indicates how many
external axes have been defined at the selected location and of
those, how many axis values have been set with this command.
Mouse over the pencil in the External Axis column to display a tool
tip with the set values.

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Instructor Demo: Working with a 7th Axis

Perform the related activity using the electronic activities.

.

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Activity: Working with a 7th Axis

Perform the related activity using the electronic activities.

.

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Creating Sequences of Simulative Operations

This topic describes the basics of creating a Sequence of Simulative
Operations.
In the previous topics of this Student Guide, we simulated individual parts of
an assembly process. A Sequence of Simulative Operations combines separate
simulative operations into an entire assembly process.
This process defines individual operations for the currently displayed
assembly, combines them into a sequence of operations, and simulates a
selected sequence. The purpose of these commands is to demonstrate and
verify the feasibility of a complete assembly procedure in the dynamic
simulated environment, and to produce a detailed assembly report.
It contains the following subtopics:
• Process Simulate on eMS Sequence of Operations Organization

• Types of Simulative Operations

• Gantt Chart Operation and Event Colors

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Process Simulate on eMS Sequence of Operations Organization

Sequence of Operations are made up of any sequence of operations and

compound operations. For example, here is a Sequence of Operations
containing three locations that are grouped using two compound operations,
as shown in the following diagram:

• Location: a location represents a single movement of a human, object,

or robot.

• Simulative Operation: Defines the procedure required to complete the

compound operation. An operation associates a part with a path, and
assigns the amount of time it takes to complete the procedure. (These
have already been created in previous activities.)

• Sequence of Process (Compound Operation): A group of operations that

either occur at the same time or are staggered throughout the compound
operation’s simulation time. It can be set as the current operation and
typically contains more than one operation or compound operation. This is
explained in more detail in Lesson 3: Creating an Sequence of Operations.

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Types of Simulative Operations

There are several types of simulative operations:

• Object flow : An operation consisting of the movement of a part along its

assembly path. These operations are represented using the icon. (Covered
in the WKP101S Process Simulate on eMS Part Flow Simulation course).

• Device : An operation consisting of any mechanical device (i.e. a robot,

human, clamps, cart, etc…) moving from one pose to another. It is
represented using the icon. (Covered in just about all courses).

• Robotic: A compound operation consisting of a sequence of locations

(positions) for the Robot TCPF. This type can be used for material
handling or welding paths. These operations are represented using these
, , , icons. (Covered in this course).

• Human: An operation or compound operation consisting of a single

human motion or a series of motions. These operations are represented
using these , , , , icons. (Covered in the WK206S Process
Simulate on eMS Human course).

• Non-sim : An activity requiring time (but will not be simulated) that

you want to include in the Sequence of Operations. These operations are
represented using the icon. (Covered in the WKP215S Process Simulate
on eMS Cyclic Event Evaluator (CEE) course).

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Creating Compound Operations

This topic describes the procedure required to create a compound operation
in Process Simulate.
It contains the following subtopics:
• Compound Operation Basics

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Creating and Linking Compound Operations

A compound operation is a group of operations that either occur at the same

time or are staggered throughout the compound operation’s simulation time.
Two Ways to Create Compound Operations:
Both of these methods are available on the right click of the Operations Tree:

• Select Operations -> New Operation —> New Compound Operation .

• Or in the Sequence Editor, select several compound operations, right click

and select Group To Compound .

Two Ways to Link Compound Operations:

• Hold down the [Ctrl] key, select more than one compound operation, and
click Link .

• Or on the Gantt chart of the Sequence Editor, drag draught down in the
middle of a compound operation and drop the other end of the link on
the succeeding compound.

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Creating a Robotic Sequence (Method 1 and 2)

This topic describes how to create a basic sequence.
Operations performed in a certain order make up a sequence. There are
several types of operations that were briefly discussed in the previous topic.
Within each operation, multiple events can be performed.
It contains the following subtopics:
• Method 1

• Method 2

• Comparing Methods of Work

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Creating a Robotic Sequence (Method 1)

Create the sequence by adding drive device, wait device, send signal, and wait
signal OLP commands to the locations.

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Creating a Robotic Sequence (Method 2)

Instead of adding drive device, wait device, send signal, and wait signal OLP
commands to the locations; we could have created this same sequence using
another method available in Process Simulate:
1. Create a Device operation to close the clamps.

2. Create a Device operation to open the clamps.

3. Use the Sequence Editor define operation links in this order:

• Close clamps

• WeldOperation 1

• WeldOperation 2

• Open clamps

Process Simulate will figure out the duration for you later when
the simulation runs

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Comparing Methods of Work

There are at least two ways to create this sequence of operations:

Method 1:
Notice that this sequence of operations only has two operations in the Gantt
chart that appear to happen at the same time. However, both robots simulate
at different times, and the clamps open and close within them.
Method 2:
Using this method we can visually see the time when each robot starts and
stops; and the time it takes for the clamps to open and close.
Which method is better depends on your preference and the way in which you
would like to use Process Simulate. The point is that Process Simulate is
flexible to your needs

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PLPs and Rough Volumes (Not Covered in Class)

This topic describes how to use the PLP and rough volumes.
It contains the following subtopics:
• Working with PLPs

• Creating Rough Volumes

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Working with PLPs

PLP − a Principle Locating Point is the point of contact of the clamp on the
part. More information on his topic can be found in the EMS228 Process
Designer for Body-In-White course.

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Creating Rough Volumes

Concurrent engineering methods are implemented in the Body In White

(BIW) process. This means that the spot weld engineer can design a weld
path that does not collide with any units in the cell, even before the units
have been drafted in detail. The unit designer need only provide the spot weld
engineer with a rough volume, i.e. a constraining volume in which the unit
designer is limited, so that the engineering process can progress concurrently.

Example of two rough volumes that can be created using the Process Simulate
Modeling functionality. They represent the fixtures holding a door frame and
can be used for collision detection until the actual units are available. They
are created at the PLPs located on the part for this Scenario (study).

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Other Robotics Features (Not Covered in this Course)

This topic describes some other Robotics features. These topics are here for
reference, but will not be covered in this course.
It contains the following subtopics:
• Creating Weld Points

• Multi-Assign Weld Points

• Automatic Weld Point Assign

• Update Weld Locations

• Unified Collision Settings

• Flip Location on Solid

• Selected Intermediate and Advanced Robotics topics (More Topics Not

Covered in the Basic Robotics Course)

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Creating Weld Points

The Weld —> Spot —> Create Weld Points option enables you to create
weld points. Usually weld points are imported from the database. However,
in the early planning stages information about weld points is not always
available and you can therefore add weld points directly in Process Simulate
if required. Weld points are displayed both in the Graphic Viewer and in the
Operations Tree. Weld points are attached and assigned to parts. You can
see to which part a weld point is assigned by right-clicking the weld point,
selecting Properties and looking at the Attached to category.

• Select Weld —> Spot —> Create Weld Points .

If the created weld point was created on a part, that part is assigned to
the weld point.

To create weld points:

1. Select Weld —> Spot —> Create Weld Points . In the Graphic Viewer,
the cursor changes to a crosshair .

2. Change the Pick Intent to Where Picked.

3. Click (on the part) in the Graphic Viewer where you want to create a weld
point. The weld point is indicated by a + symbol. The cursor remains
as a crosshair .

4. Create further weld points as required.

5. Select Weld —> Spot —> Create Weld Points again to return the
cursor to normal.

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Multi-Assign Weld Points

Assign Parts enables you to simultaneously assign multiple weld points

to multiple parts. You can then select the single part to which the weld points
are attached. Once the weld points are attached to a specific part, they move
relative to that part if the part is moved to a different location in the cell.

• Select Weld -> Assign Parts

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Automatic Weld Point Assign

Automatic Parts Assignment can be used to perform manual or automatic

weld point assignment to parts. Automatic assignment assigns based on
closeness of parts to welds.

• Select Weld -> Automatic Parts Assignment .

To use this tool:

1. Select some weld points from the Graphic Viewer or Operations Tree.

2. Select Weld -> Automatic Parts Assignment . The Automatic Part

Assignment window is displayed, containing a list of all parts that have
already been assigned to the selected weld points, if any.

3. The following buttons are available in the toolbar of the Automatic Part
Assignment window:

• Search - Finds all the parts located within range (as defined in
the Settings dialog box) of the selected weld points and displays them
in the table. The parts that have not yet been assigned are displayed
in gray italics.

• Shift Part Left - Shifts a part in the list to the left.

• Shift Part Right - Shifts a part in the list to the right.

• Remove Part - Removes a part from the list, even if it has already
been assigned.

• Settings - Opens the Settings window, which contains the distance

and box size fields. Distance defines the search range for parts (based
on the active unit, as defined in Options). Any parts located less than
this distance from a weld point are automatically assigned to that
weld point. Box Size defines the size of the box drawn around the
weld points in the Graphic Viewer when they are selected in the table.

• Assign - Assigns parts to the weld points selected in the table.

• Export to Excel - Exports the list to a CSV file, which can be

viewed by Microsoft Excel.

• Filter Out Assigned - When selected, filters out weld points with
assigned parts from the list.

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4. Select Search to have the system find all the parts that are within
range of the selected weld points and display them in the table.

5. Review the list of parts, and either select Assign to assign the part,
or click Remove Part to remove the part from the list. When a weld
point in the list is selected, each part within range is displayed in the list
and in the Graphic Viewer in a different color.

Click Filter Out Assigned to filter out weld points that already
have assigned parts from the list

6. If required, select Shift Part Left or Shift Part Right to modify

the order of the parts assigned to the weld points. By default, the part
listed in the Part 1 column is defined as the attached part (also known as
the leading part). This is the part to which the weld point is actually
attached. If this part is moved in the Graphic Viewer, the weld point
moves relative to it.
To select a different part as the attached part, click in the Attach To
column and select a part from the displayed dropdown list

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Update Weld Locations

• For Spot Welding:

Weld -> Spot —> Update Weld Locations Projection enables users to
detect weld locations that may need to be re-projected. The command lists
all weld locations which are candidates for re-projection based on:
o Weld Point Change – weld points with positions that have changed
since the corresponding weld location was last projected.

o Part Change – part on to which the location was originally projected

has changed Users can then decide whether to re-project the locations,
while maintaining their current approach angle.

Clicking Weld -> Spot —> Update Weld Locations Projection when
all weld locations are update to date produces the following message: No
locations were found requiring project update.

• For Continuous processes:

Weld -> Continuous —> Update Continuous MFG enables users to

detect locations that may need to be re-projected. The command lists all
locations which are candidates for re-projection.

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Unified Collision Settings

Functionality
• One collision set for all weld applications (Robot Smart-Place, Automatic
Approach Angle, Weld Distribution Center, Pie Chart)

• Choose between default collision set or collision viewer active sets

• Define default collision set with or without self collision lists

• Improved behavior of ignoring gun tip collision: during welding only at

weld location and between gun and welded part only

• Previous behavior of constant exclude is optional

• Detection sphere range can be set by the user

Why is this important to you?

• Prevent errors by clear and consistent collision detection

15-114 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Final Steps for Robotic Path Development

• Save time with default collision set

• Increase process quality and save planning time – detect only valid gun
tip collisions

Process Simulate on eMS Basic Robotic Simulation Student Guide 15-115

Final Steps for Robotic Path Development

Flip Location on Solid

The Weld —> Flip Locations —> Flip Locations On Solid command is
described here. This command is different from Weld —> Flip Locations —>
Flip Locations On Surface discussed earlier.
Functionality
• Flip weld locations consider assigned parts and their thickness

• Auto-detect external surfaces

• Show assigned parts

• Ability to consider additional parts

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 Final Steps for Robotic Path Development

Why is this important to you?

• Support solid modeled CAD data

• Using part thickness information leads to precise results

• Save time by minimizing required weld location manipulations

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Final Steps for Robotic Path Development

Selected Intermediate and Advanced Robotics topics (More Topics Not

Covered in the Basic Robotics Course)
For a more complete list of topics and information on thee
courses, see the Tecnomatix course catalog online at
http://training.industrysoftware.automation.siemens.com/finder/ilt_list.cfm

These topics are covered in the WKP215S Process Simulate on eMS Cyclic
Event Evaluator (CEE) course:
• Creation of smart components and logic blocks

• Simulation of logic

• Event based simulation

• Gripper Operations

• Etc…

These topics are covered in the WKP315S Process Simulate on eMS Robotics
Advanced course:
• Robot Configuration (Solutions and Turns)

• Robotic Path Templates

• RRS Simulation

• Robot Program Tool

• Robot Program Editing

• Etc…

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 Final Steps for Robotic Path Development

Putting It All Together

At the beginning of this class you had little or no knowledge of Process
Simulate. Through class you have been exposed to many Process Simulate
features and had time to practice what you have seen. You must continue to
use this tool after class in conjunction with other users in your company,
additional training classes, and Siemens PLM Software services personnel in
order to become an expert.

Process Simulate on eMS Basic Robotic Simulation Student Guide 15-119

Final Steps for Robotic Path Development

The Basic Process Overview

The basic flow followed in this book is made up of three basic steps that were
covered throughout this Student Guide:

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 Final Steps for Robotic Path Development

The Detailed Process Overview

The process of performing weld spot allocation is made up of six basic steps
that will be covered throughout this topic. We will follow this same process
in this class.

The process of performing weld gun allocation is made up of three basic steps
that will be covered throughout this topic. We will follow this same process
in this class.

Process Simulate on eMS Basic Robotic Simulation Student Guide 15-121

Final Steps for Robotic Path Development

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 Final Steps for Robotic Path Development

Summary
Subjects learned in this topic:
• how to use several techniques to test the robot’s ability to reach locations
in its path.

• reviews Process Simulate collision detection tools that were covered in

detail earlier in this course.

• Tools that can be used to modify paths so that collisions are avoided.

• Various buttons found on the Path toolbar and Operations menu that
can be used to create via locations.

• Several tools that can be used to modify a location in a path.

• Several tools that can be used to modify a path.

• Additional path (weld operation) creation tools.

• Several techniques to edit location attributes and provides some basic

examples of locations attributes from the Process Simulate default
controller.

• How to do signal I/O (without the Cyclic Event Evaluator).

• How to do multiple robot work balancing using location attributes and

Interference Zone.

• How to create swept volumes of an object moving along its path.

• What hard and soft joint limits are and how to set kinematic soft limits.

• Adding some events to our simulation.

• How to use setup and use external axis (joint). For example, a robot on a
rail (7th axis) or gantry is considered an external axis (joint) or a robot on
a multi axis gantry system.

• Creating a Sequence of Simulative Operations.

• Procedure required to create a compound operation in Process Simulate.

• How to create a basic sequence.

• How to use the PLP and rough volumes

• Some other Robotics features.

Process Simulate on eMS Basic Robotic Simulation Student Guide 15-123

Final Steps for Robotic Path Development

Instructor Note:
Summary instructor notes.

15-124 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
Index

Numerics/Symbols Automatic Path Planner (APP) Robot

Settings . . . . . . . . . . . . . . . . . . . 15-41
7th Axis and More (External
Automatic Weld Point Assign . . . . 15-111
Axis) . . . . . . . . . . . . . . . . . . . . . 15-91
Available Types for Display by
Type . . . . . . . . . . . . . . . . . . . . . . 2-50
A
Accessing and Using the Customize B
Window . . . . . . . . . . . . . . . . . . . . 2-31 Basic Concepts . . . . . . . . . . . . . . . . . 1-1
Accessing Data in Process Basic Definitions . . . . . . . . . . . . . . . 1-5
Simulate . . . . . . . . . . . . . . . . . . . 1-17 Basic Kinematics . . . . . . . . . . . . . . . 9-5
Accessing Online Help and Release Basic Location Attributes . . . . . . . 15-57
Notes . . . . . . . . . . . . . . . . . . . . . . 2-74 Basic Object Types . . . . . . . . . . . . . 1-46
Adding Events to a Sequence of Simulative Basic Options Setup . . . . . . . . . . . . 1-22
Operations . . . . . . . . . . . . . . . . . 15-80 Basic Principles . . . . . . . . . . . . . . . 12-8
Adding Kinematics to a Simple Basic Relocate Command Usage . . . 3-24
Robot . . . . . . . . . . . . . . . . . . . . . . 9-48 Basic Robotic Simulation Course
Adding Text in the Graphic Overview . . . . . . . . . . . . . . . . . . . . 19
Viewer . . . . . . . . . . . . . . . . . . . . . 5-16 Basic Section Cutting Usage . . . . . 5-50
Additional Arc weld Tools . . . . . . . 14-28 Basic Usage of Continuous Mfg Features
Additional Commands . . . . . . . . . . 2-67 and Operations . . . . . . . . . . . . . 14-24
Additional Event Types . . . . . . . . 15-83 Basic Viewing Command Usage . . . 2-27
Additional General Continuous Mfg Branching Basics . . . . . . . . . . . . . . 9-29
Feature Tools . . . . . . . . . . . . . . . 14-27
Additional Operation Menu
C
Tools . . . . . . . . . . . . . . . . . . . . . 14-31
Additional Paint Tools . . . . . . . . . 14-29 Cam Joint Basics . . . . . . . . . . . . . 10-41
Additional Path Creation Tools . . . 15-53 Cancel Checkout . . . . . . . . . . . . . . 1-30
Advanced Relocate Command Changing Pick Behavior and Creating
Usage . . . . . . . . . . . . . . . . . . . . . 3-26 Frames . . . . . . . . . . . . . . . . . . . . . 3-7
Advanced Techniques for Creating Check In . . . . . . . . . . . . . . . . . . . . 1-29
Frames . . . . . . . . . . . . . . . . . . . . 3-11 Check In and Check Out . . . . . . . . 1-25
Arc Weld Basics . . . . . . . . . . . . . . . 14-3 Check In and Check Out Basics . . . 1-26
Assigning Attributes . . . . . . . . . . . 9-46 Check Out . . . . . . . . . . . . . . . . . . . 1-28
Attribute Assignment Basics . . . . . 9-47 Checking Nodes In and Out . . . . . . 1-27
Attributes of Cranks . . . . . . . . . . . 10-8 Collapse to Selection . . . . . . . . . . . 2-72
Automatic Approach Angle . . . . . 15-28 Collision Basics . . . . . . . . . . . . . . 15-15
Automatic Path Planner (APP) for Robot Collision Detection Basics . . . . . . . 5-25
Paths . . . . . . . . . . . . . . . . . . . . . 15-39 Collision Factors . . . . . . . . . . . . . . 5-45

Process Simulate on eMS Basic Robotic Simulation Student Guide Index-1

Index

Collision Introduction . . . . . . . . . . 5-34 D

Collision Report Level . . . . . . . . . . 5-41
Collision Viewer . . . . . . . . . . 5-26, 15-16 Data Structure1 . . . . . . . . . . . . . . . 1-23
Comparing Methods of Work . . . . 15-104 Define an Object As a Gripper (Discussion
Complete Kinematic Basics . . . . . . 10-6 Only) . . . . . . . . . . . . . . . . . 12-41, 13-4
Compound Equipment . . . . . . . . . 10-47 Define an Object As a Servo Gun
Configuring levels of detection (Discussion Only) . . . . . . . . . . . . 12-67
granularity . . . . . . . . . . . . . . . . . 5-37 Defining a Collision Set (List Pair)
Continuous Applications . . . . . . . . 14-1 . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Continuous Location Defining an object as a Tool . . . . . . 9-39
Constraints . . . . . . . . . . . . . . . . 14-19 Defining Poses on the Gun
Continuous MFG Prototype . . . . . . . . . . . . . . . . . . . 9-36
Representation . . . . . . . . . . . . . . 14-13 Defining Speed and Acceleration . . 9-33
Continuous MFGs and Continuous Defining the Cam Joint . . . . . . . . 10-42
Feature Operations . . . . . . . . . . 14-23 Defining the Train Joint . . . . . . . . 10-36
Crank Basics . . . . . . . . . . . . . . . . . 9-22 Description . . . . . . . . . . . . . . . . . . 9-54
Cranks . . . . . . . . . . . . . . . . . . . . . 9-24 Description of Joint Dependencies . . 9-18
Creating a Compound Operation . . 15-99 Design Targets . . . . . . . . . . . . . . . . 12-6
Creating a Robotic Sequence (Method 1 Designing a Spot-Welding Line . . . 12-5
and 2) . . . . . . . . . . . . . . . . . . . . 15-101 Dimensions . . . . . . . . . . . . . . . . . . 2-56
Creating a Rough Mounted Workpiece Direct Kinematics . . . . . . . . . . . . . 4-14
(Pedestal Welding) Path . . . . . . . 12-49 Disconnected System Root . . . . . . . . 6-9
Creating a Study . . . . . . . . . . 1-55, 11-3 Discussion of Steps to Add Poses to an
Creating and Editing a Weld Object . . . . . . . . . . . . . . . . 12-40, 13-3
Path . . . . . . . . . . . . . . . . . . . . . . 12-24 Display by Type Basics . . . . . . . . . 2-49
Creating and Linking Compound Display or Hide the Floor . . . . . . . . 2-73
Operations . . . . . . . . . . . . . . . . . 15-100 Docked and Floating Viewers . . . . . 1-74
Creating and Using Snapshots . . . . . 5-7 Docking Viewers . . . . . . . . . . . . . . 1-72
Creating Device Operations . . . . . . . 4-7 Duplicate Weld Operation . . . . . . 15-54
Creating High-Level Resource and Dynamic and Static Collision
Operation Trees . . . . . . . . . . . . . . 1-33 Detection . . . . . . . . . . . . . . . . . . 15-14
Creating Objects Basics . . . . . . . . . 1-34 Dynamic Clipping . . . . . . . . . . . . . 2-61
Creating Rough Volumes . . . . . . . 15-107 Dynamic Collision Report . . . . . . . 15-18
Creating Sequences of Simulative
Operations . . . . . . . . . . . . . . . . . 15-96 E
Creating Weld Points . . . . . . . . . . 15-109
Editing Location Attributes . . . . . 15-56
Custom columns in the Paths
Entity Selection . . . . . . . . . . . . . . . 2-35
Editor . . . . . . . . . . . . . . . . . . . . 15-59
Event Basics . . . . . . . . . . . . . . . . 15-84
Customizing the User
Examining Object Types . . . . . . . . 1-45
Configuration . . . . . . . . . . . . . . . . 2-30
Example of a Non-Parallel Pantograph
Cutting Sections with Section
(a.k.a. four bar linkage) . . . . . . . 10-11
Planes . . . . . . . . . . . . . . . . . . . . . 5-49
Example of a Parallel Pantograph (a.k.a.
Cutting Sections with Section
four bar linkage) . . . . . . . . . . . . . 10-9
Volumes . . . . . . . . . . . . . . . . . . . . 5-55
Example of a Prismatic Screw (a.k.a.
slider linkage) . . . . . . . . . . . . . . 10-12
Expand to selection . . . . . . . . . . . . 2-71

Index-2 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Index

External Axes Usage . . . . . . . . . . 15-93 I

External Axis Basics . . . . . . . . . . 15-92 Implementation Notes . . . . . . . . . 10-31
External Axis Definition Basics . . . 10-3 Introduction to Collision
External TCP Usage Differences . . 12-51 Detection . . . . . . . . . . . . . . . . . . . 5-24
Introduction to Display By Type . . . 2-48
F Introduction to Events . . . . . . . . . 15-81
Introduction to Fast Placement and
Factors that Affect Collision Restore Design Relative Position . . 3-4
Detection . . . . . . . . . . . . . . . . . . . 5-44 Introduction to Kinematic Cranks . . 9-21
Fast Placement Usage . . . . . . . . . . . 3-5 Introduction to Movie Manager . . . 5-62
Final Steps for Robotic Path Introduction to Path
Development . . . . . . . . . . . . . . . . 15-1 Modification . . . . . . . . . . . . . . . . 15-19
Finding the View Control Menus . . 2-16 Introduction to Pedestal Welding . . 12-50
First Draw the Kinematic Tree . . . . 9-23 Introduction to Placement . . . . . . . . 3-2
Function Basics . . . . . . . . . . . . . . 10-26 Introduction to Placement
Fundamentals of Kinematics . . . . . . 4-2 Manipulator . . . . . . . . . . . . . . . . . 3-14
Introduction to Relocate . . . . . . . . . 3-22
G Introduction to Selection Filters
(Optional) . . . . . . . . . . . . . . . . . . 2-45
General Kinematics Usage Commands Introduction to Studies . . . . . . . . . 1-56
(part 1) . . . . . . . . . . . . . . . . . . . . . 4-5 Introduction to the Training Manual
General Kinematics Usage Commands Structure . . . . . . . . . . . . . . . . . . . . 1-3
(part 2) . . . . . . . . . . . . . . . . . . . . . 4-8 Introduction to Weld Gun Search . . 12-60
General Robotics . . . . . . . . . . . . . . 11-1 Inverse Kinematics . . . . . . . . . . . . 4-15
Generic eMS Process Overview . . . 1-15 Inverse Kinematics Definition . . . . 9-53
Generic Process Introduction . . . . . 1-16 Inverse Kinematics Device Creation and
Geometric Gun Search Basics . . . 12-61 Usage . . . . . . . . . . . . . . . . . . . . . 9-52
Get Check In and Check Out Inverse Kinematics Review . . . . . . 4-11
Status . . . . . . . . . . . . . . . . . . . . . 1-31
Graphic Viewer . . . . . . . . . . . . . . . . 2-4 J
Graphic Viewer Control Overview . . 2-15 Jumping and Moving to a
Graphic Viewer Text Usage . . . . . . 5-17 Location . . . . . . . . . . . . . . . . . . . 15-10
Graphical Visualization . . . . . . . . . 2-59 Jumping to a Location Basics . . . . 12-54
Graphical Visualization and
Performance . . . . . . . . . . . . . . . . . 2-58
K
Graphics Background Options . . . . 2-20
Gun Example of Kinematic Kinematic Branching . . . . . . . . . . . 9-28
Branching . . . . . . . . . . . . . . . . . . 9-30 Kinematic Functions . . . . . . . . . . . 9-19
Kinematics Background . . . . . . . . . . 9-2
Kinematics Background Basics . . . . 9-4
H Kinematics Basics . . . . . . . . . . . 4-3, 9-1
Hard limits . . . . . . . . . . . . . . . . . 15-70 Kinematics Basics Summary . . . . . 9-14
Hierarchical Trees and Libraries of Kinematics Usage Basics . . . . . . . . 4-18
Nodes . . . . . . . . . . . . . . . . . . . . . 1-13
How Do I Define a Gun for L
Searching? . . . . . . . . . . . . . . . . . . 9-42 Lead and Follow Basics . . . . . . . . . 9-17

Process Simulate on eMS Basic Robotic Simulation Student Guide Index-3

Index

Leading Joint and Follow Factor . . . 9-16 Modifying Locations Using the Path
Level of Kinematic Inverse . . . . . . . 4-16 Editor . . . . . . . . . . . . . . . . . . . . 15-29
Library Nodes (of Parts, Operations and Modifying Paths Using Operation
Resources) . . . . . . . . . . . . . . . . . . 1-49 Properties . . . . . . . . . . . . . . . . . 15-45
Linear Measurement . . . . . . . . . . . 2-55 More Continuous Mfg Feature
Links and Joints of Cranks . . . . . . 9-25 Applications (Arc weld, Paint, and
List of eMServer Tools in Process Debur) . . . . . . . . . . . . . . . . . . . . 14-26
Simulate . . . . . . . . . . . . . . . . . . . . 6-4 More Continuous Robotic
List of Other Process Designer Commands Applications . . . . . . . . . . . . . . . . 14-12
in Process Simulate . . . . . . . . . . . . 6-5 More Kinematic Branching and
List of Process Designer Commands in Cranks . . . . . . . . . . . . . . . . . . . . . 10-5
Process Simulate . . . . . . . . . . . . . . 6-3 More on Collision Detection . . . . . . 5-33
Location Creation Basics . . . . . . . 15-23 More on Kinematic Functions . . . 10-25
Location Creation Tools . . . . . . . . 15-22 More Section Cutting Usage . . . . . . 5-56
Location Modification Basics . . . . 15-27 More Topics (Not Covered in
Location Modification Tools . . . . . 15-26 Class) . . . . . . . . . . . . . . . . . . . . 10-57
Mount Tool . . . . . . . . . . . . . . . . . 12-44
Mouse Movement Options . . . . . . . 2-22
M
Movie Manager . . . . . . . . . . . . . . . 5-61
Manufacturing Feature Types . . . 12-12, Multi Sections . . . . . . . . . . . . . . . 12-27
14-14 Multi-Assign Weld Points . . . . . . . 15-110
Markup Editor Toolbar . . . . . . . . . 5-13 Multiple Robot Simulation & Work
Markup Editor Usage . . . . . . . . . . 5-12 Balance . . . . . . . . . . . . . . . . . . . 15-64
Material Handling (Pick and Place)
Operations . . . . . . . . . . . . 12-46, 13-9 N
Material Handling Applications . . . 13-1
Measurement and Units . . . . . . . . 2-52 Navigating with the Keyboard . . . . 1-42
Method 1 . . . . . . . . . . . . . . . . . . . 15-102 Navigating with the Mouse . . . . . . 1-41
Method 1: Starting and Exiting Process Navigation Tree Basics . . . . . . . . . 1-39
Simulate Directly . . . . . . . . . . . . . 1-19 Near Miss Value Setup . . . . . . . . . . 5-40
Method 2 . . . . . . . . . . . . . . . . . . . 15-103
Method 2: Starting and Exiting Process O
Simulate from Process Designer . . 1-20
Methodology and Workflow . . . . . . . 1-4 Object Tree Viewer . . . . . . . . . . . . 1-69
Methodology to Define a Kinematic Objects Tree Viewer Nodes . . . . . . . 1-70
Device . . . . . . . . . . . . . . . . . . . . . . 9-8 On Demand Window Viewing . . . . . 1-76
Mirror . . . . . . . . . . . . . . . . . . . . . 15-42 Online Help . . . . . . . . . . . . . . . . . . 2-76
Modeling a More Complex Object . . 8-18 Operation Tree Viewer . . . . . . . . . . 1-68
Modeling and Kinematics Orienting Workpiece Locations . . . 12-56
Functionality . . . . . . . . . . . . . . . . 7-10 Other Basics . . . . . . . . . . . . . . . . . . 7-6
Modeling and Kinematics Other Notes . . . . . . . . . . . . . . . . . . . 8-7
Overview . . . . . . . . . . . . . . . . . . . . 7-1 Other Robotics Features (Not Covered in
Modeling Basics . . . . . . . . . . 7-5, 8-1, 8-3 this Course) . . . . . . . . . . . . . . . . 15-108
Modeling Concepts . . . . . . . . . . . . . . 8-2 Other Selected Basic Topics . . . . . . . 6-1
Modeling Gun Shanks . . . . . . . . . . 8-15 Other Selected Modeling & Kinematics
Modeling Overview . . . . . . . . . . . . . 8-3 Topics . . . . . . . . . . . . . . . . . . . . . 10-1

Index-4 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Index

Overview of Continuous Process Simulate Introduction . . . . 1-60

Applications . . . . . . . . . . . . . . . . . 14-2 Process Simulate Support . . . . . . 15-36
Overview of Gripper Creation Process Simulate Swept
(Optional) . . . . . . . . . . . . . 12-39, 13-2 Volumes . . . . . . . . . . . . . . . . . . . 15-75
Overview of Process Simulate Projecting Continuous Mfg
Basics . . . . . . . . . . . . . . . . . . . . . . 7-2 Features . . . . . . . . . . . . . 14-18, 14-20
Projecting Spot Mfg Features . . . . 12-17
Projecting Weld Locations . . . . . . 12-20
P
Prototype / Instance Basics . . . . . . 1-50
Painting Basics . . . . . . . . . . . . . . . 14-8 PRRR Offset Slider . . . . . . . . . . . 10-18
Path Modification Basics . . . . . . . 15-20 PRRR Slider . . . . . . . . . . . . . . . . 10-16
Path Modification Tools . . . . . . . . 15-35 Putting It All Together . . . . . . . . . 15-119
Path Modification Tools Basics . . . 15-37
Path Segment Simulation . . . . . . 15-30 Q
Performance Options . . . . . . . . . . . 2-62
Performance Recommendations . . . 2-64 Quick Help Topics . . . . . . . . . . . . . 2-75
Pick and Place Basics . . . . . 12-47, 13-10 Quick Introduction to Kinematics . . . 4-1
Pie Chart . . . . . . . . . . . . . . . . . . . 12-58
Placement Commands . . . . . . . . . . . 3-1 R
PLPs and Rough Volumes (Not Covered in
Class) . . . . . . . . . . . . . . . . . . . . 15-105 Rails, Gantries, and Positioners . . . 10-2
Pose Definition Basics . . . . . . . . . . 9-37 Reach Test . . . . . . . . . . . . . . 12-53, 15-5
Principles of Inverse Kinematics . . 4-12 Recording Process Simulate Simulations
Process Designer Commands in Process to an .AVI File . . . . . . . . . . . . . . . 5-58
Simulate . . . . . . . . . . . . . . . . . . . . 6-2 Reference Frame Definitions . . . . . 3-15
Process Methodology . . . . . . . . . . . 12-7 Release Notes . . . . . . . . . . . . . . . . 2-79
Process Methodology, revisited . . . 12-36 Relocate Command . . . . . . . . . . . . 4-13
Process Simulate Analysis Tools and Relocate Command Overview . . . . . 3-23
Study Data . . . . . . . . . . . . . . . . . . 5-1 Resetting and Saving
Process Simulate Assembler . . . . . . 11-2 Customizations . . . . . . . . . . . . . . 2-34
Process Simulate Basic Modeling Right Click Collapsing . . . . . . . . . 1-44
Tools . . . . . . . . . . . . . . . . . . . . . . . 7-9 Right Click Expanding . . . . . . . . . . 1-43
Process Simulate Basics . . . . . . . . . 1-61 Right Click Menus . . . . . . . . . . . . . 2-6
Process Simulate Basics Review . . . . 7-4 Robot Smart Place . . . . . . . . . . . . . 15-6
Process Simulate Commands . . . . . 1-62 Robot Viewer . . . . . . . . . . . . . . . . . 15-9
Process Simulate Disconnected Robotic Principles . . . . . . . . . . . . 12-37
Introduction . . . . . . . . . . . . . . . . . . 6-8 Robotic Reach Basics . . . . . . . . . . . 15-4
Process Simulate Disconnected Robotic Swept Volumes and Interference
Usage . . . . . . . . . . . . . . . . . . . . . 6-11 Zones . . . . . . . . . . . . . . . . . . . . . 15-73
Process Simulate Environment . . . . 2-1 Robotics Applications . . . . . . . . . . . 11-7
Process Simulate Function Robotics Introduction . . . . . . . . . . . 11-6
Definitions . . . . . . . . . . . . . . . . . 10-27 Robotics Overview . . . . . . . . . . . . . 11-5
Process Simulate Inference Rotation Methods . . . . . . . . . . . . . 2-23
Zones . . . . . . . . . . . . . . . . . . . . . 15-77 RPRR Offset Slider . . . . . . . . . . . 10-20
Process Simulate Interference RRRP Offset Slider . . . . . . . . . . . 10-22
Volumes . . . . . . . . . . . . . . . . . . . 15-76 RRRP Slider . . . . . . . . . . . . . . . . 10-14

Process Simulate on eMS Basic Robotic Simulation Student Guide Index-5

Index

Rules of Thumb . . . . . . . . . . . . . . . 5-29 Speed and Acceleration Basics . . . . 9-34

Spot Welding Applications . . . . . . . 12-1
S Spot Welding Basics . . . . . . . . . . . . 12-4
Save/Restore Window Layouts . . . . 1-77 Spot Welding Primer (Optional
Saving a .PSZ file . . . . . . . . . . . . . . 6-10 Topic) . . . . . . . . . . . . . . . . . . . . . . 12-3
Scenario Data Administrative Starting Out . . . . . . . . . . . . . . . . . . 7-3
Note . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Status and Title Bars . . . . . . . . . . . 1-63
Scene/Scenario Data . . . . . . . . . . . . 5-3 Steps for Creating Multi
Scene/Scenario Data Storage in the Sections . . . . . . . . . . . . . . . . . . . 12-28
Database . . . . . . . . . . . . . . . . . . . . 5-4 Steps for Driving Devices . . . . . . . 15-62
Scene/Scenario Setup . . . . . . 12-42, 13-5 Steps for Sending Signals to
Searching for Objects . . . . . . . . . . . 2-70 Robots . . . . . . . . . . . . . . . . . . . . 15-65
Section Plane Alignment Tools . . . . 5-52 Steps to Orienting the Locations . . 12-57
Seeing the Connection . . . . . . . . . . 1-51 Storing Pictures of the Scene . . . . . 5-22
Selected Intermediate and Advanced Strategic Planning . . . . . . . . . . . . 12-10
Robotics topics (More Topics Not Covered Supported Workflows . . . . . . . . . . . 1-18
in the Basic Robotics Course) . . . 15-118 Swept Volume Basics . . . . . . . . . . 15-74
Selection Filter Basics . . . . . . . . . . 2-46
Selection Techniques . . . . . . . . . . . 2-36 T
Selection Toolbar . . . . . . . . . . . . . . 5-30 TCP Tracker . . . . . . . . . . . . . . . . 15-11
Sequence of Operations Teach Pendant . . . . . . . . . . . . . . . 15-58
Organization . . . . . . . . . . . . . . . 15-97 Techniques for Creating Frames . . . 3-10
Servo Gun Definitions . . . . . . . . . 12-66 Test Robot’s Reachability to the
Servo Gun Usage . . . . . . . . . . . . . 12-65 Locations . . . . . . . . . . . . . . . . . . . 15-3
Servo Guns . . . . . . . . . . . . . . . . . 12-64 The Attach Command versus the Attach
Setting Pick Intent . . . . . . . . . . . . . 3-8 Event . . . . . . . . . . . . . . . . . . . . . 15-85
Setting Pick Level Refresher . . . . . . 3-9 The Basic Process Overview . . . . . 15-120
Setting up a Material Handling Scenario/ The Cam Joint - Function
Scene . . . . . . . . . . . . . . . . . . . . . . 13-6 Example . . . . . . . . . . . . . . . . . . 10-40
Setting up a Mounted Workpiece The Concept of Prototype and
Path . . . . . . . . . . . . . . . . . . . . . . 12-52 Instance . . . . . . . . . . . . . . . . . . . . 1-48
Setting up a Mounted Workpiece The Detailed Process Overview . . 15-121
Scenario/Scene . . . . . . . . . . . . . . 12-43 The Four Basic eMS Objects . . . . . . 1-10
Signal (I/O) Definition & The Placement Tools . . . . . . . . . . . . 3-3
Simulation . . . . . . . . . . . . . . . . . 15-61 The Process: From Least Constraints to
Simple Robot Kinematics Basics . . . 9-49 Most Constraints . . . . . . . . 12-9, 12-38
Smart Place Modes . . . . . . . . . . . . 15-8 The Theory of Tecnomatix eBOP . . . 1-9
Snapshot Usage . . . . . . . . . . . . . . . . 5-8 The Train Joint - Function
Soft limits . . . . . . . . . . . . . . . . . . 15-71 Example . . . . . . . . . . . . . . . . . . 10-34
Solid Creating with Primitives . . . . . 8-8 Tool Definition . . . . . . . . . . . . . . . . 9-41
Solid Creation Basics . . . . . . . . . . . . 8-9 Tool Definition Basics . . . . . . . . . . 9-40
Solid Modeling Overview . . . . . . . . . 8-5 Toolbar Manipulation . . . . . . . . . . . 2-69
Sources for Basic Manufacturing Feature Tools Used . . . . . . . . . . . . . . . 8-16, 8-19
Orientation . . . . . . . . . . . 12-15, 14-17 Train Joint Basics . . . . . . . . . . . . 10-35
Sources for Manufacturing Training Introduction . . . . . . . . . . . 1-2
Features . . . . . . . . . . . . . 12-14, 14-16 Tree Viewer Basics . . . . . . . . . . . . . 2-5

Index-6 Process Simulate on eMS Basic Robotic Simulation Student Guide MTXW115S-S-100
 Index

Types of Operations . . . . . . . . . . . 15-98 Viewer Area . . . . . . . . . . . . . . . . . . 1-64

Typical Process Simulate Usage . . . . 1-7 Viewer Overview . . . . . . . . . . . . . . 1-66
Viewing and selecting PMI . . . . . . . 2-39
U Viewing Manufacturing
Features . . . . . . . . . . . . . 12-13, 14-15
Unified Collision Settings . . . . . . . 15-114 Viewing Object Properties . . . . . . . 1-52
Units . . . . . . . . . . . . . . . . . . . . . . . 2-53
Update Weld Locations . . . . . . . . 15-113 W
Updating back the eMS Database . . 6-12
Using Inverse Kinematics . . . . . . . 4-17 Ways of Creating & Placing Objects in
Using Process Designer to Figure Out How Modeling . . . . . . . . . . . . . . . . . . . 8-21
to Manufacture a Product . . . . . . . 1-11 Ways to Get Kinematic Objects into
Using Process Simulate Process Simulate . . . . . . . . . . . . . . 9-3
Disconnected . . . . . . . . . . . . . . . . . 6-7 WDC Overview . . . . . . . . . . . . . . 12-31
Using the Markup Editor . . . . . . . . 5-11 WDC Primary Functionality . . . . 12-32
Using the Navigation Tree . . . . . . . 1-38 WDC Settings . . . . . . . . . . . . . . . 12-34
Using the Placement Weld Distribution Center (WDC) . . 12-30
Manipulator . . . . . . . . . . . . . 3-16, 3-18 Weld Location Constraints . . . . . . 12-18
Using the Working Frame to Weld Representation . . . . . . . . . . 12-11
Build . . . . . . . . . . . . . . . . . . . . . . 8-20 What is Process Simulate? . . . . . . . . 1-6
Using Wireframe to Create Solids . . 8-11 Window Layout Basics . . . . . . . . . . 1-73
Window Manipulation . . . . . . . . . . 2-68
Wireframe Basics . . . . . . . . . . . . . . 8-12
V
Working with Groups . . . . . . . . . . . . 2-8
Verifying the Weld Location Working with Hard and Soft
Orientation . . . . . . . . . . . . . . . . 12-25 Limits . . . . . . . . . . . . . . . . . . . . 15-69
View Control and Graphic Viewer Working with PLPs . . . . . . . . . . . 15-106
Setup . . . . . . . . . . . . . . . . . . . . . . 2-14 Working with the Main Branch . . . 10-7
View Control with the Mouse . . . . . 2-25 Working with Viewers . . . . . . . . . . . 2-3
View Control with the Space Mice . . 2-26

Process Simulate on eMS Basic Robotic Simulation Student Guide Index-7