WKP115S Activities PDF

WKP115S-Process Simulate Basic
Robotic Simulation
Actividades
COMIMSA
12 al 16 de diciembre 2011
Saltillo, Coahuila
Contenido
BASIC CONCEPTS............................................................................................................................ 7
Activity: Starting Process Simulate and Opening the Basic Project .............................................. 7
Activity: Setting and Viewing Basic Options ................................................................................ 9
Activity: Create the High-Level Operation Tree (1) .................................................................... 13
Activity: Create the High-Level Resource Tree (2) ..................................................................... 15
Activity: Associate the Trees Together ...................................................................................... 17
Activity: Examine the Object Types that are Available .............................................................. 19
Activity: Examine the Part Library ............................................................................................. 20
Activity: Examine the Resource Library ..................................................................................... 22
Activity: Setting the Working Folder ......................................................................................... 24
Activity: Creating a New Study ................................................................................................. 26
Activity: Browsing the Process Simulate Scene ......................................................................... 29
Activity: Docking and Floating Windows ................................................................................... 31
Activity: Saving a Window Layout ............................................................................................. 34
Activity: Using a Window Layout .............................................................................................. 36
PROCESS SIMULATE ON EMS ENVIRONMENT ............................................................................... 37
Automotive Activity: Getting an Overview of the Objects in the Object Tree ............................ 37
Activity: Object Tree Basics and Groups.................................................................................... 42
Activity: Using the Right Click Popup Menu .............................................................................. 46
Activity: Basic Graphic Viewer Controls .................................................................................... 47
Activity: Selecting Objects in the Graphic Viewer ...................................................................... 50
Activity: Additional Methods of Multiple Entity Selection ......................................................... 53
Activity: Using Toggle Display ................................................................................................... 56
Activity: Blanking all the Frames using Selection Filters (Optional) ............................................ 57
Activity: Blanking all the Frames using Display by Type ............................................................. 58
Activity: Relationship Between Measuring and Units ................................................................ 59
Activity: Changing Visualization Performance ........................................................................... 61
Activity: Changing Graphical Visualization ................................................................................ 64
PLACEMENTS COMMANDS .......................................................................................................... 72
Activity: Using Fast Placement.................................................................................................. 72
Activity: Creating a Frame ........................................................................................................ 75
2 WKP115S-Process Simulate Basic Robotic Simulation

NEOCORTEX©, SIEMENS PLM©. Prohibida su reproducción parcial o total
Activity: Shifting and Rotating Instances On-screen .................................................................. 78
Activity: Relationship Between Placement Manipulator, Measuring, and Units ........................ 80
Activity: Incremental Shifting of Objects from a Reference Frame ............................................ 83
Activity: Relocating an Object Relative to Two New Frames...................................................... 85
Activity: Relocating an Object Relative to Two Existing Frames ................................................. 86
QUICK INTRODUCTION TO KINEMATICS ....................................................................................... 87
Activity: Jogging the Joints of a Simple object ........................................................................... 87
Activity: Defining Kinematic Poses ............................................................................................ 90
Activity: Creating a Simulative Operation from Poses ............................................................... 93
Activity: Examining the Kinematic Tree of a Robot .................................................................... 95
Activity: Making the Robot Move ............................................................................................. 98
PROCESS SIMULATE ANALYSIS TOOLS AND STUDY DATA ............................................................ 102
Activity: Creating Snapshots ................................................................................................... 102
Activity: Creating Markups ..................................................................................................... 104
Activity: Setting the Note Options .......................................................................................... 106
Activity: Creating Notes in the Graphic Viewer ....................................................................... 108
Activity: Creating Dimensions in the Graphic Viewer .............................................................. 111
Activity: Outputting the Graphic Viewer to a File or Printer .................................................... 112
Activity: Collision Viewer and Fast Collision Sets ..................................................................... 115
Activity: Defining Collision Sets (List Pairs) .............................................................................. 117
Activity: Collision Setup and Collision Viewer ......................................................................... 118
Activity: Filtering Collision Results .......................................................................................... 121
Optional Activity: Creating and Moving a Section Plane .......................................................... 124
Optional Activity: More on Cutting Sections ........................................................................... 128
Optional Activity: Creating and Moving a Section Volume ...................................................... 131
Activity: Outputting a Simulation to an .AVI File ..................................................................... 132
Optional Activity: Using Movie Manager ................................................................................ 133
OTHER SELECTED BASIC TOPICS ................................................................................................. 135
Activity: Using some Project Management Commands ........................................................... 135
Activity: Starting and Exiting Process Simulate Disconnected .................................................. 137
Activity: Updating Process Simulate Disconnected from the eMS Database ............................ 142
Activity: Updating the eMS Database from Process Simulate Disconnected ............................ 146

MODELING AND KINEMATICS OVERVIEW................................................................................... 148
Activity: Starting Process Simulate and Setting the Working Folder ........................................ 148
Activity: Opening Your Study .................................................................................................. 150
MODELING BASICS ..................................................................................................................... 152
Activity: Modeling a Table ...................................................................................................... 152
Optional Activity: Revolving 2D Entities to Make a Solid ......................................................... 161
Optional Activity: Extruding 2D Entities to Make a Solid ......................................................... 166
Optional Activity: Sweeping 2D Entities to Make a Solid ......................................................... 172
Optional Activity: Modeling a Simple Robot for Kinematics .................................................... 182
KINEMATICS BASICS ................................................................................................................... 211
Activity: Simple Kinematics (Part 1) ........................................................................................ 211
Activity: Add Joints to a Simple object .................................................................................... 221
Activity: Leading Joints and Follow Factors (Gun) ................................................................... 225
Instructor Demo: Kinematic Looping (Optional Activity) ......................................................... 231
Activity: Kinematic Looping .................................................................................................... 232
Activity: Gun Kinematic Definition (Part 1) ............................................................................. 236
Activity: Gun Kinematics (Part 2) ............................................................................................ 241
Activity: Speed and Acceleration ............................................................................................ 243
Activity: Defining OPEN, SEMIOPEN, and CLOSE Poses............................................................ 245
Activity: Create the TCP and MNT Frames .............................................................................. 249
Activity: Defining an object as a Spot Weld Gun ..................................................................... 252
Activity: Defining an object as a Gripper ................................................................................. 254
Activity: Adding Kinematics to a Robot Model ........................................................................ 258
Activity: Using Direct Kinematics to Move the Robot .............................................................. 268
Activity: Adding a Toolframe .................................................................................................. 269
Activity: Using Inverse Kinematics to Move the Robot ............................................................ 274
Activity: More Inverse Kinematics (Optional Extra Credit)....................................................... 277
OTHER SELECTED MODELING & KINEMATICS TOPICS ................................................................. 290
Activity: Sample Rail Creation Overview ................................................................................. 290
Instructor Demo: Other Slider Cranks including RPRR Offset Slider ......................................... 292

Instructor Demo: Implementing Joint Logic with Functions (Optional Activity) ....................... 295
Instructor Demo: Kinematics Following a Surface (Optional Activity) ...................................... 298
Instructor Demo: Examine the Train Joint............................................................................... 301
Instructor Demo: Examine the Cam Joint................................................................................ 302
Activity: Setting up Compound Equipment ............................................................................. 304
GENERAL ROBOTICS ................................................................................................................... 310
Activity: Creating a New Study (Again) ................................................................................... 310
Activity: Training Data Overview ............................................................................................ 312
SPOT WELDING APPLICATIONS................................................................................................... 315
Activity: Viewing Spot Mfg Features in Process Simulate ........................................................ 315
Activity: Projecting Spot Mfg Features .................................................................................... 318
Activity: Adjusting a Weld Path .............................................................................................. 321
Activity: Gun Shank Validation ............................................................................................... 328
Activity: Using Weld Distribution Center (with Automatic Approach Angle) ............................ 333
Activity: Putting the Gripper on the Robot (for Ped. Welding) ................................................ 337
Activity: Get/Put the Part in the Fixture .................................................................................. 342
Activity: Creating a Rough Mounted Workpiece Path ............................................................. 346
Activity: Orient the Locations ................................................................................................. 349
Activity: Weld Gun Search ...................................................................................................... 355
Instructor Demo: Simulating Robots with Servo Guns ............................................................. 363
Activity: Working with Servo Guns ......................................................................................... 364
MATERIAL HANDLING APPLICATIONS ......................................................................................... 371
Activity: Pick and Place (Material Handling) Setup .................................................................. 371
Activity: Create the Basic (PNP) Process ................................................................................. 375
Activity: Stacking Boxes .......................................................................................................... 383
Activity: Doing the Second Pass (Optional Activity) ................................................................. 387
CONTINUOUS APPLICATIONS ..................................................................................................... 390
Activity: Using Continuous Feature Operations....................................................................... 390
Activity: Creating Arc MFGs for the Whitehouse Part ............................................................. 398
Activity: Creating Debur MFGs for the Whitehouse Part ......................................................... 405
Activity: Creating Paint MFGs for the Whitehouse Part ........................................................... 410
Activity: Creating Arc Seams for the Whitehouse part (using Project Arc Seam)...................... 417

BASIC CONCEPTS
Activity: Starting Process Simulate and Opening the Basic Project
The objective of this activity is to open a Process Simulate session from the specified
studies.
Login to database using your eMS user ID

Open your Basics Project
Login to database using your eMS user ID
1. Before starting Process Simulate, verify that your Space Mouse is connected to the
computer and that the driver is loaded, if you intend on using this optional device
during your Process Simulate session.
Note:
If the driver is loaded, a blue ring will glow around the manipulator.
2. Double click on the Process Simulate desktop icon.
3. Login (using your eMS database login ID) with no password.
User Type eMS User ID

instructor administrator
student user1
student user2
student user3
student user4
student user5
student user6

etc... etc...
student user8
student user9
4. Click [OK].
1. From the Open Project window, select the Basics Project — user## project (where
## is the user number assigned to your by the instructor).
2. Click [OK].

Activity: Setting and Viewing Basic Options
The objective of this activity is to set basic Graphic Viewer settings such as the Process
Simulate System Root.
Note:
The path to all library objects is relative to the System Root. To enhance data
management efficiency, studies from several projects can reference the same objects
under the same System Root.
Set the background color to black

Set the mouse movement mode to Continuous
Check the system root settings
Set the background color to black
1. In Process Simulate, select Tools -> Options.

2. In the Options window, select the Appearance tab

3. From the drop down list in the lower left corner (that currently shows Vertical),
select Solid.
4. Change the Background color to black.
Note:
If Corners is selected instead of Vertical, you could select four different colors to
be used at once, instead of just one color. It is your choice.
Set the mouse movement mode to Continuous

Note:
Direct viewing: Objects only move when you move your mouse. This is the Process
Simulate default configuration.
Continuous viewing: Objects continue to move at the initial speed of mouse movement.
This is the Robcad default
1. In the Options window, select the Graphic Viewer tab.
2. Select Continuous viewing to change the Process Simulate graphics manipulation

to act more like Robcad. Otherwise leave it on Direct Viewing.
Check the system root settings
Note:
You do not have permissions to change the System Root value in class. Local
administrative rights are required.
1. Select the eMServer tab and verify the settings are what the instructor suggests
for class.

Warning:
If this setting is wrong you will not have any 3D data in class and will not be able to
complete 90% of the activities. This is a critical setting.
2. Click [OK] to close the Options window.

Activity: Create the High-Level Operation Tree (1)
The objective of this activity is to create a high-level Operation Tree.
Create the top level of the Operation Tree (1)

Add two stations to it (to hold their operations)
Create the top level of the Operation Tree (1)
1. Expand the Basics Project — user## project.

2. In the Navigation Tree, right click the Operation collection (folder) and select
Check Out .
3. In the Check Out window, click [OK].
4. In the Navigation Tree, right click the Operation collection (folder) and select
New
5. From the New window, browse and locate CompoundOperation object type.
6. Scroll to the right and enter Operation Tree for the Name.
7. Check the checkbox for it or enter 1 for the Amount.
Note:
The Name can contain any enterable character and can be up to 256 characters
long.
8. In the New window, click [OK].

9. Expand the Operation folder.

10. Right click the Operation Tree CompoundOperation (not the folder) and select
Navigation Tree .
Add two stations to it (to hold their operations)
1. In the Navigation Tree (2) (with Operation Tree as the root object), right click
the Operation Tree CompoundOperation and select New .
2. From the New window, browse and locate CompoundOperation object type.
3. Enter 2 for the Amount.
4. Scroll to the right and enter Station [1] for the Name.
Note:
When creating multiple objects a number can be entered in [brackets which will be
the starting point for the increment. More can be done as well.

6. Expand below Operations Tree.

Activity: Create the High-Level Resource Tree (2)
The objective of this activity is to create a high-level Resource Tree.
Create the top level of the Resource Tree (2)

Add two stations to it (to hold their resources)
Create the top level of the Resource Tree (2)
1. In the Navigation Tree, right click the Resource collection (folder) and select
Check Out .
2. In the Check Out window, click [OK].
3. In the Navigation Tree, right click the Resource collection (folder) and select
New .
4. From the New window, browse and locate CompoundResource object type.
5. Scroll to the right and enter Resource Tree for the Name.
6. Check the checkbox for it or enter 1 for the Amount.
Note:
The Name can contain any enterable character and can be up to 256 characters
long.

8. Expand the Resource collection (folder).

9. Right click the Resource Tree CompoundResource (not the folder) and select
Navigation Tree .
Add two stations to it (to hold their resources)
1. In the Navigation Tree (3) (with Resource Tree as the root object), right click the
Resource Tree CompoundResource and select New .
2. From the New window, browse and locate CompoundResource object type.
4. Scroll to the right and enter Station [1] for the Name.
Note:
When creating multiple objects a number can be entered in [brackets which will be
the starting point for the increment. More can be done as well.

6. Expand below Resource Tree.

Activity: Associate the Trees Together
The objective of this activity is to associate the structures together.
Resource Assignment: Associate the Resource Tree and Operation Tree

Part Assignment: Associate End Items from the Product Tree to the Operation Tree
Adding Resources to the Resource Tree
Resource Assignment: Associate the Resource Tree and Operation Tree
Caution:
Normally we would not do the assignment at the top level. .
1. From the Navigation Tree (3) (displaying the Resource Tree as the root object),
select the Resource Tree CompoundResource.
2. Drag and drop it onto the Operation Tree CompoundOperation.
3. Right click the Operation Tree CompoundOperation and select Properties .
4. In the Properties window, select the Resources tab to see the relationship just
made.
5. From the Navigation Tree (3) (displaying the Resource Tree as the root object),
select the Resource Tree CompoundResource.
6. In the Properties window, select the Operations tab to see the other half of the
two-way relationship just made.
Part Assignment: Associate End Items from the Product Tree to the Operation Tree
1. Unpin the Sequence Editor viewer to make more room.

2. From the Navigation Tree, expand the Product collection (folder).
3. From the Navigation Tree, right click the Product Tree CompoundPart and select
Navigation Tree .
4. From the Navigation Tree (4) (displaying the Product Tree as the root object), right
click Product Tree and select Expand —> Expand 3 Levels.

5. Drag and drop the Purchased Assy1 CompoundPart onto the Station 1
CompoundOperation.
6. Drag and drop the Part C part onto the Station 1 CompoundOperation.
7. Select the Station 1 CompoundOperation.
8. In the Properties window, select the Product tab to see the relationship just made.
9. Drag and drop the Part D Part onto the Station 2 CompoundOperation.
10. Close the Properties window.
11. Close the Navigation Tree (4) (displaying the Product Tree as the root object)
Adding Resources to the Resource Tree
1. From the Navigation Tree browse into the Libraries collection (folder) and right
click the Resource Library library and select Navigation Tree .
2. From the Navigation Tree (displaying the Resource Library library as the root
object) expand the tree.
3. Drag and drop the robot onto Station 1 CompoundResource.
4. Drag and drop the human onto Station 2 CompoundResource.

Activity: Examine the Object Types that are Available
The objective of this activity is to see some of the various object types.
Look at the Object Types
Look at the Object Types
1. Look through the folders of the Navigation Tree viewer.
Note:
A custom caption has been created for this class for operation tree nodes allowing
the allocated time for each node to be shown in the tree.
2. Try to find as many different node types as possible. Use the chart described
earlier for help on identifying them.

Activity: Examine the Part Library
The objective of this activity is to open the Navigation Tree viewer for the Part library
in Libraries folder.
Open the Part Library using the Navigation Tree viewer

Look at a Part Prototype’s properties
Open the product tree using the Navigation Tree viewer
Use the magnifying glass to see the instance/prototype relationship
Look at a Part Instance’s properties
Open the Part Library using the Navigation Tree viewer
1. Close all open Properties and Navigation Tree windows except for the original
Navigation Tree.
2. In the Libraries collection (folder) of the docked Navigation Tree viewer, right
click on the PartLibrary .
3. From the short-cut menu that appears, select Navigation Tree . A viewer named
Navigation Tree (2) opens.
4. In the Navigation Tree (2) viewer, expand the tree by clicking the + to the left of
PartLibrary.
Look at a Part Prototype’s properties
1. Right click a PartPrototype object in the PartLibrary and select Properties .
Note:
Each time you drag a part prototype from a library to a product tree (i.e. a
CompoundPart), it creates an instance of the part in the product tree. Instances
inherit most of their attributes from the part prototype.
2. Pay attention to the PartPrototype Type on the General tab in the Properties
window.
3. Lock the Properties window to this object by clicking Lock Displayed Information
.
Note:
When is displayed, the content is locked. When is displayed the content is unlocked.

Open the product tree using the Navigation Tree viewer
1. In the Product collection (folder) of the docked Navigation Tree viewer, right
click on the Product Tree .
2. From the short-cut menu that appears, select Navigation Tree . A viewer
named Navigation Tree (3) opens.
Use the magnifying glass to see the instance/prototype relationship
1. Drag and drop a PartPrototype from the Navigation Tree displaying the contents of
the PartLibrary onto the magnifying glass on the Navigation Tree (3)
viewer displaying the Product Tree .
2. The Product Tree is expanded and the instances in the tree are highlighted.
Look at a Part Instance’s properties
1. Right click the highlighted Part object in the Product Tree and select
Properties .
2. In the Properties (2) viewer that opens, notice the small (i) in the Type field which
indicates that the part is an instance type.
3. Pay attention to the instance Type on the General tab in the Properties window.
4. Close the Properties windows.
5. Close the Navigation Tree (2) and Navigation Tree (3) views you just opened.

Activity: Examine the Resource Library
The objective of this activity is to open the Navigation Tree viewer for the Resource
library in Libraries folder.
Look at the Prototypes in the Resource Library

Look at the instances in the Resource Tree
Look at the Prototypes in the Resource Library
1. Close all open Properties and Navigation Tree windows except for the original
Navigation Tree.
2. Open the Resource Library in the Libraries collection (folder) using a
Navigation Tree .
3. In the just opened Navigation Tree (2), expand the tree by clicking the + to the left
of ResourceLibrary .
4. Pick on a single resource prototype in the library.
Note:
Each time you drag a prototype to the tree it creates an instance. Instances inherit
most of their attributes from the prototype.
5. In the ResourceLibrary , right click the resource prototype and select Properties
.
6. Pay attention to the prototype Type on the General tab in the Properties window.
7. Close the Properties window.
Look at the instances in the Resource Tree
1. In the Navigation Tree, browse into the Resource collection (folder).

2. Open the Resource Tree using a Navigation Tree viewer and browse through
the tree.
3. Expand the Resource Tree until you see an instance of a resource .
4. This time drag an instance from the resource tree and drop it on the magnifying
glass of the resource library.
5. Close the Navigation Tree (2) and Navigation Tree (3) viewers you just opened.
Note:

Operation Library : There is no meaning to prototype and instances for
operations. Each operation is an individual. The operation library is used mostly for
a starting point or a repository of standard operations, which are used more than
once in the process.

Activity: Setting the Working Folder
The objective of this activity is to set the software’s working folder (temporary scratch
area).
Check out your working folder and set it as the working folder
1. Continue working in the same project opened earlier.
Note:
It is assumed that all activities in this topic where completed before continuing to
this activity.
2. Close allNavigation Tree views except the main one (i.e. Navigation Tree (2) and (3)
viewers should be closed).
3. In Navigation Tree, browse into the Working Folders collection (folder).
4. Check out your assigned collection (folder) according to this chart: Right click it
and select Check Out .
eMS User ID Working Folder
administrator
administrator's Working Folder
user1
User1 Working Folder
user2
user3
user4
user5
user6
etc... etc...

user8
user9
5. Click [OK].
6. Select File —> Project Management —> Set as Working Folder.
Note:
The text of your working folder is now displayed bold.

Activity: Creating a New Study
The objective of this activity is to create an empty study.
Browse to your study folder

Create a new RobcadStudy in the Demo folder
Open the study with Process Simulate
1. Continue working in the same project opened earlier.
Note:
It is assumed that all activities in this topic where completed before continuing to
this activity.
2. In the Navigation Tree, expand the Studies StudyFolder.

3. Locate your study folder according to this table:
eMS User ID StudyFolder
administrator
Line 0
user1
Line 1
user2
Line 2
user3
Line 3
user4
Line 4
user5
Line 5
user6
Line 6
etc... etc...
user8
Line 8

user9
Line 9
Right click your StudyFolder (as shown in the chart above) and select Check out .
Select with Hierarchy (This is one of the rare times we will use Check out with
Hierarchy).
Click [OK].
Expand your Line ## study folder.
Create a new RobcadStudy in the Demo folder
1. Right click on your Line ## StudyFolder and select New .

2. From the New window, check the checkbox for RobcadStudy .
3. Rename it to Study.
4. Click [OK].
5. Drag and drop the Operation Tree CompoundOperation onto the study. Expand
the tree under the study.
Note:
Normally you would not add the entire operation tree to a study. Normally it
would be a smaller chunk of related processes and resources.
6. Close all the Navigation Tree viewers except for the original one.
1. Right click the Study RobcadStudy and select Load in Standard Mode .
2. Right click in the Graphic Viewer and select Display All .
3. Right click in the Graphic Viewer and select Zoom to Fit .
Note:

For this activity, we have provided 3D data for the human and robot resource (but
not for the product data. We will use much more complex data later in class that
will include 3D data for both product and resources.

Activity: Browsing the Process Simulate Scene
The objective of this activity is to browse the Scene loaded into Process Simulate.
Expand the ProductTree to See What Came Across (1)

Expand the Resource Tree to See What Came Across (2)
Expand the Operation Tree to See What Came Across (3)
Look at the Relationships
Look at the Properties
Expand the ProductTree to See What Came Across (1)
1. Locate the Object Tree viewer and click the Object Tree tab for it.
2. In the Object Tree viewer, right click the Parts folder select Expand -> 2 Levels.
Expand the Resource Tree to See What Came Across (2)
1. In the Object Tree viewer, right click the Resources folder and select Expand -> 3
Levels.
Expand the Operation Tree to See What Came Across (3)
1. Locate the Operation Tree viewer.

2. Click the + next to Operation Tree CompoundOperation to expand it.
Note:
In Process Simulate the options that show on the right click menus can be easily
customized based on what is selected and which viewer you are in.
Look at the Relationships
1. If the Relations Viewer is not shown, select View —> Open With—> Relations
Viewer .
2. Select the Operation Tree CompoundOperation .
3. Look in the Relations Viewer and notice the Resource Tree CompoundResource
is related to it.

Note:
Recall that we made this relationship by assigning the Resource Tree

CompoundResource to the Operation Tree CompoundOperation .
4. In the Operation Tree, select the Station 1 CompoundOperation .

5. Look in the Relations Viewer and notice the Purchased Assy 1 and Part C are
related to it.
Note:
Recall that we made this relationship by assigning the Purchased Assy 1 and Part C
to Station 1 .
6. In the Operation Tree, select the Station 2 CompoundOperation .

7. Look in the Relations Viewer and notice Part D is related to it.
Note:
Recall that we made this relationship by assigning Part D to Station 1 .
Look at the Properties
1. In the Operation Tree, pick the Operations Tree and select View —> Open with —
> Properties .
2. Notice the attributes for the selected object.
3. Select other objects in the Operations Tree to see their attributes as well.
Note:
This window can be used for any database object shown in Process Simulate.
4. Close the Properties viewer.

Activity: Docking and Floating Windows
The objective of this activity is to change window docking.
Locate the desired viewers

Undock a viewer window
Dock it back to the same place
Dock it to another position
Dock it to a Tab Group
On Demand Windows
Locate the desired viewers
1. Continue working in Process Simulate.

2. Locate and select the following open viewers in Process Simulate:
o Navigation Tree
o Object Tree
o Operation Tree
o Sequence Editor
o Path Editor
o Collision Viewer
o Relations Viewer
1. In the Operation Tree upper right corner (the title area), click Window Position
and select Floating.
Dock it back to the same place
1. Double click the title area of the Operation Tree.
and select Floating.

Dock it to another position
1. Begin dragging the (floating or docked) Operation Tree viewer using the title area
of the window.
2. A four-way arrow indicator appears in the center of the docked viewer you are
dragging across.
3. Drag the floating viewer to one of the arrows of the four-way arrow indicator.
4. It will dock the viewer along that edge of the viewer you are dragging across.
Dock it to a Tab Group
1. Begin dragging the (floating or docked) Operation Tree viewer using the title area
of the window.
2. A four-way arrow indicator appears in the center of the docked viewer you are
dragging across.
3. Drag it over the Object Tree.

4. Drag the floating viewer to the icon in the center of the four-way arrow indicator.
5. It will dock the Operation Tree viewer as a tab within a tab group that also contains
the Object Tree.
On Demand Windows
and select Auto Hide.
Note:

Or click the Pin .
2. Mouse over a window on the left side of the Process Simulate window.
and select Auto Hide.
Note:
Or click the Pin .

Activity: Saving a Window Layout
The objective of this activity is to save a couple of window layouts.
Position, and Size Windows

Save a New Layout
Create Second Window Layout
Position, and Size Windows
1. Open, position, and size all windows for this layout.
Save a New Layout
1. From the Process Simulate toolbar, click Layout Manager .

2. From the Layout List window, click New.
3. In the New Layout window, click Use Current for both options.
4. Click [OK].
Note:
The list of layouts on your computer may be different.

5. In the Layout List window, enter a new name for the layout: If you are user##,
enter Layout1_user## (where ## is your user number).
Note:
If the name of the new Layout is not highlighted in blue, pick it, press [F2], and
enter the new name.
6. Click Close.
Create Second Window Layout
1. Change the window layout a little, by moving some windows around.

2. Create second window layout in the same way, named Layout1_user## (where ##
is your user number).

Activity: Using a Window Layout
The objective of this activity is to switch between a couple of window layouts.
Apply your Layouts

Apply the Standard Layout
Apply your Layouts
Note:
The previous activity needs to be completed before doing this one.
1. From the Process Simulate toolbar, select the Layout drop-down and choose
Layout1_user## (where ## is your user number).
2. The layout is applied to all open and successively opened windows.
3. Now apply your Layout2_user## (where ## is your user number).
Apply the Standard Layout
1. Apply the Standard window layout shown in the list.

PROCESS SIMULATE ON EMS ENVIRONMENT
Automotive Activity: Getting an Overview of the Objects in the Object Tree
In this activity, we will explore the nodes and structure of the Operation Tree, Assembly
Tree and Object Tree viewers. These viewers are very useful in getting an overview of a
complex product or resource structure with many levels of related entities.
Automotive Data: Login to database using your eMS user ID

Automotive Data: Open the desired project
Automotive Data: Check out your working folder and set it as the working folder
Automotive Data: Load the Study
Automotive Data: Expand the Product Tree (1)

Automotive Data: Expand the Resource Tree (2)
Automotive Data: Expand the Operation Tree (3)
Automotive Data: Login to database using your eMS user ID
1. Before starting Process Simulate, verify that your Space Mouse is connected to the
computer and that the driver is loaded, if you intend on using this optional device
during your Process Simulate session.
Note:
If the driver is loaded, a blue ring will glow around the manipulator.
3. Login (using your eMS database login ID) with no password.

student user1
student user2
student user3
student user4
student user5
student user6
etc... etc...
student user8
student user9
4. Click [OK].
Automotive Data: Open the desired project
Note:

Load a preexisting area of an operation tree that contains 3D data (associated part and
resource instances with .COJTs).
1. In Process Simulate, close the current project, if one is open: Select File —> Close
Project.
2. If asked “You are about to close the project. Do you wish to continue”, select Yes.
However, if asked “Do you wish to update eMServer”, select No.
3. In Process Simulate, open an existing project: Select File —> Open Project.
4. In the Open Project window, select Robotics Example and click [OK].
5. In the Navigation Tree, expand the tree one level.
Automotive Data: Check out your working folder and set it as the working folder
1. In Navigation Tree, browse into the Working Folders collection (folder).

2. Check out your assigned collection (folder) according to this chart: Right click it
and select Check Out .

administrator administrator's Working Folder
user1 User1 Working Folder
etc... etc...

3. Click [OK].
Note:
The text of your working folder is now displayed bold.
Automotive Data: Load the Study
1. From the Navigation Tree, browse into the Studies study folder.
2. Browse into the Line## study folder, where ## is the user number assigned to by
your instructor.
3. Right click on the Robotics Example study and select Check Out .
4. Click [OK].
5. Right click on the Robotics Example study and select Load in Standard Mode
.
6. Wait for a couple seconds for the data to load.
Automotive Data: Expand the Product Tree (1)
Note:
Expand it to see what came across, if you didn’t already.
1. Click the Object Tree tab.

2. In the Object Tree viewer, right click the Parts folder and select Expand -> 2
Levels. The associated parts, if any, are shown.
Automotive Data: Expand the Resource Tree (2)
Note:
1. In the Object Tree viewer, right click the Resources folder and select Expand -> 1
Level. The associated resource structure is shown.
Automotive Data: Expand the Operation Tree (3)

Note:
1. Click the + next to the Operation Tree process to expand it.

Activity: Object Tree Basics and Groups
The objective of this activity is to learn more about the tree structure and its hierarchy.
Browsing the Object Tree

Creating Compound Resources
Creating and Working with Groups
Browsing the Object Tree
1. Successively clicking the display status squares (Blank and Display ) next to
the nodes on the Object Tree viewer causes the displaying or blanking of entities in
the Graphic Viewer.
Note:
When you click the box next to a node, it switches between a filled box and an
empty box. When the box is fully filled, the object is completely displayed in the
tree. When it is partially filled, the object is only partially displayed in the Graphic
Viewer When you see an X in the box, no 3D data is available.
2. As mentioned previously, clicking the + or - icons next to a node expands or hides

the next level, respectively. It is useful to expand the tree fully to display all levels,
since some entities are nested within subcomponents. It is important to learn to
identify the entity icons.
Note:
Expanding Trees:
One level of a tree can be expanded by clicking the + icon next to a node in a tree.
The [*] key from the Number Pad area of the keyboard (which is [Fn] —> P on an
American laptop keyboard layout) can be used to expand all levels of the tree. We
will also learn how to do this using the right-click menu in the next topic.
Collapsing Trees:
One level of a tree can be collapsed by clicking the - icon next to a node in a tree.
We will also learn how to do this using the right-click menu in the next topic
3. Individual parts/resources or compound parts/compound resources can be added

or removed from a group. . Complete groups can be moved by highlighting the

desired objects in the tree (with the left mouse button), then dragging and
dropping it onto the desired location on the tree.
Creating Compound Resources
1. In Object Tree viewer, select the first object in the Resources folder.
Note:
Only other compound objects can be used as the parent for a new compound
object.
2. Select Modeling —> Create Part Resource —> Create Compound Resource .
Note:
A new CompoundResource1 object is created in the Resources folder of the Object

Tree.
Note:
Whenever a new object is added to a study, it will be added to the bottom of the
list of entities on the Object Tree viewer.
3. Pick the new CompoundResource1 object, press [F2], and enter My Compound
Resource for the Name.
Note:
Nodes in the object tree (that are not read-only) can be renamed by first selecting
them and second, clicking them again. A frame will appear around the selected
text, which a new name can be entered
Note:
You can also press the [F2] key to begin renaming objects.
4. Drag and drop the desired resources on to My Compound Resource.
Note:
This compound resource will be stored back to the original resource tree and
change its structure after eMServer Selective Update is clicked.

Note:
You cannot add both parts and resources to the same compound object.
Creating and 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.
1. Select View —> Viewer —> Logical Collections Tree.

2. In the Logical Collections Tree viewer select the Groups folder and select Tools —>
Groups —> Create Group .
3. From the Graphic Viewer or Object Tree viewer , pick some parts or resources.
Note:
A group can contain any combination of other groups, resources, compound

resources, parts, or compound parts.
4. In the Create Group window, enter a Name for the group such as My Group, and
click [OK].
5. In the Logical Collections Tree viewer right click on the My Group group and look at
the options on the right click menu. .
Note:
Notice the Create Group , Flatten Hierarchy , Export Groups to Excel ,

and Replace Compounds with Groups options.
Note:
This group will be stored only in the study and will not affect the original resource
tree structure after eMServer Selective Update is clicked.
Note:
You can add both parts and resources to the same compound object.
Note:

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.

Activity: Using the Right Click Popup Menu
The objective of this activity is to use the right click menu in the Graphic Viewer and
Object Tree viewers. When using the various options on the menu, make sure to observe
their effects in the Graphic Viewer.
Change the color of an object from the Object Tree

Blank the object from the Object Tree
Display all the objects from the object tree
Change the color of an object from the Object Tree
1. Right click a human in the Object Tree viewer.

2. From the right click menu, select the menu to the right of Modify Color .
3. Choose a color from the displayed window.
4. Pick on nothing in the Graphic Viewer to unselect the object and see its new color.
5. Undo the color change: Select Edit -> Undo .
Blank the object from the Object Tree
1. Right click the human again and select Blank .

2. Undo the blanking: Select Edit -> Undo .
Display all the objects from the object tree
1. Right click in the Object Tree viewer, but not on an object.

2. Select Display All .

Activity: Basic Graphic Viewer Controls
In this activity, you learn some of the view commands
Change the background color

3D Space Mouse Movement Options
Regular Mouse Movement Options
1. In Process Simulate, select Tools -> Options.

2. From the Options window, select the Appearance tab.
3. Select Background color.

4. Choose Corners from the drop down.
5. Choose a color for each corner.
6. Click Preview.
7. Click [OK].
3D Space Mouse Movement Options
Optionally, use your Space Mouse to manipulate the Graphic Viewer contents.
Note:

The device needs to be attached to your computer and the driver loaded before
your Process Simulate session is started.
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
Regular Mouse Movement Options
1. Hold down the Middle mouse button (i.e. press the mouse wheel like a button).
2. 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.
3. Hold down the Right mouse button.
4. Moving the mouse in any direction affects the direction panned, when continuous
viewing is set.
5. Hold down the Middle and Right mouse button.
6. Moving the mouse in any direction changes the viewpoint.
7. 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.
Note:
The behavior of the regular mouse movement options can be modified by selecting
Tools —> Options, and choose an option on the Graphics Viewer tab.

Activity: Selecting Objects in the Graphic Viewer
The objective of this activity is to learn how to select objects and manipulate them in the
Graphic Viewer .
Picking Entities
Change the color of a whole object in the Graphic Viewer
Change the color of part of an object in the Graphic Viewer
Blank and Display the object from the Graphic View
Highlight objects using the mouse wheel
Viewing and selecting PMI
Picking Entities
1. Select the Entity Pick Level. (Most likely it is set to Component right now).
Note:
A short cut key to toggle between the two Pick Levels is the [F12] key.
2. Pick a non-kinematic object (i.e. a rails, lift assists, or tool base). Notice the whole
thing is still highlighted.
3. Pick a kinematic object (i.e. a robot or human). Notice that only part of it is
highlighted.
4. Select the a non-kinematic object (i.e. a rails, lift assists, or tool base)
5. Select Modeling —> Entity Level —> Load Entity Level .
6. Notice that you can now expand into the object and select its entities.
7. Pick it again.
8. Select Modeling —> Entity Level —> Unload Entity Level .
Change the color of a whole object in the Graphic Viewer
1. Set the Pick Level to Component.

2. Right click the human in the Graphic Viewer and select the menu to the right of
Modify Color .
3. Choose a color from the displayed window.
4. Pick on nothing in the Graphic Viewer to unselect the object and see its new color
of the whole human.
5. Select Edit -> Undo .
Blank and Display the object from the Graphic View
1. Right click the human again and select Blank .

2. Right click in the Graphic Viewer but not on an object.
3. Select Display All .
Highlight objects using the mouse wheel
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.
4. 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.
5. Continue all the way up the tree.
Viewing and selecting PMI
1. In the Object Tree, browse into the Resources folder.

2. In the Object Tree, expand into the CompoundResource.
3. Expand into the toolcrib.
4. Right click on pmi_notes_15 and select Zoom to Selection.
5. Select Modeling —> PMI —> Load PMI .

6. Look at the PMI on the part in the Graphic Viewer.
7. In the Object Tree, expand into pmi_notes_15.
8. In the Object Tree or Graphic Viewer, pick one of the PMI objects.

Activity: Additional Methods of Multiple Entity Selection
The objective of this activity is to learn additional methods of selecting multiple items.
Note:
An object can be selected in the Graphic Viewer by clicking the left mouse button and
drawing a box around the desired object(s). If any part of the object(s) is in the window, it
will be selected. Objects can also be selected by clicking them on the Object Tree viewer.
All selected objects can be deselected by clicking in the empty space around them in the
Graphic Viewer . A selected object can be individually deselected by clicking it, either in
the Graphic Viewer or in the Object Tree viewer, while pressing the [Ctrl] key.
Object Tree Object Selection

Multi-Selecting and Deselecting Objects in the Graphic Viewer
Multi-Selection using the [Ctrl] key or [Shift] key
Using the View Menu
Object Tree Object Selection
1. Any node can be selected by clicking it; previously selected nodes are then
deselected. To select several separate nodes simultaneously, hold down the [Ctrl]
key and click the additional nodes, as required. To select a range of nodes
together, select the first node you want, hold down the [Shift] key and click the last
node you want.
Note:
The Shift Key:
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:
The [Ctrl] key enables you to select more than one non-consecutive 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.

2. Objects can also be selected from the Graphic Viewer. To select whole objects,
make sure the Pick Level is set to Component. To select parts of an object, make
sure the Pick Level is set to Entity.
Note:
Pick Level:
There are two main Pick Levels in Process Simulate, Entity and Component. These
levels determine what is selected when you click an object. If the Pick Level is set
to Component and you click one entity of an object, the entire object becomes
selected. If the Pick Level is set to Entity, then only that entity (that is, part of the
whole object) is selected.
Multi-Selecting and Deselecting Objects in the Graphic Viewer
1. Press the left mouse button and draw a box around several objects in the Graphic
Viewer. Note which objects turn green.
2. Deselect the entities by selecting the empty space around them in the Graphic
Viewer.
Multi-Selection using the [Ctrl] key or [Shift] key
1. Pick an object in a tree.

2. Hold down the [Ctrl] key and pick an object.
3. Continue holding down the [Ctrl] key and pick another object.
4. Release the [Ctrl] key.
5. Pick an object in a tree.
6. Hold down the [Shift] key and pick another object.
7. Release the [Shift] key.
Using the View Menu
1. Select multiple objects using the left mouse button and the [Ctrl] key
2. Select View -> Blank . Note how the selected objects change in the Graphic
Viewer, depending on your selection.

Note:
You can also access these options by right clicking an object in the Graphic Viewer

Activity: Using Toggle Display
The objective of this activity is to learn how to toggle between the blanked and displayed
objects in the Graphic Viewer.
Note:
Using the Toggle Display command toggles between the blank objects and the
displayed objects, that is, all displayed objects become blanked and all blanked objects
become displayed.
Toggle the display of blanked and displayed objects
Toggle the display of blanked and displayed objects
1. Blank several objects in the Graphic Viewer, using one of the methods
described previously in this chapter.
2. Select View -> Toggle Display .
3. You should now see only those objects that you just blanked (and maybe a few
locations or paths).
4. Blank some of the objects in this view, and then Toggle Display back again.
5. The objects you just blanked are now displayed.

Activity: Blanking all the Frames using Selection Filters (Optional)
The objective of this activity is to learn how to use selection filters to select and blank
entities by type.
Blank all the frames using method 1
Note:
This toolbar is turned off by default. Right-click the current toolbar and select Selection to
activate it.
1. From the Selection toolbar, click Select with Filter .

2. From the Selection toolbar, choose to select all the frames by clicking Selection
Type Frames .
3. Click Select All (of the selected type). Notice that only the frames are
selected.
4. Select View -> Blank .
5. Click Select from the Viewing toolbar or click Select with Filter again.

Activity: Blanking all the Frames using Display by Type
The objective of this activity is to learn how to use Display By Type to select and blank
entities by type.
1. Select View -> Display all .

2. Select View -> Display By Type .
3. From the Display By Type window, choose Frames from the list.
4. From the Display By Type window, choose Hide Selected Types .
5. Close the Display By Type window.

Activity: Relationship Between Measuring and Units
The objective of this activity is to learn about units and measuring within Process
Simulate.
Measure the distance from the one object to another

Change the units
Measure the same distance again
Measure the distance from the one object to another
1. Click Minimal Distance on the Tools toolbar (or select Tools -> Measurements
-> Minimal Distance ).
2. Click the two objects in the Graphic Viewer. The distance between the two is
displayed. (Your numbers and objects may differ from those shown below).
3. Remember the approximate distance and the picked objects.
4. Close the Minimal Distance window.
Change the units
1. Select Tools -> Options.

2. In the Options window, select the Units tab.

3. Change the current Linear unit type to inch.
4. Select [OK].
Measure the same distance again
1. Bring up the Minimal Distance window and pick approximately same two points to
measure. Notice the units are now converted to inches. (Your numbers and objects
may differ from those shown below).

Activity: Changing Visualization Performance
In this activity, you will learn more about how to change the performance settings.
Experiment with Level of Details

Change the level of details to a more typical setting
Experiment with culling
Change the culling to a more typical setting
Experiment with Level of Details
1. Center the currently displayed objects in the Graphic Viewer by clicking Zoom To
Fit .
3. From the Options window, select the Performance tab.
4. Move the slider in the Level of Details area towards Speed.

5. Click [OK].
6. The display of the objects in the cell change.
7. Zoom in and out using the middle mouse button.
8. Note the difference between this level of detail and the one used earlier.
Change the level of details to a more typical setting

2. From the Options window, select the Performance tab.
3. Move the slider in the Level of Details very close to Quality.

Note:
Two right arrow clicks from Quality, is the most optimal setting (i.e. good quality
and increased performance).
4. For the Rendering mode, select Use OpenGL display lists.
5. Click [OK].
6. The display of the objects in the cell change.
7. Zoom in and out using the middle mouse button.
8. Note the difference between this level of detail and the one used earlier.
Experiment with culling
1. Reopen the Options window, if it was closed, and select the Performance tab.

2. Check Cull parts with less than.
3. Enter 0.05.
4. Click [OK].
5. See how this affects graphics visualization.
Note:
This option cannot be used when it is desirable to see small objects, such as PLPs
or welds (since they would not be shown). Smaller culling values, such as 0.01%,
may be helpful in other use cases (i.e. general or final assembly).
Change the culling to a more typical setting
1. Reopen the Options window, if it was closed, and select the Performance tab.
2. Uncheck Cull parts with less than.

Activity: Changing Graphical Visualization
In this activity, you will modify the visualization of Graphic Viewer objects.
Toggling all objects’ visualization

Changing a single object’s visualization
Using Dynamic Clipping
Toggling all objects’ visualization
1. On the Object Tree, browse into the Resource folder.

2. Right click desk_contents and select Display Only .
3. Select View —> Feature Lines .

4. The feature lines mode is shown. Notice the effect in the Graphic Viewer.
Note:
Your data may look different than what is shown in the picture.

5. Select View —> Wireframe Mode . Notice the effect.
6. The wireframe mode is shown. Notice the effect in the Graphic Viewer.

7. Select View —> Shaded Mode .
8. The shaded mode is shown. Notice the effect in the Graphic Viewer.
Note:
Your data may look different than what is shown in the picture.

9. Select View —> Features Lines Over Solid .
10. The features lines over solid mode is shown. Notice the effect in the Graphic
Viewer.

11. Slowly, press the [F10] key several times successively. Notice the effect in the
Graphic Viewer.
12. Return to Shaded Mode .
Changing a single object’s visualization
1. Select an object (such as a human) and select View —> Object Viewing ->
Transparent .
2. Pick off of the object.
3. Rotate the view around and notice how you can see through the object now.

Note:
Transparency enables users to select a complicated assembly and view its inner
objects.
4. Select the transparent object and select View —> Object Viewing -> Shaded .
5. Pick off of the object.
6. Notice the effect.

Using Dynamic Clipping
1. Pick a point of interest in the Graphic Viewer.

2. Select View —> Graphic Viewer —> View Center to set the desired point of
interest at the center of the Graphic Viewer display.
3. Select View —> Dynamic Clipping Planning Settings .

4. In Dynamic Clipping Plane Settings window, move theClipping Plane slider a little
bit away from Camera.
5. Hold down the middle mouse button and move the mouse toward the right to
zoom in to the view centered point. Notice now the geometry in the way is clipped
so better show the desired geometry.
6. In Dynamic Clipping Plane Settings window, click Close.
Note:
In the future, to return to this clipping, just toggle View —> Dynamic Clipping
on and off as needed.

PLACEMENTS COMMANDS
Activity: Using Fast Placement
The objective of this activity is to learn how to use the Fast Placement command.
Open your assigned station for a resource query

Use Fast Placement
Undo the positional changes (method 1)
Use Fast Placement again
Undo positional changes (method 2)
Open your assigned station for a resource query
Note:
We checked out and assigned our working folders in the previous activities. Once set for a
project, it will remain set forever (or until another folder is set as the working folder).
1. In the Navigation Tree, browse into the StudyFolder (object type is also
studyfolder).
2. In the Navigation Tree, browse into the Underbody studyfolder.
3. In the Navigation Tree, browse into the Mtr Comptr studyfolder.
4. Locate your assigned study:
eMSUser Id Studies
user1 M11LH
user2 M11RH
user3 M10
user4 M20
user5 M31
user6 M32
user7 M33
user8 M30
user9 M40
user10 M50

administrator M11LH (copy)
5. Right click your assigned study, select Check Out , and click [OK].
6. Right click your assigned study, and select Load in Standard Mode .
7. Do NOT save changes to the previously loaded scenario.
Note:
We are only playing around with the data in order to better understand now the
software works.
Use Fast Placement
Note:
We are not going to save changes to this study either.
1. Select View -> Graphic Viewer -> View Point .

2. Select Top from the View Point window.
3. From the Standard toolbar, set the Pick Level to Component.
4. Click Fast Placement on the toolbar, and then select and drag each object
around the screen.
Note:
Fast Placement does not work in the Z direction
5. When you have finished, click Select to return to normal mode.

6. Select Zoom to Fit .
Undo the positional changes (method 1)
1. Use Edit -> Undo to undo the object placement.

2. Repeat as necessary to undo all the fast placement.
Use Fast Placement again
1. Click Fast Placement on the toolbar, and then select and drag a single object
and drag it to 3 different locations.
2. When you have finished, click Select to return to normal mode.
Undo positional changes (method 2)
1. Select the object you just moved in the Graphic Viewer.
Note:
Multiple objects could also be selected by holding down the [Ctrl] key and picking
them.
2. Select Tools -> Placement -> Restore Design Relative Position .

3. The object returns to original position with one click (instead of 3 clicks with the
undo).

Activity: Creating a Frame
The objective of this activity is to learn how to create a frame.
Create a frame by 6 Values

Create a Frame By 3 Points
Create a Frame Between 2 Points
Create a Frame By Circle Center
Look at the frame’s name
Create a frame by 6 Values
1. Select Modeling -> Create Frame -> Create Frame by 6 Values .

2. Pick a point in the Graphic Viewer.
Note:
You can keep clicking positions in the Graphic Viewer to change the placement of
the frame.
3. When the frame is placed correctly, click [OK] in the Create Frame By 6 Points
window.
Note:
The frame is displayed in the Graphic Viewer.
4. Select the Object Tree tab to display the Object Tree.
Note:
The frame is also displayed in the Frames folder of Object Tree.
Create a Frame By 3 Points
1. Select Modeling -> Create Frame -> Create Frame By 3 Points .

2. Pick a point in the Graphic Viewer. to set the origin of the frame
3. Pick a point in the Graphic Viewer. to set the direction of the X-axis of the frame
4. Pick a point in the Graphic Viewer. to define the XY-plane of the frame
Note:
Right hand rule, determined by the three pick points, is used to determine which
way Z points away from this plane. Click Flip Frame if it is on the wrong side.
5. Click [OK].
Create a Frame Between 2 Points
1. Select Modeling -> Create Frame -> Create Frame Between 2 Points .
2. Pick a point in the Graphic Viewer. to define the first point.
3. Pick a point in the Graphic Viewer. to define the second point.
4. By default the frame will create in the middle (at 50%) of the line between the two
points. Use the slider to move the frame between the two points to the desired
position.
Note:
Click Flip Frame if it is on the wrong side.
5. Click [OK].
Create a Frame By Circle Center
1. Select Modeling -> Create Frame -> Create Frame By Circle Center .
2. Pick a point in the Graphic Viewer. to define the first point of the circle.
3. Pick a point in the Graphic Viewer. to define the second point of the circle.
4. Pick a point in the Graphic Viewer. to define the third point of the circle.
Note:
The frame is created at the center of the circle formed by the three pick points.
Right hand rule, determined by the three pick points, is used to determine which
way Z points away from this plane. Click Flip Frame if it is on the wrong side.
Note:
If picking on geometry on a geometric circle or cylinder shape, set the Pick Intent
to Snap and pick on or near the circle or shape to snap to

the center. In this case, you should use Create Frame By 6 Values instead of

this option. This option is best, for geometric circles or cylinders that are so
imperfect that Process Simulate does not recognize them as such (i.e. a hexagon).
5. Click [OK].
Look at the frame’s name
1. Mouse over one of the created frames in the Graphic Viewer and notice the
frame’s name is displayed.
2. Look in the Frames folder in the Object Tree.

Activity: Shifting and Rotating Instances On-screen
The objective of this activity is to learn one way to position instances within a session.
Selected object(s) can be shifted by entering values in the X, Y, or Z fields, or by clicking
the up and down arrow keys in the Translate area of the Placement Manipulator window.
Note:
Objects can be selected for placement in several ways:
Pick them (from the Objects Tree or Graphic Viewer) and select Tools -> Placement
-> Placement Manipulator .
Pick them and select Placement Manipulator from the toolbar.
Draw a selection window around them and select Placement Manipulator .
Open the Placement Manipulator window

Use the Manipulator Frame to move the object
View the coordinates of the object relative to a specific frame of reference
1. (Make sure your Pick Level is set to Component).
2. Pick an object
3. Select Tools -> Placement -> Placement Manipulator .
4. A large frame with arcs appears at the center of the selected object. This is called
the Manipulator Frame.
Use the Manipulator Frame to move the object
1. In the Graphic Viewer, pick and drag the red X-axis of the Manipulator Frame.
2. The relative coordinates (that is, the distance moved on the currently selected axis
since the object was selected) are displayed in the field in the Translate area, at
the top of the Placement Manipulator window, as shown below:
3. In the Graphic Viewer, pick and drag the green Y-axis of the Manipulator Frame to
move it on the Y-axis.
4. In the Graphic Viewer, pick and drag the white square between the green Y-axis
and X-axis of the Manipulator Frame to move it on the XY-plane..
5. Notice in the Placement Manipulator window that the Frame of Reference is set to
Geometric Center.
6. In the Graphic Viewer, pick and drag the green arc of the Manipulator Frame to
rotate the object around the Y-axis of the geometric center.
Note:
Notice how it moves.
7. In the Placement Manipulator window, change the Frame of Reference to Working

Frame.
8. Again in the Graphic Viewer, pick and drag the green arc of the Manipulator Frame
to rotate the object around the Y-axis of the working frame.
Note:
Notice how it moves differently than before.
View the coordinates of the object relative to a specific frame of reference
1. Click Expand Dialog in the Placement Manipulator window to expand the

window, as shown below:
2. Make sure that Working frame appears in both the Frame of Reference and
Location relative to fields. If it does not, select it from the drop down list.
Note:
Notice that the current absolute coordinates of the object being manipulated are
displayed in the table at the bottom of the window. It is NOT suggested to enter
new coordinates using this bottom part of the placement manipulator. Instead, use
this area as a print out of where your object is currently sitting in reference to the
selected frame.
3. In the Placement Manipulator window, click Reset to return to the place where it
was when this window was opened.
Note:
If you would like to reset the position of the object after closing the Placement
Manipulator window, Select the object and choose Tools -> Placement -> Restore
Design Relative Position

4. In the Placement Manipulator window, click Close.
Activity: Relationship Between Placement Manipulator, Measuring, and Units
The objective of this activity is to learn another way to position instances within a
session. We will use the session from the previous activity.

Measure the distance from the bottom of one object to the top of another
Measure the minimal distance between two objects
Move the object
Change the units and see the affect
1. Pick an object.
3. In the Placement Manipulator window, set Working frame as the Frame of
Reference.
4. Do not close the Placement Manipulator window yet.
Measure the distance from the bottom of one object to the top of another
Note:
For example, if you wanted to put the second object on top of the first object.
1. Select Tools -> Measurements -> PTP Distance .

2. On the toolbar, set the Pick Intent to Snap.
3. Set the Pick Level to Component
4. For the First Object, click the bottom of the first object.
5. For the Second Object, click the top of the second object.
6. The distance between the two picked points is displayed in the Graphic Viewer and
in the Point To Point Distance window.

7. Close the Point To Point Distance window.
Measure the minimal distance between two objects
1. Select Tools -> Measurements -> Minimal Distance .

2. For the First Object, click the first object.
3. For the Second Object, click the second object.
4. The distance between the two objects is displayed in the Graphic Viewer and in the
Minimal Distance window.
5. Do not close the Minimal Distance window.
Move the object
1. In the Placement Manipulator window, notice the current step size units are mm.
2. Select the Step size link, in the translate part of the Placement Manipulator
window, enter 100, and select [OK].
3. Click Z and select the black right arrow twice.
4. In the Graphic Viewer, drag the object around using the Manipulator Frame.
5. To undo all the placements on this object, click Reset.
6. Close the Minimal Distance window.
7. Close the Placement Manipulator.
Change the units and see the affect

2. From the Options window, select the Units tab.
3. Change the number of decimal places for Linear to 3.
4. Change the current unit type to inch.

5. Click [OK].
6. Bring up the Placement Manipulator window for an object again. Notice the units
are now converted to inches.
7. Bring up the Minimal Distance window and measure the same two objects. Notice
the units are now converted to inches.

Activity: Incremental Shifting of Objects from a Reference Frame
The objective of this activity is to learn how to use linear and rotational step sizes.
Selected objects can be moved by step size along a chosen linear or rotational axis. This
step size can be changed and stored until the next time the command is used.
Rotate an object about its Geometric Center

Rotate an object about the Working Frame
Rotate an object about its Geometric Center
1. Pick an object.
3. Select the rotation Step size link in the Placement Manipulator window.
4. In the Step Size window, change the rotation step size to 45 degrees by entering 45
in the Rotation step (deg) field and clicking [OK].
5. Click Rx in the Placement Manipulator window and rotate an object in 45 degrees
increments around the X-axis by clicking the Move Negative and Move
Positive arrows.
Warning:
Do not click the Move Negative To Collision or Move Positive To Collision

arrows. They will continue the rotation until a collision occurs. If none occurs
(or if collision detection is not configured), it will come back with a warning saying
“No collisions have been detected”.
Rotate an object about the Working Frame
Note:
The Placement Manipulator window is still open.
1. Select Working frame from the Frame of Reference pull-down lists.

2. Rotate an object again either by using the Move Negative and Move Positive
arrows, or by grabbing an arc shaped axis of the Manipulator Frame and
dragging it in the Graphic Viewer.
Note:
If Snap by step size is checked in the Placement Manipulator window, dragging the
Manipulator Frame will jump the object according to the specified Step Size.
3. In the Placement Manipulator window, click Reset.

4. Click Close

Activity: Relocating an Object Relative to Two New Frames
The objective of this activity is to learn how to use the Relocate command to relocate an
object relative to two new frames.
Relocate by Using a From Frame and a To Frame
Relocate by Using a From Frame and a To Frame
1. On the Standard toolbar, set the Pick Intent to Snap.
2. Set the Select Level to Component.
3. Pick an object.
4. Select Tools -> Placement -> Relocate .
5. In the Relocate window, click in the From frame field.
6. Click in the Graphic Viewer at any convenient location.
7. In the Relocate window, click in the To frame field.
8. Click in the Graphic Viewer at another convenient location.
9. Click Apply. The object travels the distance and direction defined by the two
frames (pick points).
10. Do not close the Relocate window.

Activity: Relocating an Object Relative to Two Existing Frames
The objective of this activity is to learn how to use the Relocate command to relocate an
object relative to two already existing frames. An existing frame may be the self-origin,
the world frame, any frame in the Graphic Viewer , or any entity in the session.
Relocate an Object Another Way
Relocate an Object Another Way
1. In the Relocate window, select the corner of an object for the From frame.
2. Select the corner of another object for the To frame.
3. Select the Maintain orientation checkbox.
4. Click Apply.
5. The corner of an object is now shifted the X, Y and Z distance between the From
Frame and the To Frame, while the object's orientation is maintained.

QUICK INTRODUCTION TO KINEMATICS
Activity: Jogging the Joints of a Simple object
The objective of this activity is to open the study called Door Kinematics and jog its joints.
Open the desired data

Open the Joint Jog window
Method 1 to jog the joints
1. Close the current project: Select File —> Close Project.

2. If asked “You are about to close the project. Do you wish to continue”, select Yes.
However, if asked “Do you wish to update eMServer”, select No.
3. Select File —> Open Project.
4. Select Project_209S and click [OK].
5. Browse to the Studies study folder.
6. Browse to the Line## StudyFolder study folder, where ## is the user number
assigned to you by the instructor.
7. Browse to the model kinematics study folder.
8. Right click the model kin demos study and select Check Out .
9. Click [OK].
10. Right click the model kin demos study and select Load in Standard Mode .
11. From the Process Simulate Object Tree, right click the room_door_demo object in
the Resources folder, and select Display Only .
12. Select View —> Zoom to Fit .
13. In the Graphic Viewer, pick out in space to deselect the door.

1. Set the Pick Level to Component.
2. Select the door.

3. Select Kinematics -> Joint Jog .
Tip:
You may want to show the Kinematics toolbar.

1. In the Joint Jog window, click the mouse on j1 gear and do not release the mouse
button.
2. Move the mouse left and right across the whole the Graphic Viewer to see the
selected joint move. (Notice you are not limited to moving the joint inside the Joint
Jog window).
3. Release the mouse button.
4. Repeat these steps for the j2 gear.
Note:
When approaching the limits of a joint the slider and Value will turn red to signify
that you are no longer in the defined working limits. To change the Working Limits
select Tools —> Options and go to the Motion tab.
1. In the Joint Jog window, click Options

2. In the Joint Jog Settings window, enter 10 for the Prismatic joints step size.
3. In the Joint Jog Settings window, enter 15 for the Rotational joints step size.
4. click [OK].
5. For j1, repeatedly click these buttons to jog a joint.

Activity: Defining Kinematic Poses
The objective of this activity is to define kinematic poses for an existing kinematic door
device.
Set the units

Create a New Pose
Jog the joints and create another pose
Move the door between the defined poses
Update the database
Set the units
1. Continue using the same study loaded in the previous topic.

2. Right-click in the Graphic Viewer on nothing and selecting Options from the
displayed popup menu.
3. From the Options window, select the Units tab in the displayed Options window.
4. Select mm from the Linear pull down list.
5. Select Deg from the Angular pull down list.
6. Click [OK].
Create a New Pose

1. Make sure that the Pick Level is set to Component.
2. In the Graphic Viewer, right click the room_door_demo and select Home to
return it to the position it was in where the kinematics were defined (that is, j1=0,
j2=0).
Note:
This is called the HOME pose.
3. In the Graphic Viewer, right click the room_door_demo and select Pose Editor .
4. in the Pose Editor, click New.
5. Leave the joint values at j1=0 and j2=0. This is the same as the HOME pose in step
2.
6. For the Pose Name, enter CLOSED.
7. Click [OK].
Jog the joints and create another pose
1. in the Pose Editor, click New.

2. From the New Pose window, select and hold the j1 gear, and move the mouse left
and right across the Graphic Viewer to jog the door to an open position.
Note:
Exact joint values can be entered, or the up or down arrows on the field can be
used to set the value (the step size for the up or down arrows can be set in Joint
Joint Properties.
3. Repeat the process for the j2 gear.

4. For the Pose Name, enter OPEN.
5. Click [OK].
Move the door between the defined poses
1. In the Pose Editor window, select the CLOSED pose, and click Jump.
2. Select the OPEN pose, and then click Jump again.
3. This jumps the door from the CLOSED pose to the OPEN pose.

4. In the Pose Editor window, click Reset to reset the mechanism back to the HOME
pose.
Update the database
1. Select File -> eMServer Selective Update .
2. Check Operations.
3. Click [OK]
4. Click [OK].

Activity: Creating a Simulative Operation from Poses
The objective of this activity is to create a compound sequence from a mechanical

operation.
Create a simulation to move the door between poses

Play the simulation
Create a simulation to move the door between poses
1. Select Model Kin demos CompoundOperation in the Operations Tree viewer.

2. Select Operations —> New Operation —> New Compound Operation .
3. In the New Compound Operation window, enter Operation for the Name.
4. In the Operations Tree, select the MyOperations
CompoundOperationMEOpRevision.
5. Hold down the [Ctrl] key.
6. Select the room_door_demo.
8. Select Operations -> New Operation —> New Device Operation .
Note:
In the New Device Operation window, the Name and Device fields are already filled
in.
9. In the New Device Operation window, select CLOSED from the From pose pull
down list.
10. Select OPEN from the To pose pull down list.
11. Click [OK].
Play the simulation
Note:
If the Sequence Editor is not shown, select View —> Viewers —> Sequence Editor.
1. From the Sequence Editor, click Jump Simulation to End .

2. From the Sequence Editor, click Jump Simulation to Start .
3. From the Sequence Editor, click Play Simulation Forward .

Note:
The speed of simulation can be adjusted in several ways: either (method 1) change
the time of the operation, (method 2) change the defined joint speeds, or (method
3) change the simulation time interval. There are very different reasons to use
these three techniques.

Activity: Examining the Kinematic Tree of a Robot
The objective of this activity is to look at the kinematic definition of a robot.

Look at the kinematics in the Kinematics Editor
Note:
This activity will continue to use the model kin demos study loaded earlier. It contains the
room_door_demo and the real_robot objects.
1. Verify that the Pick Level is set to Component.
1. In the Process Simulate Object Tree pick the top folder named model kin demos .
2. Select Edit —> Find.
3. In the Find window for the Name, enter *robot* and click Find Next and Cancel.
Note:
The * on the beginning and ending are important.
4. From the Process Simulate Object Tree, right click the real_robot object in the
Resources folder, and select Display Only .
Look at the kinematics in the Kinematics Editor
1. Select the robot.

2. Click Kinematics -> Kinematics Editor .

3. The links of the robot in the Graphic Viewer are temporarily colored according to
the colors of the links in the Kinematics Editor window.
4. Close the Kinematic Editor window.
Note:
The creation of kinematics is described later in this course.

Activity: Making the Robot Move
The objective of this activity is to see how to move a robot.
Jog the robot’s joints

Use Robot Jog to move the robot
Create new robotic operation for the robot
Create the first location for the robot
Create another via location for the robot
Play the simple simulation
Jog the robot’s joints

3. Using the Joint Jog window, jog the joints using the sliders and observe how they
move.
Note:
Notice how this type of movement is different from Joint Jog.

2. Select Kinematics -> Robot Jog .

3. While the Robot Jog window is open, grab the Manipulator Frame in the Graphic
Viewer and pull the robot around.
Note:
The robot jog window is only available for robot objects (i.e. objects with a TCPF
frame at the end of its kinematic tree).
Note:
If the robot is not moving when you pull the Manipulator Frame, verify that Snap
by Step Size is not checked. this option is located under the Expand Dialog
area of the Robot Jog window. Having this box checked with a step size that is too
big for the robot will cause the robot to not move when the Manipulator Frame is
dragged.

1. Select Model Kin demos CompoundOperation in the Operations Tree viewer.
2. Select Operations —> New Operation —> New Compound Operation .
3. In the New Compound Operation window, enter Operation2 for the Name.
4. In the Operations Tree, select the Operation2 .
6. Select the room_door_demo
8. Select Operations -> New Operation —> New Weld Operation .
9. Take the defaults for the rest of the fields and click [OK].
Note:
The creation and validation of proper weld processes is described in detail later in
this in course. The information provided in this topic should not be considered
enough to begin processing welds in the Process Simulate environment.
Create the first location for the robot
1. On the Operation Tree viewer, pick the new bolded real_robot_Weld_Op robotic
operation.
2. Select Operation -> Path Editing -> Add Current Location .
Note:
The path editing buttons can also be found on the Path toolbar which is turned off
by default.
1. On the Operation Tree viewer, pick the via location in the real_robot_Weld_Op
robotic operation.
2. Select Operation -> Path Editing -> Add Location After .
3. Use the Manipulator Frame to move the robot's wrist to another location.
4. Close the Robot Jog window.
5. Repeat steps 2 through 4 to create a third location in the robot operation (robot
path).

1. On the Operation Tree, right click real_robot_Weld_Op and select Set Current
Operation .
2. From the Sequence Editor, click Jump Simulation to End .

PROCESS SIMULATE ANALYSIS TOOLS AND STUDY DATA
Activity: Creating Snapshots
The objective of this activity is to create some snapshots.
Create a Flow Operation

Create a couple snapshots
Use the snapshots
Sort the snapshots
Create a Flow Operation
1. Reload the data that you used earlier in this course (i.e. Airplane, Robotics, or
Structure data), if it is not already loaded.
Note:
At this point in the course you should have at least one basic simulative operation
created. If not, then create one (i.e. object flow, device, or robotic) using the
follow steps.
2. Select an object in the Graphic Viewer.

4. Select a compound operation in the Operation Tree.
5. Select Operations —> New Operations —> New Object Flow Operations .
6. Pick a point on the floor.
7. Click [OK].
Note:
More attention is paid to creating flow operations in the WKP101SProcess Simulate

on eMS Part Flow course.
Create a couple snapshots
1. Select View -> Viewers -> Snapshot Editor.

2. Make sure the Snapshot Editor viewer is wide enough to see all the icons on its
toolbar.

3. From the Snapshot Editor toolbar, click New Snapshot .
4. A new snapshot of the graphic information currently displayed in the Graphic
Viewer is created with the default name Snapshot# and the snapshot is displayed
in the upper part of the Snapshot Editor.
5. Rename the snapshot to Zoomed View by selecting the snapshot name just
created and pressing the [F2] key or picking the Edit Snapshot icon.
6. Change the display in the Graphic Viewer in some way, such as by rotating,
panning, or zooming.
7. Create another snapshot the same way and name it to Another View.
Use the snapshots
1. Double click on the Zoomed View snapshot.

2. Look in the Graphic Viewer.
3. Double click on the Another View snapshot.
4. Look in the Graphic Viewer.
Note:
By default, only the point of view is applied but you can also select to apply the
location and visibility of objects. Click the Apply Snapshot drop-down arrow
and select one or more from the following: Point of View, Objects Visibility,
Objects Location, Device Poses and Objects Attachments.
Sort the snapshots
1. In the Snapshot Editor, right click on nothing in the upper pane.

2. From the menu select Sort Snapshots .

Activity: Creating Markups
The objective of this activity is to learn how to use the markup editor.
Open the Markup Editor

Save a picture of the Operation from the Markup Editor window
Open the Markup Editor
1. Select File -> Outputs -> Markup Editor.
Note:
The markup editor can also be opened by following this procedure: Open the
Snapshot Editor, select a snapshot, and pick Add Markup from the Snapshot
toolbar. Using this technique, the markups can be reused later (even after the
snapshot image is refreshed).
2. From the Markup Editor toolbar click Add Note .

3. Pick somewhere on the picture.
4. In the Edit Text window for Font Size, select36.
5. In the Edit Text window, enter the desired text such as Look at this exciting note.
6. Click [OK]
7. On the picture drag the note bigger so that you can see the text (drag the handle
bars to the right).
8. From the Markup Editor toolbar click New Text .
9. Pick somewhere on the picture.
10. Type This is so fun.
11. On the picture drag the text bigger to make the text the desired size.
12. From the Markup Editor toolbar click New Scribble Polygon .
13. Circle something in the picture.
Save a picture of the Operation from the Markup Editor window
Note:
Markups can be printed or saved as a graphics file. Any markups added to the view are
saved back to the view for later use.

1. From the Markup Editor window, select Save as File .
2. In the Save As window, enter a name for the filename or take the default.
3. Append your user name to the end of the markup filename (i.e. _user1).
4. Browse to the C:\Temp folder.
5. Click Save.
6. In the Markup Editor window, click Close.

Activity: Setting the Note Options
The objective of this activity is to setup the note flags.

Change the note color options

2. Select the Appearance tab.

3. Select Background from the top list.
4. Select Solid (instead of Vertical) on the lower list.
5. Change the background color to light brown.
6. Click Preview.
Change the note color options
1. From the Options window, select the Appearance tab, if it is not already selected.
2. Browse into New Object Colors in the top list.
3. Select Note Background from the top list.

4. Change the color.
5. Select Note Border from the top list.
7. Select Note Text from the top list.
Note:
Changes to the note colors will affect new notes that are created.

9. Click [OK].
Activity: Creating Notes in the Graphic Viewer
The objective of this activity is to learn how to create notes in the Graphic Viewer.
Note:
When using File -> Outputs —> Attach File to create pictures or markups of a view
containing notes, the font size of the notes, as well as the image size, can be set when the
picture is created.
Create a note for everything in the Graphic Viewer

Create a text note another way
Edit the note
Toggle its display between a flag and text
Change the display of the notes
Change an existing note
Create some labels
Create a note for everything in the Graphic Viewer
1. In the Graphic Viewer, draw a selection window around everything.

2. Select Tools -> Notes -> Object Notes .
3. In the Graphic Viewer, drag and drop the notes to a desired position.
4. Select View -> Viewers -> Object Tree.
5. In the Notes folder of the Object Tree, the notes can be blanked, displayed, or
deleted from here.
Note:
It will be saved in the current scenario if you decide to save it. Since it is considered
“engineering data—just like dimensions, frames, notes, and labels—it is not stored
in the product, operation or resource trees.
Create a text note another way
1. Pick somewhere in the Graphic Viewer where you would like to add a note.
2. Click the Tools -> Notes -> Create Note (or click Create Note on the
toolbar).
3. In the Note Editor window, enter the required text in the Text area.
4. Delete the contents of the Link area, or enter a different web link.
5. Click [OK].
Note:
The note can be edited, deleted, or toggled between displaying the text or the flag.
You can also change its color or blank it, as required. To perform any of these
actions, you need to right click the note and then select one of these buttons:
Blank , Modify Color , Edit Note , Toggle Note Visibility , or Delete
.
Edit the note
1. Select a note.
2. Select Tools -> Notes -> Edit Note .
3. Change the text.
4. Pick in the object field and choose a new anchor point for the leader line.
5. Click [OK].
Toggle its display between a flag and text
1. Select a note or group of notes (if more than one exists) from the Graphic Viewer
or Objects Tree.
2. Select Tools -> Notes -> Toggle Note Visibility .
3. Notice how the note is shown in the Graphic Viewer (as a flag).
4. Select Tools -> Notes -> Toggle Note Visibility .
5. Notice how the note is shown in the Graphic Viewer.
Change the display of the notes

2. Select the Appearance tab.
3. Expand New Objects Colors.
4. Select Note Background.
5. Choose a new color.
6. Repeat this process to change the default color settings for Note Border and Note
Text.
7. Click [OK].
8. Create another note.

Note:
The new note now takes on the new default color settings for Note Background,
Note Border and Note Text.
Change an existing note
1. Right click a note and select Modify Color .

2. Choose a new color.
3. Drag the notes to the desired position.
Create some labels
1. Pick an object in the Graphic Viewer.

2. Select Tools —> Labels —> Create Label .
3. Click [OK].
4. Drag the label to the desired position.
5. Zoom in and out and notice the difference between notes and labels
Note:
One other difference is that labels are associated and saved with the object,
whereas notes are associated and saved with the study.

Activity: Creating Dimensions in the Graphic Viewer
The objective of this activity is to learn how to create dimensions in the Graphic Viewer.
Add a Dimension
Create a markup
Add a Dimension
1. Select the Tools -> Measurements -> Create Dimension -> Point to Point
Dimension .
2. Pick two points in the Graphic Viewer.
3. Drag the dimension to position it.
Note:
The note flags and measured dimension can be saved as a picture or edited in the
markup editor and then saved as a picture.
Create a markup
1. Create a markup.
2. Select File -> Outputs -> Markup Editor.
3. Notice the notes and dimensions are shown here.
4. Close the Markup Editor window.

Activity: Outputting the Graphic Viewer to a File or Printer
The objective of this activity is to learn how to output the Graphic Viewer to a file or
printer.
Set the background color to white

Output a picture of the Graphic Viewer
Set the background color to white
1. Choose Tools -> Options.

2. From the Options window, select the Appearance tab.
3. Select Background color.

4. Choose Solid from the drop down that currently says Vertical or Corners.
5. Choose white for the color
6. Click [OK].
Output a picture of the Graphic Viewer
1. Select File -> Import / Export -> Export Images.

2. In the Export Cell window, select a file type (for example .BMP, .JPG, .png or .TIFF
format) from the Save as type drop-down list (output types may vary).

3. Browse into the C:\temp or your Desktop folder.
4. Enter a filename that contains your user id.
5. Click Save to save the graphics file.
6. When you have finished, change the background color back to blue.
Note:
A picture of the Graphic Viewer can also be output by selecting a database object
and then selecting File —> Outputs —> Attach File .

Activity: Collision Viewer and Fast Collision Sets
The objective of this activity is to learn how the Collision Viewer works.
Activate the collision viewer

Set up fast collision
Check that the collision lists are setup correctly
Look at the collision report
Activate the collision viewer
1. If the Collision Viewer is not shown minimized along the bottom edge of the
Process Simulate window: select View -> Viewers -> Collision viewer.
2. If it is not already there, position the Collision Viewer at the bottom of your screen
by dragging and dropping.
3. Expand the Collision Viewer and Pin it so it will stay expanded.
4. In the Collision Viewer, click Show / Hide Collision Sets to display the left pane
of this window.
Set up fast collision
1. On the Selection toolbar, select Selection Type Parts and Selection Type
Resources .
2. Then click Select all (notice the geometry in the Graphic Viewer that is
selected).
3. From the Collision Viewer toolbar, click Fast Collision .
4. Activate the collision checking by clicking Collision Mode On/Off on the
toolbar.
Note:
The fast_collision_set should be checked in the left pane of the Collision Viewer.
1. Use Fast Placement or the Placement Manipulator to move some of the

objects into a collision with other objects.

Note:
Normally we would use collision detection is statically or dynamically (i.e. in the

context of a simulation). In this case we are just moving the parts into collision to
test our collision setup and understand the mechanisms behind Process Simulate
collision detection.
2. Collisions will be highlighted in red as they occur.
Note:
When checking collisions during a simulation we can have the simulation stop at
the first collision or just beep and continue. In both cases the colliding objects are
highlighted in red.
Look at the collision report
1. If there are collisions to report, the Collision Viewer window will display the
collisions (red) and near misses (yellow) that occur.
2. Expand an object in the list. You can see the objects which this piece is colliding
with. For example (depending on your data, this picture may look different):
3. Deactivate the fast_collision_set: In the left panel of the Collision Viewer, uncheck
the box next to fast_collision_set.

Activity: Defining Collision Sets (List Pairs)
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.
Create a new pair of lists

Emphasis the objects in the collision set
Test Collision detection
Create a new pair of lists
1. Click New Collision Set in the Collision Viewer.

2. In the Collision Set Editor window, click in the Check area.
3. In the Graphic Viewer, select objects for the first list.
4. In the Collision Set Editor window, click in the With area.
5. In the Graphic Viewer, select objects for the second list that are not already
colliding with objects in the first list.
6. Click [OK].
7. Rename the collision set: In the left panel of the Collision Viewer, pick on the
new_collision_set and press the [F2] key.
8. Enter MyFirstList.
Emphasis the objects in the collision set
1. Select the MyFirstList collision set.

2. Click Emphasize Collision Set .
3. Look at the blue and yellow objects in the Graphic Viewer.
4. Click Emphasize Collision Set again.
Test Collision detection
1. Use the Placement Manipulator to temporarily move one of the objects from
one list into a collision with an object from the other list.
2. Reset the object placement after you have seen that your collision set is working.

Activity: Collision Setup and Collision Viewer
In this activity, you learn how the collision window works, including its new features.
Start checking for collisions

Setup the Collision options
Look at the collision report in the Collision Viewer
Start checking for collisions
In this example we will use a fast collision.
1. Create a fast collision set between two objects

2. In the left panel of the Collision Viewer, check the box next to fast_collision_set
and uncheck the box next to other collision lists, if there are any.
3. Collision detection should be turned on.
1. Right-click in the Graphic Viewer and select Options from the displayed shortcut
menu.
2. Select the Collision tab.
3. Check the Check for Collision Near-Miss checkbox.
4. For the Near-Miss Default Value enter 50
5. Check theStop Simulation when a Collision is Detected checkbox.

6. Check the Play Sound when a Collision is Detected checkbox.

7. Click [OK]
1. Use Fast Placement or the Placement Manipulator to move some of the

objects into a collision with other objects.
2. Collisions will be highlighted in red as they occur.
Look at the collision report in the Collision Viewer
1. If there are collisions to report, the Collision Viewer window will display the
collisions (red) and near misses (yellow) that occur. For example (your data may
look different than the picture below ):

2. Expand an object in the list. You can see the objects which this piece is colliding
with. For example (your data may look different than the picture below ):

Activity: Filtering Collision Results
In this activity, you learn more about collision detection and the new features.

Color Selected Pair
Filter — List All Pairs
Filters — List Colliding Pairs
Show Selected Pair Only
Highlight the area of collision for a specific line item
1. Click Collision Options from the Collision Viewer.

2. The Collision tab is already selected.
3. Uncheck the Stop Simulation when a Collision is Detected checkbox.
4. Uncheck the Play Sound when a Collision is Detected checkbox.
5. Click Browse and browse into the .\sysroot\sound effects folder.

6. Select the desired .WAV file.
7. Click Open.
8. Click [OK].
Color Selected Pair
1. Click a line item in the Collision Viewer.

2. Click the down arrow to the right of Show Colliding Pair .
3. From the drop down list and select Color Selected Pair .
4. Click Show Colliding Pair (It activates).
5. Click another line item in the Collision Viewer.
Note:

In the Graphic Viewer the colliding objects from he selected line item are shown in
blue and red. All other objects are shown white.

7. Look at the results in the Graphic Viewer.
Filter — List All Pairs
1. Click the down arrow to the right of Filter Collision Results .

2. From the drop down list and select List All Pairs .
3. Look at the results in the Collision Viewer.
Filters — List Colliding Pairs
1. Click the down arrow to the right of Filter Collision Results .

2. From the drop down list and select List Colliding Pairs .
3. Look at the results in the Collision Viewer.
Show Selected Pair Only
1. Click the down arrow to the right of Show Colliding Pair .

2. From the drop down list and select Show Selected Pair Only .
3. Click Show Colliding Pair (It deactivates).
4. Click Show Colliding Pair (It activates).
5. Click a line item in the Collision Viewer.
Note:
In the Graphic Viewer the colliding objects from he selected line item are shown in
red. All other objects are blanked.

7. Look at the results in the Graphic Viewer.
8. Click Show Colliding Pair (It deactivates).
Highlight the area of collision for a specific line item

2. Click Show/Hide Colliding Contour .
3. See the resulting curve displayed at the area of collision in the Graphic Viewer.
4. Click Show/Hide Contour View .
5. In the Collision Curves pane of Collision Viewer, select a curve.
6. In the Collision Curves pane of Collision Viewer, click Zoom to Selected .
7. Pick on another line item and see the results in the Graphic Viewer.
8. Click Freeze Viewer
9. Blank one of the colliding objects. Notice the collision contour left on the other
colliding object.

Optional Activity: Creating and Moving a Section Plane
The objective of this activity is to cut sections through the objects in a scene.
Display only the desired objects (parts/resources)

Create a section through these objects (parts/resources)
Manipulate the section
Perform a measurement on the section
Look at the section in the Object Tree and more
Display only the desired objects (parts/resources)
1. Pick the first desired objects (parts/resources).

3. Pick several other desired objects (parts/resources).
4. Right click one of the selected objects (parts/resources) and choose Display Only
.
Create a section through these objects (parts/resources)
1. Optionally, pick a point on the objects (parts/resources) for the origin of the
cutting plane.
Note:
If nothing is selected, it will be created at the Working Frame. It can always be

moved or repositioned later.
2. Select Tools —> Section —> New Section Plane .
Note:
The Section Manager window is open and the new section is shown in the Sections
folder of the Objects Tree and in the Graphic Viewer.
3. In the Section Manager window, click the down arrow to the right of the current
Section Alignment to select Align to X.
Note:
This will cut a section on the YZ-plane of the working frame at the selected point.
4. In the Section Manager window, click Activate Section to cut the section.
Note:
this causes the section to the be cut in the main Graphic Viewer.
Manipulate the section
1. In the Section Manager window, repeatedly click Move Negative or Move

Positive to move the section across the Z-axis of the section plane (that is,
perpendicular to the section). Note how the section moves as you move the slider.
Note:
If the Section Manager window is accidently closed, right click the section in either
the Sections folder of the Objects Tree and in the Graphic Viewer and select
Section Manager.
2. Change the step size by clicking the Step size link and changing the step size in the
displayed window and move it some more.
Section Alignment to select Align to Point and pick a point on the part.

Note:
This will maintain the same section orientation, but move it to the selected point.
Section Alignment to select Align to Surface and pick and point on the part.
Note:
This will move it to the selected point and orient the section tangent to the point.
5. Move the section using the new step size by clicking Rotate Positively .
Perform a measurement on the section
1. Change the Pick Intent to Where Picked.
2. Click Point to Point Distance on the toolbar.

3. Measure the point to point distance between two entities in the Section Viewer.
The cross-section line is drawn in the Graphic Viewer.
Note:
In another topic, we will learn how to create a 3D text using Create Note and
Create Dimension , which help highlight problem areas. This information could
be output as a picture for use in a report.
Look at the section in the Object Tree and more
1. Select View -> Viewers -> Object Tree.

2. Expand the Sections folder in the Object Tree.
3. In the Object Tree, the section can be blanked, displayed, deleted, and more by
right clicking on it.
Note:

If the Section Manager window is accidently closed, right click the section in either
the Sections folder of the Objects Tree or in the Graphic Viewer. Then select
Section Manager.
4. Add section contours tot the results in the Graphic Viewer: Select Tools —>
Sections —> Show Section Contours .
5. Add capping and look at the results in the Graphic Viewer: Select Tools —>
Sections —> Capping .
6. Add hatching and look at the results in the Graphic Viewer: Select Tools —>
Sections —> Hatching .
7. Close the Section Manager window.

Optional Activity: More on Cutting Sections
The objective of this activity is to cut some more sections.
Open a Section Viewer and Section Manager for an existing section

Switch the contents of the Section viewer from a clip to a cut
Save the section as a JT file and more
Different Ways to Cut a Section
Opening Additional Graphic Viewers
Managing Sections on the Objects Viewer
Open a Section Viewer and Section Manager for an existing section
1. In the Objects Tree viewer, right-click the section and select New Section Viewer
from the displayed popup menu.
2. A section clip will be displayed in a new Section window.
Note:
Now the section is shown in the Section window and the Graphic Viewer.
3. Right-click the section and select Section Manager from the displayed popup
menu, if it is not already open.
4. In the Section Manager window, click Deactivate Section .
Note:
Now the section is only shown in the Section window.
Switch the contents of the Section viewer from a clip to a cut
1. Select Tools —> Section —> Cut section .
Note:
The section cut is now two-dimensional.
2. Select Tools —> Section —> Orient View to Section Plane .

4. Hold down the [Alt] key and draw a box with the left mouse button to zoom in to
an area of interest in the Section window.
Save the section as a JT file and more
1. Draw a selection box with the left mouse button around the section entities.
2. Select Tools -> Sections -> Save Section Contour as Component .
3. For File name, enter C:\temp\SectionComp.cojt.
4. Click Save.
5. Right-click the section plane and select Blank from the displayed popup menu
to blank it.
6. Right-click the section plane and select Delete from the displayed popup menu
to remove it.
Different Ways to Cut a Section
1. Pick a point on an object and cut a section. The section is cut at that point.
2. Pick nothing then cut a section. The section is cut at the working frame. You can
then shift the object to where you want it.
3. Change the Pick Intent to Self Origin.
4. Change the Pick Level to Component
5. Pick an objects (parts or resources) to have the section plane originate at the
object origin.
Opening Additional Graphic Viewers
1. Create a cross section along the XY-Plane of the working frame.

2. Slide the section to just below all the objects and make the section mode is on cut
and not clip.
3. Open a new section viewer (Graphic Viewer ) for the section.
4. Set this new Graphic Viewer and the main Graphic Viewer side-by-side.
5. Change the View Point in one Graphic Viewer to Right and the other to Top.
Managing Sections on the Objects Viewer

1. From the Object Tree viewer, rename the section just created to View 2.
2. Close the section’s Graphic Viewer.
3. Use the Object Tree viewer to blank the section located in the Sections folder.
4. Whenever you want a second Graphic Viewer, just open a new section viewer for
this section.
5. If you no longer want a section, right click it and select Delete .

Optional Activity: Creating and Moving a Section Volume
The objective of this activity is to create a section volume.
Create and place a basic section volume

Scale and shape section volume
Create and place a basic section volume
1. Select Tools —> Sections —> New Section Volume .

2. Using the Section Manager window, position the box as desired
3. In the Section Manager window, click Activate Section .
4. Move the section volume as desired.
5. Select either Tools —> Sections —> Clip Inside or Tools —> Sections —> Clip
Outside .
Scale and shape section volume
1. Using the Section Manager window, check Scaling

2. In the Graphic Viewer with the mouse, drag the yellow manipulators protruding
from the section box to size of a side of the object.
3. Using the Section Manager window, uncheck Scaling
4. Using the Section Manager window, check Shape
5. Pick an edge of the volume box.
Note:
The edge is highlighted in blue.
6. In the Graphic Viewer with the mouse, drag the blue edge of the section box to
change it to other prismatic shapes.
7. Using the Section Manager window, uncheck Shape
8. Close the Section Manager window.

Activity: Outputting a Simulation to an .AVI File
The objective of this activity is to output simulation to an .AVI file.
Start recording an AVI

Stop recording the .AVI and Play the video
Start recording an AVI
1. In the Operation Tree, right click on the process and select Set Current Operation
.
2. Select File -> Outputs -> AVI Recorder .
3. In the Save Video File as window for Frame size, select Percentage of Window.
Warning:
Using the default 720x576 Frame size typically cuts off the left side of the resulting
video.
4. Browse to the Desktop folder.

5. For the File name, enter my_video.avi.
6. Click Save. The AVI toolbar is displayed.
7. In the Sequence Editor, click Play Simulation Forward on the toolbar and watch
the simulation in the Graphic Viewer.
Note:
We have not created a simulation yet, so just use Fast Placement or the
Placement Manipulator to move some of the objects
Stop recording the .AVI and Play the video
1. Click Stop Recording .

2. Look where the video was placed.
3. Click [OK].
4. Double-click the my_video.avi file on the desktop. The Windows Media Player
opens (or whatever your default AVI player is), and the .AVI file is played.

Optional Activity: Using Movie Manager
In this activity, you learn to use movie manager to create AVIs of simulations.
Open the Movie Manager

Prepare to create several AVIs at once
Play one of the created AVIs
Turn off presentation mode
Open the Movie Manager
1. Select File -> Outputs -> Movie Manager .
Prepare to create several AVIs at once
1. On the Movie Manager toolbar, click the down arrow to the right of Create
Movie for All Marked Operations .
2. Select Overwrite all movies.
3. Click Create Movie for All Marked Operations .

4. Click [OK].
Play one of the created AVIs
1. Select one from the list.
2. Click Open File.

3. The AVI is played with your default video player (typically Windows Media Player).
4. Close the video player.
5. Close the Movie Manager window.
Turn off presentation mode
1. Click Presentation Mode .

OTHER SELECTED BASIC TOPICS
Activity: Using some Project Management Commands
The objective of this activity is to use some project management commands
Note:
In some production environments, these commands are disabled for regular users, since
they maybe considered administrative commands.
Create a new project

Create some Collections
Importing data into a project
Exporting a project to a file
Create a new project
1. Open Process Simulate and log in, if it is not already opened.

2. Select File —> Close Project, if a project is open.
3. If asked ―You are about to close the project. Do you wish to continue‖, selectYes.
However, if asked ―Do you wish to update eMServer‖, selectNo.
4. Select File —> Project management —> New Project.
5. Enter Project U797 (user##) for the project name, where ## is the user number
assigned by your instructor.
6. Click [OK].
Create some Collections
1. In the Navigation Tree, right click Project U797 (user##) and select New .
2. In the New window, check Collection .
4. Click [OK].
5. Rename one collection Process and another Libraries .
Importing data into a project
1. Select the Libraries collection

2. Select File —> Project Management —> Import eBop from File.
3. Browse into the .\sysroot\Import Export files folder.
4. Select the RoboticsExampleResourceLibrary.xml file
5. Click [OK].
Exporting a project to a file
1. In the Navigation Tree, select the Project U797 (user##) project folder.
2. Select File —> Project management —> Export selected eBop to File.
3. Browse into the .\sysroot\Import Export files folder.
4. Enter MyProject user##.xml for the Name, where ## is the user number assigned
to you by your instructor
5. Click [OK].

Activity: Starting and Exiting Process Simulate Disconnected
In this activity, you learn about the disconnected method of starting Process Simulate.
Save a .PSZ file from Process Simulate (connected)

Start Process Simulate Disconnected
Make a change and save the .PSZ File
Save a .PSZ file from Process Simulate (connected)
1. Important: Write down the name of the project you are in for later reference.
2. Load in Standard Mode the previous study that contains all the objects.
3. Select File -> Save .
4. Browse to the desired location and enter the desired name: For example, browse to
C:\temp, create a new folder here named disconnected, and browse into it.
5. For Save as type, select Study Files (*.psz) and Library Components.
Note:
In this case we will not be referring to the same system root as the connected
Process Simulate. To only output the study (with references to a system root either
local or shared), change the Save as type to Study Files (*.psz).
6. For the File name, enter Verify.psz.

7. Click Save to save the Verify.PSZ file.
Note:
In order to start Process Simulate Disconnected, you must first open the desired
study using method 1 or method 2; then select File -> Save . This will create a
.PSZ file that can be later opened using Process Simulate Disconnected. You can
use the same system root or a local system root.
8. Click Save again to save the Verify-LibraryComponents.zip file.

9. Click [OK].
10. Exit from the connected Process Simulate by selecting File —> Exit and selecting
No.
11. Open a Windows Explorer window.
12. From the Windows Explorer window, browse into the C:\temp\disconnected folder
and right click the Verify-LibraryComponents.zip file and select Extract All.
13. For the Extracted to Folder, enter C:\temp\disconnected\disconnected_sysroot.
14. Click Extract.
Start Process Simulate Disconnected

1. If the Process Simulate Disconnected icon is present on your desktop,
double-click it to launch the application. If not, start the Process Simulate
Disconnected application from the Windows Start menu, as follows:
2. Select Start -> Programs ->Tecnomatix -> Engineering Applications -> Process
Simulate Disconnected.
3. Set the disconnected library root: Select Tools —> Options.

4. In the Options window, select the Disconnected tab.
5. Click the ... Browse button and select
C:\temp\disconnected\disconnected_sysroot.
6. Click [OK].
7. Select File -> Open in Standard Mode .
8. Browse and select the desired .PSZ file: Verify.PSZ located in the
C:\temp\disconnected folder.
9. Click Open.
Note:

In Disconnected mode, users can continue working and save their work locally.
When ready to update the eMServer with the changes made when working in
Disconnected mode, users load the file to Process Simulate and activate the
eMServer Selective Update command. These features of Process Simulate are
not supported in this mode:
o eMServer commands (including the following: Navigation Tree ,

Properties viewer, eMS Selective Update , Open Project, Close
Project, Check In , Check Out ).
o New Part or Resource Prototypes.
o Retrieve Detailed Representation.
o Copy and Paste of Local objects.
o Public Layout.
o Attach File.
o Mirror .
o Weld Distribution Center .
o Duplicate Weld Operation .

Make a change and save the .PSZ File
1. Rename one of the objects in the Resource folder of the Object Tree.
2. Select File -> Save .

Activity: Updating Process Simulate Disconnected from the eMS Database
In this activity, you learn how to selectively update a PSZ file.
Add Update PSZ File to the toolbar

Run Update PSZ File
Update Your Disconnected System Root
Look at the Results
Add Update PSZ File to the toolbar
1. Continue where the last activity left off: with a .PSZ file opened with Process
Simulate Disconnected.
2. In Process Simulate Disconnected, select File -> Exit.
3. Start and login to Process Simulate (connected).
4. Open the same project again.
5. Load the same study again (that you output the .PSZ file from earlier).
6. Select Tools —> Customize.
7. In the Customize window, browse the Commands list and locate Update PSZ File
command
8. Drag and drop it on the toolbar.
9. Click Save Customization.
10. Click Close.
Note:
You should also update the Standard windows configuration, as described earlier
in class.
Run Update PSZ File
1. Make a change in the study such as changing the name of a different object in the
Resources folder.
2. Click Update PSZ File.

3. Click Yes.
4. For Parts and resources to update, pick the specific parts and resources (that have
changed) that you would like to update in the PSZ file.
5. Click the first Browse button and select the original PSZ file.
6. Click the second Browse button and enter a new name (or take the default).
7. Check Save library components. Click the third browse button and select the
C:\temp\disconnected folder and enter a file name for the zip file such as
sysroot_update.zip.
8. Click [OK]

9. Click Yes.
10. Exit from Process Simulate (connected).
Update Your Disconnected System Root
Note:
This step assumes that your Disconnected System Root is different than your (connected)
System Root. For example, it is only on your laptop.
1. Open a Windows Explorer window.

2. From the Windows Explorer window, browse into the C:\temp\disconnected folder
and right click the update_sysroot.zip file and select Extract All.
3. For the Extracted to Folder, enter C:\temp\disconnected\disconnected_sysroot.
4. Click Extract.
5. Choose to over write all files and folders, as prompted.
Look at the Results
1. Start Process Simulate Disconnected by double clicking the desktop icon.
2. In the Process Simulate Disconnected, select Tools —> Options.

3. In the Options window, select the Disconnected tab.
4. Verify that the same disconnected system root folder is specified as your
Disconnected System Root.

Note:
This step assumes that your Disconnected System Root is different than your
(connected) System Root. For example, it is only on your laptop.
5. Click [OK].
7. Browse into the C:\temp\disconnected folder and select the new .PSZ file: for
example:verify_20110712_084803.psz.
Note:
Recall that in earlier in this activity, we specified a source and target PSZ file.
Select the target PSZ previously specified.
8. Click Open.
9. Look at the updated data.

Activity: Updating the eMS Database from Process Simulate Disconnected
In this activity, you learn how to update the eMS Database from Process Simulate
Disconnected
View the change in Process Simulate

Update the database
View the change in Process Simulate
1. Continue where the last Activity left off: with a study opened with Process Simulate
Disconnected.
2. In Process Simulate Disconnected, select File -> Exit.
3. Start and login to the Process Simulate (connected).
4. Open the same project again.
6. Browse and select the latest .PSZ file; such as verify_20110712_084803.psz.
Update the database

2. Check Operations.
3. Click [OK]
4. Click [OK].

MODELING AND KINEMATICS OVERVIEW
Activity: Starting Process Simulate and Setting the Working Folder
The objective of this activity is to set the software’s working folder (temporary scratch
area).
Login and open the Project_209S project

Login and open the Project_209S project
1. If you are not already logged into Process Simulate, double click on the Process
Simulate desktop icon.
2. Login (eMS login id) with no password.

student user1
student user2
student user3
student user4
student user5
student user6
etc... etc...
student user9
student user10
3.
4. Click [OK].
5. From the Open Project window, select the Project_209S project.
6. Click [OK].

1. Browse into the Working Folders folder.

2. Check out your working folder according to this chart: Right click it and select
Check Out .

administrator administrator
user1 user1
user2 user2
user3 user3
user4 user4
user5 user5
user6 user6
etc... etc...
user9 user9
user10 user10
3. Click [OK].

Activity: Opening Your Study
The objective of this activity is to open a Process Simulate session from the specified
studies.

Open a study node with Process Simulate
1. In the Navigation Tree, expand the Studies studyfolder.

eMS User ID Study

administrator Line 11 StudyFolder
user1 Line 1 StudyFolder
etc... etc...
3. Right click your Line ## StudyFolder and select Check Out .

4. In the Check Out window, select with Hierarchy and click [OK].
5. Expand your StudyFolder .
Open a study node with Process Simulate
1. In the Navigation Tree, expand your processing study folder.

2. Right click your station02 study.
3. From the short-cut menu, select Load in Standard Mode .
Note:

If nodes in your study are checked out by another user, they cannot be updated in
the eMS database (i.e. Process Designer) after you are done working in Process
Simulate.
4. Wait for Process Simulate to load your study.

5. Select Zoom To Fit from the standard toolbar. The product, welds, and
associated resources are shown in the graphics window.

MODELING BASICS
Activity: Modeling a Table
In this activity, you will learn the basic functions of modeling.
Create new study

Open it with Process Simulate
Start Modeling a New Object
Set the units and the Pick Level
Create the table geometry
Make the solids into a table
Save your work
Turn on the Modeling toolbar
Model the Table Again and Add More Geometry
Cancel the Modeling Session
Extra credit modeling
Create new study
1. If a project is currently opened, select File —> Close Project.
Note:
If a project is opened, then you will be able to select File —> Close Project.
However if no project is opened, then you will be able to select File —> Open
Project.
2. To the question ―You are about to close the project. Do you wish to continue?‖,
answer Yes.
4. In the Open Project window, select Project_209S from the Project List and click
[OK].
5. In the Navigation Tree, browse into the Working Folders collection, right click
your User## collection, and select Check Out.
6. Click [OK].
7. Select File —> Project Management —> Set as Working Folder and click [OK].
8. Right click the User## collection and select New .
9. In the New window, check the checkbox for Studyfolder , and click [OK].
Note:

We could have chosen to create our new study in an existing study folder anywhere
in the project.
10. Right click the Studyfolder just created and select New .
11. In the New window, check the checkbox for RobcadStudy , and click [OK].
12. Pick the Robcadstudy , press [F2], and enter temp for the new name.
Open it with Process Simulate
1. Right click on the temp study and select Load in Standard Mode .
2. No, don’t store changes to the previous study.
Start Modeling a New Object
1. Modeling —> Create Part Resource —> New Resource

2. In the New Resource window, select Work_Table .
3. Click [OK].
4. Pick the new object name and press the [F2] key.
5. Name it mytable_userX (if you are userX, otherwise append your user id to the
end of the name for training purposes).

Set the units and the Pick Level

3. For Linear, select mm.
4. Click [OK].
Note:
All data in Process simulate are stored in mm. This setting only changes the display
units. Display units can be changed at any time.
5. Set the Pick Level to Entity.
Create the table geometry
1. In the Object Tree, select the mytable_user## object (replace ## with your user
number; such as 1 for user1),.
2. Select Modeling -> Create 3D -> Box Creation -> Create a Box .
3. In the Create Box window, enter: 1000 for the Length.
4. Press the [Tab] key to go to the next field.
5. For Width, enter 1000.

6. Press the [Tab] key to go to the next field.
7. For Height, enter 1000.
8. Click Expand Dialog .

9. For Locate at, select Working Frame.
10. Click [OK].

13. In the Create Box window, enter: 2000x800x800.
Note:
You can press the [Tab] key to move between the fields such as Length and Width.

15. Click [OK].

19. Click [OK].
Make the solids into a table
1. Change the Pick Level to Entity.
2. Hold down the [Ctrl] key

3. Select the two rectangular boxes.
5. Select Modeling -> Edit -> Subtract .
6. For Subtract entities, pick the two long boxes.
7. In the Subtract window, pick in the From entity field.
8. Pick the 1000 mm cube.
9. In the Subtract window, check the Delete original entities checkbox.

10. Click [OK].
Save your work
1. From the Object Tree, select your mytable_user##.

2. Select Modeling -> End Modeling .

3. In the Save Component As window, browse into the desired folder under the system
root, such as .\sysroot\Libraries\modeling_kinematics\toolprototypes folder.
4. Click Save.
1. Return to Process Simulate.

2. Turn on the Modeling toolbar: Right click on the existing toolbar and select
Modeling.
3. Notice that many of the buttons we are selecting are available directly from this
toolbar.
Model the Table Again and Add More Geometry
1. From the Resources folder of the Object Tree, select the mytable_user## object.
2. Select Modeling -> Set Modeling Scope .
3. In the Set Modeling Scope window, click Yes, if prompted.


7. Click [OK].
Cancel the Modeling Session
1. From the Resources folder of the Object Tree, select the mytable_user## object.
2. Select Modeling -> Reload Component .
3. Throw away changes to the object
Note:
The modeling icon is removed from the object and it is returned to the way it looked
the last time we saved (aka clicked End Modeling ).
Extra credit modeling
1. Select the mytble_user## object.

3. Click Yes.
4. Model and place a donut or bagel onto your table: 1
5. Model and place a drinking glass for your table: 1(outside of cup) , 2 (inside of
cup) , 3 (orange juice in cup)
6. Make the glass translucent: Right click on the glass and select Object Viewing ->
Transparent .
7. Model a coffee mug: 1 (outside of cup) , 2 (handle) ,3 , 4 (inside of
cup) , 5 , 6 (coffee in cup)
8. Model two chairs for your table (model the bottom of the chair just like the table):
1, 2, 3, 4, 5 (then add back rest)
9. Put a sun umbrella over your table on a pole: 1 ,2
10. From the Object Tree, select your mytable_userX.
11. Select End Modeling from the Modeling toolbar

Optional Activity: Revolving 2D Entities to Make a Solid
The objective of this activity is to learn some of the 2D and editing commands.
Start modeling fun1_user##

Optionally, turn the floor on
Create a straight line along the X-axis of the Working Frame
Create a wavy curve
Trim the ends of the curve
Delete the two small curves extending beyond the line
Create a surface of revolution
End the modeling session for fun1_user##
1. In the Navigation Tree, browse into your User## working folder.

2. Right click your temp study, and select Load in Standard Mode , to reload it.
3. No, don’t store changes to the study.
5. In the New Resource window, select ToolPrototype .
6. Click [OK].
8. Name it fun1_user# (replace ## with your user number; such as 1 for user1),.
Optionally, turn the floor on
1. Optionally, select View -> Display Floor .
Note:
2D sketching is performed on the XY-plane of the Working Frame (unless you

sketch on the side of an existing object). When sketching on the XY-plane of the
Working Frame, it doesn’t matter if the floor is displayed.
Create a straight line along the X-axis of the Working Frame
1. Select Modeling -> Create 2D -> Create Polyline.

2. In the Create Polyline window for X of the first point, enter 0.

3. Press the [Tab] key.
4. For Y, enter 200.
6. For Z, enter 0.
8. Press the [Tab] key. You are now entering coordinates for the second point.
9. In the Create Polyline window for X of the second point, enter 1000.
11. For Y, enter 200.
13. For Z, enter 0.
16. Click [OK].
Create a wavy curve
Caution:
Create a wavy curve that only crosses the line at the curve’s ends. Also the line should not
cross the Working Frame’s X-axis
1. Turn off the display of the floor: If the floor is displayed, select View -> Display
Floor .
2. Set the Pick Intent to Where Picked.
3. Select Modeling -> Create 2D -> Create Curve .

4. Pick several points on the XY-plane of the Working Frame defining a curve, but
don’t cross the Working Frame’s X-axis (this is our revolution axis). The curve
should be on the opposite side of the line as the Working Frame. Also only cross
the line we created at the end points (not the middle). We are going to trim off the
part of our wavy line that is between the straight line and the X-axis in the next step.
See the picture at the end of this step.

5. Click [OK].
Trim the ends of the curve
Note:
Trim the ends of the curve so that it intersects the polyline, perfectly.
1. Select Modeling -> Create 2D -> Split Curve on Intersection .

2. In the Split Curve on Intersection window for Curve, select Curve1.
3. Pick in the Intersecting entity field.
4. Select Polyline1.
5. Click [OK].
Delete the two small curves extending beyond the line
1. From the Object Tree, Blank the whole object.

2. Slowly Display the entities to find the two that should be deleted.
3. Make sure that the Pick Level is set to Entity.
4. Delete the two undesired entities.

5. Display the whole object.
Create a surface of revolution
1. Select the wavy curve just created.

2. Select Modeling -> Edit -> Revolve .
3. For Start and End, pick the fun1_user## object (replace ## with your user number;
such as 1 for user1) in the Object Tree.
Note:
The Start and End points of the rotational axis are set to 0,0,0
4. Change the End value for X to 100.

5. For Rotation From enter: 0.
6. For Rotation To enter: 270.
7. Check Preview.
8. Click [OK].

1. From the Object Tree, select your fun1_user##.
Note:
End Modeling is only active when a modeled object is selected. Selecting an

entity of a modeled object will not make End Modeling active.

3. Save it into the .\sysroot\Libraries\modeling_kinematics\toolprototypes folder.

Optional Activity: Extruding 2D Entities to Make a Solid
The objective of this activity is to create a solid from 2D geometry.

Create three lines
Measure the length of the shortest side
Create the fillet
Merge the entities together
Extrude them into a solid

2. In the New Resource window, select ToolPrototype.
3. Click [OK].
5. Name it fun2_user## (replace ## with your user number; such as 1 for user1)..
Create three lines
Caution:
Create three lines that form a triangle where the corners do not touch.
1. Select Modeling -> Create 2D -> Create Polyline .

2. Pick two points.
3. Click [OK].
4. Follow this process to make the other two lines.
Measure the length of the shortest side

1. Select Tools -> Measurements -> PTP Distance .
2. Set the Pick Intent to Snap.
3. Pick one corner and then another.
Note:
If your lines cross each other, the system must decide which side of the intersection
to put the fillet on (many times it will be wrong). In this case, you should trim
(using the split command) one or both of the curves using the other one.
4. Close the Point to Point Distance window.
Create the fillet
Caution:
Create the fillet whose radius is about one tenth the distance you measured in the previous
step.
1. Select Modeling -> Create 2D -> Fillet .

2. Click two tangent sides of the polyline (i.e. polyline1 and polyline2).
3. In the Fillet window for the Radius, enter one tenth the distance you measured in
the previous step.
4. Check Delete original entities.
Note:
If [OK] and Preview are gray after enter the radius, pick another field or press
[Tab].
5. Click Preview.
6. Click [OK].

7. Put the same radius fillets at the next corner of the triangle.
Note:
If [OK] and Preview are gray after enter the radius, pick another field or press
[Tab].
Note:
You must have two different (non-parallel) lines to create a fillet between.
However, we only have one curve now. So, we will split the curve, as shown below,
in order to have a different curve on either side of the open end of the shape.
8. Create a polyline across two of the edges (one being a side of the last fillet to be
created).

9. Select Modeling -> Create 2D -> Split Curve on Intersection .
10. For Curve, select the triangle shape.
11. For Intersecting entity, select the polyline just created.
13. Click [OK].
14. Select Modeling -> Create 2D -> Fillet .
15. Click two tangent sides of the polyline (i.e. polyline1 and polyline2).
16. In the Fillet window for the Radius, enter one tenth the distance you measured in
the previous step.
17. Check Delete original entities .
18. Click Preview.
19. Click [OK].
20. Delete the temporary polyline by right clicking it and selecting Delete .
Merge the entities together
1. Draw a selection box around the entities.

2. Select Modeling -> Create 2D -> Merge Curves .
4. Click [OK].

Extrude them into a solid
1. Select the curve.

2. Select Modeling -> Edit -> Extrude .
3. In the Extrude window, enter 200 for the Positive value.
4. A preview of the solid is shown.
5. Stretch it a little bigger picking and dragging the manipulators on the top or bottom
of the preview solid in the Graphic Viewer.
6. Click [OK].

1. From the Object Tree, select your fun2_user##.
Note:



Optional Activity: Sweeping 2D Entities to Make a Solid
The objective of this activity is to create a solid from 2D geometry.
Start modeling the gun shank object

Create an arc
Sweep
Create a cylinder
Create the second cylinder
Finish the gun tip
Duplicate the cap geometry
Place it at the end of the other cap
Finish this gun shank
Finish the other gun shank
End the modeling session
Start modeling the gun shank object

2. In the New Resource window, select Gun.
3. Click [OK].
5. Name it shank1_user## (replace ## with your user number; such as 1 for user1).
Create an arc
1. Select Modeling -> Create 2D -> Create Arc .

2. In the Create Arc window for the Center Point, enter 0 (for X).
3. Press [Tab].
4. Enter 0 (for Y).
5. Press [Tab].
6. Enter 0 (for Z).
7. Press [Tab].
8. Follow the same process to enter 30,0,0 forStart Point
9. Follow the same process to enter 0,30,0 forEnd Point

10. Click [OK].
Sweep
1. Select the arc just created.

2. Select Modeling -> Create3D -> Sweep -> Sweep by Circle .
3. In the Sweep by Circle window, enter 17 for the Start Diameter.
4. Enter 20 for the End Diameter.
5. Click Preview.
6. Click [OK].
Create a cylinder
Tip:
Create a cylinder at the small end of the swept solid
1. Select Modeling -> Create 3D -> Cylinder Creation -> Create a Cylinder .
2. In the Create Cylinder window for Radius, enter: 6.
3. For Height enter: 5.
4. Click Expand .
5. Uncheck Maintain Orientation.
6. For the selection type for the Locate at field, select Frame by Circle Center .
7. Pick three points around the edge of the small end of the sweep.
8. In the Frame by 3 Point Circle Center window, click Flip Frame to get the Z-
axis pointing out of the solid.
9. In the Frame by 3 Point Circle Center window, click [OK].
10. Click [OK].
Create the second cylinder
Tip:
Create the second cylinder on the end of the first cylinder.
2. In the Create Cylinder window for Radius, enter: 7.5.
4. Click Expand, if it is not already expanded.
5. Uncheck Maintain Orientation, if it is not already unchecked.
6. For theLocate at field, pick the middle of the end of the last created cylinder.
7. Click [OK].

Finish the gun tip
1. Select Modeling -> Create 3D -> Cone .

2. In the Create Cone window for Lower Radius, enter 7.5.
3. For Upper Radius, enter 3.
5. Click Expand .
7. For the Locate at field, pick the middle of the end of the last created cylinder.
8. Click [OK].

Duplicate the cap geometry
1. Pick the last created solid.

3. Pick the last two created cylinders (in other words, picking everything except the
swept solid).
4. Select Modeling -> Duplicate Objects .
5. In the Duplicate window for Number along X, enter 2.
6. For X Spacing enter 30.
7. Check the Preview checkbox.
8. Click [OK]
Place it at the end of the other cap
1. Draw a selection window around the duplicate cap geometry to select it.
2. Right click the selected geometry and select Relocate .
3. In the Relocate window for the From Frame, pick the center of the end of the
duplicate cap.
4. Pick in the To frame field.
5. For the To frame, pick the center of the end of the original cap.
6. Click one of the Frame by 6 values buttons.
7. In the Location window, click Flip Frame .
8. Click [OK].

Note:
Maintain orientation and Translate only on should be unchecked.
9. Click Apply and Close.
Finish this gun shank

1. Select Modeling -> Create 3D -> Cone Creation —> Create a Cone .
2. In the Create Cone window for Lower Radius, enter 8.5.
3. For Upper Radius, enter 11.
5. Click Expand , if it is not already expanded.

7. For the Locate at field, pick the middle of the end of the last created cylinder.
8. Click [OK].

14. For the Locate at field, pick the middle of the end of the last created cone.

15. Click [OK].
Finish the other gun shank
1. Select Modeling -> Create 3D -> Cone Creation —> Crate a Cone .
2. In the Create Cone window for Lower Radius, enter 10.
3. For Upper Radius, enter 12.5.
5. Click Expand , if it is not already expanded..

7. For the selection type for the Locate at field, select Frame by Circle Center .
8. Pick three points around the edge of the large end of the sweep.
9. Click Flip Frame to get the Z-axis pointing out of the solid.
10. Click [OK].

11. Click [OK].
13. In the Create Cylinder window for Radius, enter: 12.5.

17. For the Locate at field, pick the middle of the end of the last created cone.

18. Click [OK].
1. From the Object Tree, select your shank1_userX.
Note:



Optional Activity: Modeling a Simple Robot for Kinematics
The objective of this activity is to create a simple robot for kinematics and learn modeling
commands
Tip:
A drawing of the final robot exists at the end of the activity. Use it to check your work
performed in the activity. Or if you are confident in your Process Simulate modeling skills,
model the robot only using the drawing. Most students should instead follow the activity
closely.
Caution:
All the solids for a robot in Process Simulate should be placed in one object.
Start modeling the my robot object

Perform Basic Setup
Create BASE Link
Save (End modeling) the my robot
Create LINK1
Create LINK2
Create LINK3:
Create LINK4
Create LINK5
Create LINK6
Save and End Modeling Changes
Move the new resource to your library
Drawing for the Robot Modeling Activity
Start modeling the my robot object

2. In the New Resource window, select Robot.
3. Click [OK].
5. Name it myrobot_user## (replace ## with your user number; such as 1 for user1),.
Perform Basic Setup


3. For Linear, select mm.
4. Click [OK].
Note:
All data in Process simulate are started in mm. This setting only changes the display
units. Display units can be changed at any time.
Create BASE Link
Note:
Create the geometry for what will become the BASE kinematic link:

3. Click [OK].
7. Click Expand .
8. Pick the Locate at field.
9. Pick the top of the box.
10. Check Maintain Orientation.
11. Click [OK].
13. For Locate at, pick the top of the previously created cylinder.
14. For Radius enter: 110.
16. Click [OK].
Save (End modeling) the my robot
Note:
If you are a paranoid person (it is good to be paranoid with computers), save your work
now.
1. From the Object Tree, select your myrobot_userX.

3. In the Save Component As window, browse into the
.\sysroot\Libraries\modeling_kinematics\robots folder.
4. Click Save.

1. Right click on the existing toolbar and select Modeling.

2. Notice that many of the buttons we are selecting are available directly from the
toolbar.
Create LINK1
Note:
Create the geometry for what will become the LINK1 kinematic link:

2. Click Yes.
3. Save whenever you feel you have to.

4. From the Modeling toolbar, select Create a Box .
5. Locate it on top of the previously created cylinder.
6. Enter: 260x260x360.
7. Click [OK].
8. Create one bracket:

10. For Locate at, pick (snap) to the middle of the top positive Y edge of the last
created box.
11. Enter: 160x30x150.
12. Click [OK].
13. Right click on the newly created box and select Placement Manipulator .
14. Set the translate Step Size to 15.
15. Click Y.
16. Click Move in the negative direction once.
17. Click [OK].
18. Create second bracket:
20. In the Duplicate window for Number along Y, enter 2.

22. Enter -230 for the Y Spacing.
23. Press the [Tab] key again.

24. Notice the preview in the Graphic Viewer.
25. Click [OK].
Create LINK2
Tip:
Move the working frame to center of the broad face of one of the ears of Link1:

1. Select Modeling -> Set Working Frame .
2. Pick the center of the broad face of one of the ―ears‖ of what will become kinematic
Link1.
3. Click [OK].
4. From the Modeling toolbar, select Create a Cylinder .

5. For Locate at, select Working Frame from the drop down menu.

8. Click [OK].

11. Enter: 130x540x200.
12. Click [OK].
13. Use the Placement Manipulator to move the newly created box 270 in the Y.

14. Select Modeling -> Edit -> Unite .
15. Pick the box and cylinder just created.
16. In the Unite window, check the Delete original entities checkbox.
17. Click [OK].
18. Create pivot cylinder:
19. Right click on the newly united box and cylinder that is part of LINK2 and select
Blank .
21. In the Create Cylinder window for Locate at, select Working Frame from the drop
down menu.
24. Right click the newly created cylinder and select Relocate .

25. For the From Frame pick (snap) near the middle of the height of the newly created
cylinder.
Note:
Anywhere on the exterior of the cylinder is acceptable, as long as it is a snap point

half way between the top and bottom of the cylinder.
26. For the To frame, pick near the middle of the edge of the LINK1 box’s Y edge.
27. Check the Maintain orientation checkbox.
28. Check the Translate only on checkbox.
29. Click Z.
30. Click [OK].
31. From the Object Tree, check the display status square for the blanked box and
cylinder solid that is part of LINK2.
Tip:
This is the Z-axis of the Working Frame, which is currently sitting at a different
orientation than the default.
32. Create a cutter to cut a slot from the top of the last box:
Tip:
Move the Working frame to center of the top of the box and rotate 180 about X.
33. Select Modeling -> Set Working Frame .

34. Pick the top middle of the last created box of what will become kinematic Link2.
35. Click [OK].
38. Enter: 300x140x210
40. Click Frame by 6 Values to the right of the Locate at field.
41. In the Location window, click Flip Frame.
42. Click [OK].

43. Click [OK].
45. For Subtract entities, pick the newly created (box4) box.
46. In the Subtract window, pick in the From entity field.
47. Pick Link2 (named bool1) just created.
48. In the Subtract window, check the Delete original entities checkbox.
49. Click [OK].
Create LINK3:
Tip:
Create LINK3 through LINK5 vertically, then position:

5. For Reference on object, select Geometric center from the drop down list.
6. For Locate at, select Working Frame from the drop down list.
8. In the Location window for Rx, enter 90.
9. Click [OK].
11. For Radius enter: 67.5.
13. For Locate at, select Working Frame from the drop down list.
15. In the Location window for Ry, enter 90.
16. In the Location window for X, enter -320.
Note:
This will place the small cylinder 320 mm from end of pipe.
17. Click [OK].

18. Click [OK].
19. Select the last two created cylinders.
20. Right click the highlighted objects and select Relocate .
21. For the From Frame pick (snap) near the middle of the end of the small newly
created cylinder.
22. For the To frame, pick near the middle of the inside edge of the forks of the Link3.

23. Check the Maintain orientation checkbox.
24. Check the Translate only on checkbox.
25. Click Z.
26. Click [OK].
Create LINK4
Note:
Creae LINK4:
2. For Radius enter: 64
5. For Locate at, pick the middle of the end of the long side of the big Link3 cylinder.
6. Click [OK].
Note:
The next chunk of the robot could be made in at least two different ways (option 6a
or option 6b). The activity will use option 6b, however here is the information for
option 6a: From the Modeling toolbar, select Create a Box . Uncheck Maintain
Orientation. For Locate at, pick the middle of the end of the last created cylinder.
Enter: 130x130x195.
7. OPTION 6b: Or the End can be made as a cube and a cylinder :

10. For Locate at, pick the middle of the end of the last created cylinder.
11. Enter: 130x130x130.

13. For Reference on object, select Geometric center from the drop down.
15. For Locate at, pick the middle of the end of the last created box.
19. In the Location window for Rx, enter 90.
20. Click [OK].
21. Select Modeling -> Edit -> Unite .
22. Select the last created box and cylinder.
23. Click [OK].
24. Create a cutter:

25. Right click on the last created Boolean solid and select Display Only .
27. Enter: 200x40x200.
28. For the Locate at field, pick the square back face of the Boolean solid.
30. In the Location window, click Flip Frame .
31. In the Location window for Ry, enter 90.
32. In the Location window add 60 to the X value, (i.e. 510+60= 570).
33. Make sure the Y value is 0.

34. Click [OK].
35. Click [OK].
37. For the Subtract entities , pick the last created box.
38. For the From entity, pick the last created Boolean solid.
39. Click [OK].
Create LINK5
Note:
Create LINK5:

2. For Locate at, pick the center of the inside of the radius of the last created Boolean.


5. Click [OK].
6. Right click the last created solid and select Blank .
8. Enter: 40x40x135.
9. For Locate at, pick the center of the inside of the radius of the last created Boolean.
11. In the Location window add 65 to the X value, (i.e. 640+65= 705).
12. Click [OK].
13. Click [OK].
14. Right click on nothing in the Graphic Viewer and select Display All .
Create LINK6
Note:
Create LINK6. DON'T FORGET ABOUT THIS ONE:

2. For Radius enter: 25
3. For Height enter: 15
4. For Locate at, pick the center of the end of the last created box.
5. Click [OK].

Save and End Modeling Changes
1. From the Object Tree, select your myrobot_userX.

3. Click Yes.
Move the new resource to your library

Note:
Move the new resource prototype to your eMS resource library
1. In the Navigation Tree, browse into your working folder.

2. Browse into the Importing From Engineering folder.
3. Right click the ResourceLibrary* and select Navigation Tree .
4. Expand the resource library.
5. In the first Navigation Tree browse into the Libraries folder.
6. Double click on Resource Library.
7. Expand and locate the Robots library.
8. Check out the Robots library.
9. Drag and drop the myrobot_userX into the Robots resource library.
10. Click the Back button.
11. Close the second Navigation Tree that was opened.
Drawing for the Robot Modeling Activity
Robot Base

Robot Link1

Robot Link2

Note:
In the training class we will make the width 200 instead of 190.
Robot Link3

Robot Link4

Note:
In the training class we will make the large cylinder 30, instead of 830.
Robot Link5

Note:
In the training, we will make the extension 40x40x135
Robot Link6
Note:

Diameter 50
15 Thick

KINEMATICS BASICS
Activity: Simple Kinematics (Part 1)
The objective of this activity is to define simple kinematics.
Begin Modeling the two blocks object

Open the two_blocks object for modeling
Open the Kinematics Editor for two_blocks_user##
Define each box as its own link
Create the Joint
Jog the kinematics
Begin Modeling the two blocks object
Note:
In the Project_209S project, the instructor should load the Scenario (study) two blocks
from the model kinematics studyfolder.
1. If you are not already in Project_209S:

o Select File —> Close Project and select Yes.
o Select File —> Open Project.
o Select Project_209S and click [OK]
2. In the Navigation Tree of Project_209S , browse to the Studies studyfolder.
3. Browse to the Line## study folder , where ## is the user number assigned to you
by the instructor.
4. If not already checked out, right click the model kinematics studyfolder and
select Check Out .
5. Check Check Out with Hierarchy, and click [OK].
6. Right click the two blocks study and select Load in Standard Mode .
7. From the Process Simulate Object Tree, right click the two blocks object in the
Resources folder, and select Display Only .
Open the two_blocks object for modeling
1. From the Resources folder of the Object Tree, select the two_blocks_user##
(replace ## with your user number assigned to you by your instructor) object in the
two_blocks compound resource.
3. Select [OK], to the message about unsupported geometry.
Note:
An M is now shown on top of the icon for the modeled object.
4. Select Yes, if prompted.
Open the Kinematics Editor for two_blocks_user##
1. Select the two_blocks_user## (replace ## with your user number; assigned to you
by your instructor) object.
2. Select Kinematics -> Kinematics Editor .
Define each box as its own link
1. In the Kinematics Editor window, select Create Link .

2. In the Graphic Viewer, pick the bottom box.
3. In the Link Properties window, click [OK].
5. n the Graphic Viewer, pick the top box.
6. In the Link Properties window, click [OK].

Create the Joint
1. In the Kinematics Editor window, pick the LNK1 link (i.e. the bottom box for the
parent link).
2. Hold down the [Ctrl] key and pick the LNK2 link (i.e. top box for the child link
Note:
A joint can also be created by dragging a line from the parent link to the child link.
4. In the Kinematics Editor, select Create Joint .
Note:
We will use the default axis definition from (0,0,0 to 0,0,100) and Joint type of
Revolute
5. Joint Properties window, click [OK].
Note:
Next we will test our kinematics using the Joint Jog window. The Joint Jog
button can be accessed in several places: from the toolbar of the Kinematics Editor,
by right clicking a kinematic object, from the Kinematics toolbar, or from the
Kinematics menu.
6. Close the Kinematics Editor window.
Jog the kinematics
1. Verify the Pick Level is Component.
2. Select the two_blocks_user## (replace ## with the user number; assigned to you by
your instructor) object.

4. Adjust the sensitivity of the joint steering: From the Joint Jog window, click
Options and move the Slider sensitivity slider toward low.
5. Click [OK].
6. In the Joint Jog window, select the Steering gear icon for joint J1 and drag it left
and right.
Note:
You can drag the slider beyond the Joint Jog window, which is OK.
7. Click Reset.

8. Click Close.

The objective of this activity is to use simple kinematics.
Open the Kinematics Editor for two_blocks_user## again

Edit the joint
Jog the kinematics
Open the Kinematics Editor for two_blocks_user## again
Edit the joint
1. In the Kinematics Editor window, double click on the J1 arrow.
2. In the Joint Properties window, click Expand Dialog .

3. For Limits type, select Constant.
4. For the High Limit, enter 360.
5. For the Low Limit, enter 0 (the default).
6. Leave the Speed and Acceleration values as they are.
7. Click [OK].

Jog the kinematics
1. Verify the Pick Level is Component.
4. In the Joint Jog window, select the Steering gear icon for joint J1 and drag it left
and right.
5. Click Reset.
6. Click Close.

The objective of this activity is to use simple kinematics.
Add a pose to the device

Move to your new pose
Save changes to the 3D data
Add a pose to the device
1. Select the two_blocks_user## (replace ## with your user number; such as 1 for
user1) object.
2. Select Kinematics -> Pose Editor .
3. In the Pose Editor window, click New.
4. In the New Pose window, move theSteering gear for j1 to the right.
5. In the New Pose window for Pose name, enter Turn.
6. Click [OK].
Move to your new pose
1. Method 1 to jump to a pose: In the Pose Editor window, pick HOME.

2. Click Jump.
Note:
You can also double click the pose to jump to it.

3. In the Pose Editor window, pick the Turn pose.
4. Click Jump.
5. In the Pose Editor window, click Reset and Close .
6. Select the two_blocks_user## (replace ## with your user number; such as 1 for
user1) object.
7. Method 2 to jump to a pose: Select Kinematics -> Joint Jog .
8. Select the Turn pose from the drop down that currently says HOME.
9. Click Reset and Close.

Save changes to the 3D data

2. (When loading the next Scenario (study) we can choose to not save changes to the
scenario, since none have been made)

Activity: Add Joints to a Simple object
The objective of this activity is to add joints to the door.
Open the door with Process Simulate

Envision the kinematic tree then define the required links
Define the first joint in Process Simulate
Define the second joint of the simple object
Use Joint Jog, Pose Editor, and End Modeling
Open the door with Process Simulate
1. In the Navigation Tree, browse into your User## working folder.

2. Browse into your studyfolder .
3. Right click your temp study and select Load in Standard Mode .
4. No, don’t save changes to the study.
5. Switch from the Navigation Tree to the Object Tree.
6. Select Modeling -> Insert Component from File .
7. In the Insert Component window, browse into the
.\sysroot\Libraries\model_kinematics\toolprototypes folder.
8. Select your room_door_geo_user## (i.e. for user1 select
room_door_geo_user1.cojt)
Note:
The completed example is called room_door_demo.cojt. The instructor will open

the object called room_door_geo_user11.cojt and add the joints to it. All .COJTs
are located in .\sysroot\Libraries\model_kinematics\toolprototypes folder.
9. Click Open.
Envision the kinematic tree then define the required links
Note:
There are only two joints in this case: One for the door at the hinges and another for the
handle.
1. In your mind, envision the first joint (j1): The doorframe is fixed and does not
move when the door opens. So, the doorframe link will be the parent to the door
joint. The axis of this joint goes through the hinges.

2. In your mind, envision the second joint (j2): The axis of the next joint goes through
the center of the door handle. Relative to the door handle joint, the door is the
parent link and the handle is the child link.
Note:
The links and axis have already been created for you. All you have to do is define
the joints for the mechanism.
Kinematic Tree
3. In the Object Tree or Graphic Viewer, select the room_door_geo object.
Note:
The room_door_geo_user## resource prototype has a default instance name of

room_door_geo.
4. Select Modeling —> Set Modeling Scope and click [OK].

5. Select Kinematics —> Kinematics Editor .
6. Use what you have learned to create a link for the doorframe.
7. Use what you have learned to create a link for the door.
8. Use what you have learned to create a link for the handle.
Define the first joint in Process Simulate
Note:
Use what you have learned, along with these hints, to define the kinematics.

1. In the Kinematics Editor, drag a line from the doorframe to the door.
2. For the Parent Link select door frame
3. For the Child link select the door
4. Click From
5. For the Axis From select the line though the hinges twice
6. Click [OK] to the error message.
7. Change the Z value for the To point of the axis.
8. For Joint Type click Revolute.

10. Add limits and speeds to the joint.
11. Click [OK].
Define the second joint of the simple object
1. In the Kinematics Editor, drag a line from the door to the handle.
2. For Parent Link select the door
3. For Child Link select door handle
4. Click From
5. For the Axis From select the line though the handle twice
7. Change the X value for the To point of the axis.
8. For Joint Type click Revolute.

10. Add limits and speeds to the joint.
Note:
Add the High limit before the Low limit. A negative number is lower than a
positive number. Speed and Acceleration are in current units (set on the Tools —>
Options window).
11. Click [OK].

Use Joint Jog, Pose Editor, and End Modeling
1. Right click the door object and select Joint Jog .

2. Jog the joints of the door object using the Joint Jog window.
3. Close the Joint Jog window.
4. Right click the door object and selectPose Editor .
5. Use the Pose Editor to define an open and closed pose for the door.
6. Jump it between these poses.

7. Return to the HOME pose.
8. Close the Pose Editor window.
9. Select the door object.
10. Select Modeling —> End Modeling.

Activity: Leading Joints and Follow Factors (Gun)
The objective of this activity is to create the kinematics and use leading joint concept for a
balanced gun.
Load the study (gun_lf)

Create 3 links
Create 2 joints
Jog the kinematics
Save change to the 3D data
Set the lower arm to depend on the upper arm
Enter the correct follow factor
Check the joint motion
Change follow factor to negative number
Change the HOME pose
Load the study (gun_lf)
1. From the Navigation Tree, expand into the Studies folder.

2. Expand into your Line## studyfolder (i.e. user1 uses Line1, user2 uses Line2,
etc…).
3. Check out your assigned studyfolder with hierarchy.
4. Expand into the model kinematics studyfolder.
5. Right click gun lf and select Load in Standard Mode .
6. Select the gun_lf_user## (where ## is your user number) object.

Create 3 links

3. Change Pick Level to Entity.

5. Pick the orange, body geometry.
6. In the Link Properties window, enter the name body.
7. Click [OK].
9. Pick the green, upper arm geometry.
10. In the Link Properties window, enter the name upr_arm.
11. Click [OK].
13. Pick the pink, lower arm geometry.
14. In the Link Properties window, enter the name lwr_arm.
15. Click [OK].
Create 2 joints
1. In the Kinematics Editor window, pick the first link (i.e. the body for the parent
link).
2. Hold down the [Ctrl] key and pick the second link (i.e. upr arm for the child link
3. Select Create Joint .

4. Change Pick Intent to Where Picked.
5. In the Joint Properties window, click From for the Axis.
6. Create an axis for the joint to be created by picking two places on the line.
Note:
Another method is to blank the body and pick the center of the top and bottom of
the cylinder where the two arms rotate.

7. Joint type of Revolute joint should already be selected.
8. Click [OK]. Joint j1 has been defined.
9. Follow the same process to define a joint (j2) from the body (parent link) to the lwr
arm (child link).
11. Change Pick Intent back to Snap.
Jog the kinematics
1. Select the gun_lf object.

3. Select the joint J1 slider and drag it left and right.
4. Jog joint J2 in the same way.
5. Click Reset.

Note:
When loading the next study we can choose to not save changes to the scenario,
since none have been made
Set the lower arm to depend on the upper arm
Note:
Set joint J2 to follow (i.e. lower arm to depend on the upper arm) joint J1.
1. Select gun_lf_user##
3. Select Yes.
5. In the Kinematics Editor window, pick (once) on the follow joint (i.e. j2).
6. Click Joint Kinematics Functions .
7. For Joint Dependency, click Joint Function.
Note:
The default value is Independent.
8. Click the down arrow to the right of Joint Name and select j1.
9. Click j1.
Note:
Details of the joint j2 function are displayed in the Joint Function area.
Enter the correct follow factor
Note:
Enter the correct follow factor. This factor is a ratio of one joint’s motion to another. To
define the follow factor for each of the joints so that they will be fully open when the
leading joint is fully open:
Note:
The follow factor might be −2.13, depending on how you define the kinematics.
Remember, the follow factor is a ratio of one joint’s motion to another.
Note:
Follow factor = Follow joint range / Leading joint range
1. Click Multiplication.
2. Type (-2.13) in the Joint Function window.
Check the joint motion
1. Change Pick Level back to Component.
2. Select the gun_lf_user## object.

4. Select the joint J1 slider and drag it left and right.

1. Select the gun_lf_user## object.

2. Select Modeling -> End Modeling. .
3. (When loading the next study we can choose to not save changes to the scenario,
since none have been made)
Change follow factor to negative number
1. Select gun_lf_user##
3. Select Yes.
4. Change follow factor to negative number (or to a positive number), so that the joints
(lower and upper arm) move away from each other when jogged.
5. Check the motion of joints and note difference.
Change the HOME pose
Note:
Use Joint Jog and Pose Editor windows to change the HOME pose so that gun tips are
closed when this pose is applied.
Note:
Normally the HOME pose is where all joints are equal to zero. However, this is not a
requirement. There may be a situation when you need the HOME pose to have a different
value.
1. In the Joint Jog window, jog the joint until the tips are closed.
2. Right click and select Copy for the joint value shown in this window.
3. In the Pose Editor window, select the HOME pose and click Edit.
4. Right click in the Joint value field and select Paste .
5. Click [OK].

Instructor Demo: Kinematic Looping (Optional Activity)
The objective of this activity is to add kinematics to the piston.
Begin Modeling the dump demo

Steps for the dump demo
Begin Modeling the dump demo
1. The instructor should Load in Standard Mode the dump demo study from
the model kinematics study folder (under the Line 11 studyfolder).
Steps for the dump demo
1. Show the kinematic tree of dump2_demo, and joint jog it.

2. Joint jog Pivot_J4 and show how the piston moves.

Activity: Kinematic Looping
The objective of this activity is to add kinematics to the piston.
Start Modeling the dump2 object

Use the crank wizard to define the kinematics
Use the Joint Jog window
Start Modeling the dump2 object

etc…).
5. Right click dump and select Load in Standard Mode .
6. Right click the dump2 object and select Display Only .

8. Select Yes.

2. In the Kinematics Editor, click Create Crank .
3. For Select Crank type, select Slider (RPRR).
4. Click Next.
5. On the Slider Crank Joints window, click the first point (above the Coupler Link).
6. Pick the equivalent frame in the Graphic Viewer.
7. Repeat this process for the other two axis points.

8. A triangle is drawn in the Graphic Viewer between the points.

9. Click Next.
10. On the Slider Crank Links window, click the first link.
12. Pick the equivalent entities for this link in the Graphic Viewer.
13. Repeat this process for the other three links.
14. Click Finish. The kinematic tree is defined.

Use the Joint Jog window

2. Use the Joint Jog window to jog the joints.
3. Reset the mechanism with finished.
1. Select the object.

since none have been made)

Activity: Gun Kinematic Definition (Part 1)
The objective of this activity is to define a gun with a piston (a loop).
Start modeling the gun_geo object

Kinematic Definition
Create a joint between the base and the lwr links
Test with Joint jog
Start modeling the gun_geo object

etc…).
5. Right click gun geo and select Load in Standard Mode .
6. Right click the gun_geo_user## object in the Graphic Viewer or Object Tree and
select Display Only .
8. Select Yes.

Kinematic Definition

2. The following links have already been created for you:
o lwr_arm
o upr_arm
o rod
o cyl
o bracket
Note:
This activity provides ONE way to define the kinematics of this gun. There are several
ways that it could be done. Please make sure that you are able to perform the steps as
written before trying other ways of doing the kinematics.

3. Click Next.
4. On the Slider Crank Joints window, click the first point (above the Couple Link).
5. In the Object Tree, pick the fr1 frame within your gun_geo object.
Note:
This is the frame between the blue and yellow links.
Note:
All three frames should be created in advance and should exist on one plane down
the middle of the gun. We have suggested in the activity to pick the frames in the
Object Tree in order to guarantee that the correct point is selected. If the wrong
point is selected (and the mistake is not found until you are done defining the
crank), all crank kinematics must be deleted and recreated.
6. On the Slider Crank Joints window, click the second point (to the right of the Fixed
Link).
Note:
8. On the Slider Crank Joints window, click the second point (to the left of the Fixed
Link).
Note:
Note:

A triangle is drawn in the Graphic Viewer between the three points.
10. Click Next.

11. Click Next, again to create the crank Without offset.
12. On the Slider Crank Joints window, click the first link (Fixed Link).
13. On the Slider Crank Joints window, click Existing Link.

14. Pick the equivalent link in drop down (lwr).
15. Repeat this process for the Input Link, Couple Link, and Output Link.
Link Name Correlation to Crank Linkage Diagram

base (green) (not shown, we’ll add it later)
upr (yellow) Output Link
rod (magenta) Input Link
cyl (blue) Coupler Link
lwr (orange) Fixed Link
16. Click Finish. The crank kinematic tree is defined.
Create a joint between the base and the lwr links
1. In the Kinematic Editor window, create a joint by dragging a line from the base to
the lwr link.
2. In the Joint Properties window, pick From and pick fr3 from the Object Tree.
3. In the Joint Properties window, pick To and pick fr3 from the Object Tree.
5. For the Y value for To, enter 100.
6. Click [OK].
Test with Joint jog

1. Right click your gun_geo and select Joint Jog .
Note:
There are only two joints to jog.
2. Jog the two joints of the object.
Note:
J1 rotates the lower arm. The other joint moves the upper gun arm with the
solenoid. See the first part of this topic to see why there are only two jog−able joints
for a mechanism with five joints defined. Remember, there are no joint limits set.
Note:
When you jog the gun, only one of the jaws moves. It may look a little strange right
now.
Tip:
If the motion seems wrong (i.e. the two jaws don't open but it spins around) select
the joint just created and click Reverse Joint from the Kinematic Editor.
3. Remember to click Reset before leaving Joint Jog.

5. What we would like is for both of the gun’s jaws to open and close. To create this
balanced gun we will need to add another function to the kinematics. See the next
activity for details.

Activity: Gun Kinematics (Part 2)
The objective of this activity is to see two ways to make the two jaws open: follow factor or
a function.
Continue and create a balanced joint gun

Go to Joint Jog and test
Edit the Function
Continue and create a balanced joint gun
Note:
Both arms will move the same amount in opposite directions. This can be accomplished by
making the upper arm’s joint the leading joint and the lower arm’s joint the follow joint
with a factor of −2 (or -2.13).
1. Open the Kinematic Editor.

2. Pick the joint that moves the lower arm (J2).
3. Use what you’ve learned to add this function to the joint: (T(fixed_InputJ1))*(-2)
Go to Joint Jog and test
1. Close the Kinematic Editor.

2. Right click your gun_geo and select Joint Jog .
Note:
There are only one joint to jog. This means that there is only one independent joint.
J1 moves both arms at the same time, but in opposite directions. Remember there
are no joint limits set.
3. Remember to go to the HOME pose before leaving Joint Jog
Edit the Function
1. Try editing the function and changing the −2 to some other value (i.e. 2).
2. Then jog it and notice affect on motion.

1. Right click it and selectHOME .
since none have been made).
Note:
This gun now has functions added to the joints from two sources. The first ones
were created automatically by Process Simulate because the gun contains a
kinematic loop. The functions created by Process Simulate are editable by the user.
The second function we just created in this activity to balance the movement of our
gun. It is editable by the user.

Activity: Speed and Acceleration
The objective of this activity is to define the max speed and acceleration on our gun joint.
Add speed and acceleration values

Test it
Move the object home and end modeling
Add speed and acceleration values
1. Select your gun_geo.

2. Select Modeling —> Set Modeling Scope .
4. In the Kinematics Editor window, double click on the joint.
6. For (Maximum) Speed, enter 9999.
7. For (Maximum) Acceleration, enter 9999.
8. Click [OK].
9. Click Close.
Test it
1. Use the Kinematics —> Pose Editor to create two poses that are different for
your gun_geo named TEST1 and TEST2.
2. Select your gun_geo, hold down the [Ctrl] key, and select a parent operation from
the Operation Tree.
3. Select Operations —> New Operation —> New Device Operation .
4. Select TEST1 for the From Pose, TEST2 for the To Pose.
5. Click Expand Dialog , set the Duration to 0.1, and click [OK].
6. Use the Kinematics —> Pose Editor to jump your gun_geo to the TEST1
pose.
7. Use the Sequence Editor to play the simulation.
8. Use Operation —> Operation Properties to notice how the time of simulation
is increased to how long will it take for the joints to move between the poses, based
on the assigned speed and acceleration.
9. Use the Kinematics —> Kinematics Editor to change the speed and
acceleration for the joint to 99.
10. Use the Sequence Editor to play the same simulation again.

11. Use Operation —> Operation Properties to notice how the time of simulation
is increased to how long it will take for the joints to move between the poses, based
on the assigned speed and acceleration.
Move the object home and end modeling
1. Right click it and selectHOME .

2. Select the object.
3. Select Modeling —> End modeling .

Activity: Defining OPEN, SEMIOPEN, and CLOSE Poses
The objective of this activity is to learn how to define OPEN, SEMIOPENED, and CLOSE
states for the gun.
Open gun_geo for modeling

Verify that the linear units are set to mm (and not inches)
Create the CLOSE pose
Create the SEMIOPEN pose
Create the OPEN pose
Test the poses then Reset the mechanism
Open gun_geo for modeling
1. Continue using the same data loaded in Process Simulate (gun geo).
Note:
This activity is a continuation of the previous one, and the kinematics must already
be defined.

2. Select the gun_geo object.
3. Select Kinematics -> Home .
Note:
Return the gun to the position it was in when you first defined the kinematics (that
is, j1=0, j2=0). This is called the HOME pose.

5. Select Yes.
Verify that the linear units are set to mm (and not inches)


3. Select mm from the Linear pull-down list.
4. Click [OK].
Create the CLOSE pose
1. Select Kinematics -> Pose Editor . The Pose Editor window is displayed.
2. In the Pose Editor window, click New. The New Pose window is displayed.
3. Click the up/down arrows for the joint value until it is 0.
Note:
On some guns the CLOSE pose is not zero degrees. In this case, enter the proper
joint value using the same technique described in the next step.
4. Pose Editor window, pick the pos1 just created, pick it again and enter CLOSE.
5. Click [OK].
6. (Do not close the Pose Editor window yet).
Create the SEMIOPEN pose
1. In the Pose Editor window, click New. The New Pose window is displayed.
2. Click the up/down arrows for the joint value until it is-15 (or 15, depends on the
axis direction).
Note:

This gun has two joints, but only one shows in the list. Do you remember why? It is
because j2 is dependant on j1.
3. Click [OK].
4. Pose Editor window, pick the pos1 just created, pick it again and enter
SEMIOPEN.
5. (Do not close the Pose Editor window yet).
Create the OPEN pose
Note:
Jog the gun to the open position (or type in the value in the Pose Editor directly).

2. In the Joint Jog window, select the blue j1 slider, and move the mouse left and right
in the Graphic Viewer to jog the gun to an open position.
3. From the Pose Editor window, click New.
4. Click [OK].
5. Pose Editor window, pick the pos1 just created, pick it again and enter OPEN.
Test the poses then Reset the mechanism
1. In the Pose Editor window, select CLOSE then click Jump.

2. Select OPEN, and then click Jump again. This jumps the gun from the CLOSE
pose to the OPEN pose.
3. In the Pose Editor or Joint Jog windows, click Reset to reset the mechanism back to
the HOME pose.

Activity: Create the TCP and MNT Frames
The objective of this activity is to create the frames required by the Tool Definition button.
Note:
The TCP Frame– represents the Tool Center Point Frame of the robot. The robot TCP is
super-imposed onto each location (workpoint) in the robotic path. The TCP Frame of the
robot is placed on the gun TCP frame defined by the tool definition command.
Note:
The Mount Frame – represents how the gun will be mounted to the TOOLFRAME of the
robot. By default the mount frame will be superimposed onto the TOOLFRAME of the
robot. Every robot has a TOOLFRAME located on the faceplate at the end of the robot
arm.
Create the TCP frame

Create the Mount frame
Create the TCP frame
1. Continue modeling the same gun data loaded in Process Simulate (gun geo).
2. Select Modeling -> Create Frame -> Frame by 6 values .
3. Pick once in space (on nothing to get the orientation).
4. In the Create Frame By 6 Points window, click Position.
5. Pick the top middle of the bottom gun tip (cap).
6. Click [OK]. (Usually this frame is created between the two gun tips).

7. On the Object Tree, name the frame tcp (pick it, press the [F2] key, and enter tcp).
8. Select the tcp frame.
9. Select Modeling —> Edit —> Set as Preserved Objects .
Create the Mount frame
1. Select Modeling -> Create Frame -> Frame by 6 values .

2. Pick the self origin of the gun (Usually this frame is centered on the gun mounting
plate).
3. Click [OK].

4. On the Object Tree, name the frame mnt (pick it, press the [F2] key, and enter
mnt).
5. Select the mnt frame.
6. Select Modeling —> Edit —> Set as Preserved Objects .
Note:
Continue modeling the gun.

Activity: Defining an object as a Spot Weld Gun
The objective of this activity is to use the Tool Definition command.
Open the tool definition window

Enter the tool definition parameters for this gun
Save and end modeling
Open the tool definition window
1. Continue modeling the same gun loaded in Process Simulate (gun geo).
2. Select the gun, either in the Graphic Viewer or the Object Tree.
3. Select Kinematics -> Tool Definition .
Enter the tool definition parameters for this gun
1. In the Tool Definition window, select Gun from the Tool Type drop down list.
2. In the TCP Frame field, select the tcp frame from the drop down list, the Graphic
Viewer or the Object Tree.
Note:
You can temporarily modify the position of the selected frame by clicking the drop
down arrow next to Frame of Reference and specifying the new location of the
frame using one of the four methods available.
3. In the Base Frame field, select the mnt frame from the drop down list, the Graphic
Viewer or the Object Tree.
4. In the Do not check for collisions with area, specify the objects which may collide
with the tool (i.e. the weldgun) by selecting them in the Graphic Viewer. For
example, the tips (or caps) of the gun arms. This means that collisions between the
specified objects and the tool are neither checked for nor noted.
5. Click [OK]. The selected device is defined as a tool of type gun.
Note:
In order for this definition to work, the object must be kinematic and have the
OPEN, SEMIOPEN, and CLOSE poses defined (case sensitive).


Activity: Defining an object as a Gripper
The objective of this activity is to define an existing kinematic object as a gripper.
Begin Modeling the box gripper object

Define the gripper kinematics
Create and test the gripper joints and poses
Define it as a gripper
Define another gripper (Optional Extra Credit)
Begin Modeling the box gripper object
1. In the Navigation Tree, browse and select the temp study.

2. Select File —> Load in Line Standard Mode .
4. Browse and select your box_gripper_user## object (i.e. for user1 select
box_gripper_user##.cojt. Instructor should use user11) from the
.\sysroot\Libraries\modeling_kinematics\grippers folder.
5. Click Open.
6. Right click your box_gripper_user## and select Display Only .
Define the gripper kinematics
1. Verify that the MNT frame and TCP are in the correct positions.
2. Select the object and pick Kinematics —> Kinematics Editor .
3. In the Kinematics Editor window, click Create Link .
4. Create the base link and select its geometry
5. Click [OK].
7. Create the left arm link and select its geometry
8. Click [OK].
10. Create the right arm link and select its geometry
11. Click [OK].

Create and test the gripper joints and poses
Note:
Jump from one pose to the other just to understand how the gripper functions, to find the
gripping entities (the pink ones) and to verify it has kinematics.
1. Create the first joint between base and left arm. It should be named j1 and move
prismatically along the X axis
2. Create the second joint between base and right arm. It should be named j2 and
move prismatically along the X axis.
3. Test the (direct) kinematics and reset them to HOME when done.
4. Add an OPEN pose and a CLOSE pose using the Pose Editor .
5. Jump from one pose to the other.
Note:
The existence of kinematics is a prerequisite to define any tool.
6. Close the Pose Editor window.
Define it as a gripper
1. Select the box_gripper_user## object.

2. Select Kinematics -> Tool Definition .
3. In the Tool Definition window, select Gripper as the Tool Type.
4. Leave the TCP Frame and the Base Frame fields untouched with the values as
seen in the picture.
5. Select the cylinders on the gripper as the gripping entities.
6. Leave the offset as 1.
7. Click [OK].
Note:
The gripping entities and the offset value define which parts will be attached to the
gripper when a Gripper operation is simulated. This is a mechanism that is applied
only when the gripper operation starts: It calculates which parts collide with the
gripping entities (taking into account the offset) and these parts will be
automatically attached to the TCP Frame of the gripper.
As a result of this automatic detection of parts to attach, there is a significant

importance to the selection of the gripping entities for two reasons:

o Performance while simulation is running – in order to gain performance
and reduce the time it takes to find the parts to attach, a minimal number of
entities as possible should be defined as the gripping entities and minimal
offset value.
o Accuracy – the gripping entity list must include all entities in such a way
that all parts that should be attached to the gripper will be found by the
automatic detection mechanism. In this activity, we could select only one
gripping pair (right or left one), reducing the calculations during the
simulation by factor of 2 or even select one entity (if we know the part
touches it), reducing it by x4. Due to the fact that both entities and part have
very simple geometry, this reduction will not be noticeable anyway.
8. Click [OK] to complete the gripper definition.
Define another gripper (Optional Extra Credit)
1. In the Navigation Tree, browse and select the temp study.

2. Select File —> Load in Line Standard Mode .

4. Browse and select your gripper1_user##.co object (i.e. for user1 select
gripper1_user1.cojt. Instructor should use user11) from the
.\sysroot\Libraries\modeling_kinematics\grippers folder.
5. Click Open.
6. Right click your box_gripper_user## and select Display Only .
8. Follow the same process to define this as a gripper.

Activity: Adding Kinematics to a Robot Model
The objective of this activity is to add kinematics to the robot created in an earlier activity
in order to learn the kinematic tools provided in Process Simulate.
Get the my robot geo object

Envision the kinematic chain in your head and then begin modeling
Create the first link
Create the second link
Define the next 5 links the same way
Axis Definition
Define the first joint
Define the second joint of the robot
Continue this process to define all six joints
Get the my robot geo object
1. Load in Standard Mode the temp study with Process Simulate.

2. No, don’t save changes to the study.
4. In the Insert Component window, browse into the
.\sysroot\Libraries\modeling_kinematics\robots folder.
5. Select your myrobot_geo_user##.cojt robot that you just modeled: (i.e. for user1,
select myrobot__geo_user1.cojt).
6. Click Open.
Envision the kinematic chain in your head and then begin modeling
1. Right click the my_robot_geo_user## object and select Display Only .

2. What are the links, what are the joints, and so on. We will need to define 7 links and
6 joints
Note:
The 7 links will be named: base, lnk1, lnk2, lnk3, lnk3, lnk4, lnk5, and lnk6. The
joints will be names J1, J2, J3, J4, J5, and J6.


5. Click Yes.
6. Create frames in an easy to select location to be used to create the axes of the robot
(one for each axis). Remember that when entering the axis for joint, the From/To
point coordinates are in reference to the working frame.
Create the first link
1. Select the robot object.

4. Select the bottom three solids for the first link.
5. In the Link Properties window for name, enter base.

6. Click [OK].
7. The three entities colors are changed to orange.
Create the second link

2. Select the next three solids from the bottom.

3. Click [OK].
4. The three entities colors are changed to green.
Note:
The default name lnk1 is assigned to this link
Define the next 5 links the same way
1. Define the next 5 links the same way, for a total of 7 links:
Here is lnk2:

Here is lnk3:
Here is lnk4:

Here is lnk5:
Here is lnk6:
Axis Definition
1. Here are the axes we will use:
Tip:
In this step, we will create a frame to make an easily selectable point for the axis
definition. See the steps that follow.

2. Set Pick Intent to Snap.
3. Select Modeling —> Create Frame —> Frame By 6 Values .
4. In the Frame By 6 Values window, click Position.
5. Pick the center of the one of the ends of the cylinders that is shown above to be an
axis.
Note:

We only need to create one frame for each axis representation.
The same axis can be used for the definition of the J4 and J6 joints.
6. Click [OK]
7. Repeat this process for the other axes shown in the picture above.
Note:
We don't need to create a frame for the axis between the base and lnk1 links.
Define the first joint
1. Pick the base link.

3. Pick lnk1.
4. In the Kinematics Editor window, click Create Joint .
7. For High Limit, enter 180.
8. For Low Limit, enter -180.
9. For Speed, enter 110.
10. For Acceleration, enter 9999.
11. Click [OK]
Define the second joint of the robot
1. Pick the lnk1 link.

3. Pick lnk2.
4. In the Kinematics Editor window, click Create Joint .
5. Pick From.

6. In the Graphic Viewer, pick the center of the end of the depicted cylinder.
7. Pick the center of the center of the end of the opposite end of the cylinder.
10. For High Limit, enter 70.
11. For Low Limit, enter -70.
12. For Speed, enter 110.
13. For Acceleration, enter 9999.
14. Click [OK].
Continue this process to define all six joints
Note:
Reference joint range values for the purposes of this activity only. Choose the appropriate
axis for each joint.J4 and J5 use the same axis.
1. Continue this process to define all six joints. Use this table for reference:
Parent Child Constant Low Constant High Max Max

Joint
Link Link Limit Limit Speed Accel.
J3 lnk2 lnk3 -70 70 110 9999
J4 lnk3 lnk4 -190 90 170 9999
J5 lnk4 lnk5 -110 110 170 9999
J6 lnk5 lnk6 -340 340 240 9999
Note:
Normally the joint ranges for J2 and J3 are dependant on each other. In this activity, we
will define them as constant. This is not suggested for production robotic kinematics.


Activity: Using Direct Kinematics to Move the Robot
The objective of this activity is to test the kinematics of the robot that we created.
Test the 6 joints in the mechanism
Test the 6 joints in the mechanism
1. Change the Pick Level to Component.
2. Right click the robot and select Joint Jog .

3. Move the sliders for each joint and observe how it moves.
Note:
The current value of the joint being jogged is displayed in the Joint Jog window are
relative to home pose.
Note:
The range is specified based upon all joint values being 0 at the home pose. HOME
pose is defined by the position of the links when you defined the kinematics.
4. Return the robot to HOME pose: Click Reset.
Caution:
Don't forget to click Reset on the Joint Jog window before closing the window.

Activity: Adding a Toolframe
The objective of this activity is to add a TOOLFRAME onto the kinematic device in order
to make it into a robot (able to use inverse kinematics).
Continue modeling the my robot geo object

Look at the kinematic links
Define Inverse Kinematics
Continue modeling the my robot geo object
1. Continue using the same data loaded in Process Simulate.

4. Click Yes.

Look at the kinematic links
Note:
Look at the temporary coloring of the kinematic links of the mechanism.


Note:
Recall that this robot has 6 joints that are all rotational (i.e. its primary kinematic
branch configuration is RRRRRR).
Define Inverse Kinematics
Note:
Make this device into a robot (i.e. inverse kinematics).
1. In the Graphics Window zoom in on the robot’s wrist.

2. Change the Pick Level to Entity .
3. Change the Pick Intent to Snap .

4. From the Kinematics Editor window, click Create Toolframe .
5. Pick (Snap) the middle of the end of lnk6 (the cyan link) at the end of the robot
wrist.
6. In the Create Toolframe window, verify the Attach to link field is highlighted.
7. Pick anywhere on the lnk6 (the cyan link), at the end of the robot wrist. (Yes, pick
it again).
8. Click [OK].
9. Look at the robot’s entities in the Object Tree.
10. (Several frames, including the TOOLFRAME are created.)

Note:
The GTAC website (http:\\support.ugs.com) contains several hundred commercial

robots from robotic vendors. In most cases you will not have to model your own
robots.

Activity: Using Inverse Kinematics to Move the Robot
The objective of this activity is to use the inverse kinematics that have been defined.

Create a location for the robot
Note:
Notice how this type of movement is different from Joint Jog.
1. Continue using the same data.

2. Right click the robot and select Robot Jog to open the Robot Jog window, as
shown below.
3. Grab the Robot Jog Manipulator Frame in the Graphic Viewer and pull the robot
around.
4. Don’t close the Robot Jog window yet.
Note:
The robot jog window is only available for robot objects (i.e. objects with a TCPF
frame at the end of its kinematic tree).
1. Select your robot.

2. Select Operations -> New Operation -> New Weld Operation .
3. In the New Weld Operation window for the Scope, select Operation Root from the
drop down.
4. Take the defaults for the rest of the fields and click [OK].
Note:
The creation and validation of proper weld processes is described in detail later in
this course. The information provided in this topic should not be considered enough
to begin processing welds in the Process Simulate environment.
Create a location for the robot
1. On the Operation Tree viewer, pick the new bolded Weld_Op robotic operation.
2. Select Operations -> Path Editing -> Add Current Location .
Note:
The path editing buttons can also be found on the Path toolbar which is turned off
by default.
1. On the Operation Tree viewer, pick the new location in the new bolded Weld_Op
robotic operation.
2. Select Operation -> Path Editing -> Add Location After .
3. Use the Manipulator Frame or Robot Jog window to move the robot to another
position.

5. When you are done, select Kinematics -> Home to return to the HOME pose.
1. On the Sequence Editor, click Play Simulation Forward .

2. After the simulation runs, click Jump Simulation to Start .

Activity: More Inverse Kinematics (Optional Extra Credit)
The objective of this activity is to provide additional inverse kinematics examples. These
are considered optional activities. In this case, only the basic steps will be provided.
Defining Transporter (AGV) Kinematics

Defining Fork Lift Kinematics
Defining Overhead Crane Kinematics
Defining another Type of Crane Kinematics
Defining (Regular) Lift Assist Kinematics
Defining (Special) Lift Assist Kinematics
Defining Transporter (AGV) Kinematics
Note:
We will model the crawler and crawler_top as separate objects. Later we would define the
crawler top as a tool to be mounted to the transporter. In this case this ―tool‖ would contain
the one translational joint and would add flexibility to how the poses could be applied for it.
(Otherwise if the bed kinematics were part of the crawler, the poses would contain all the
joints of the robot and the bed, making the modification of the simulation difficult).
Note:
If you are not sure what the kinematics should look like, open crawler_demo and
crawler_top_demo, mount it, then Robot Jog it. Delete it from the study when finished.

1. Right click the crawler_user## in the Object Tree and select Display Only .
3. Create four empty links.
4. Add all the geometry (except the bed) to link4
Note:
You do not have to put geometry into a link.
5. The first joint (between link1 and link2) should be named X and move
prismatically along the X axis.
Note:

It does not matter where the axis is defined for prismatic joints as long as it goes in
the right direction.
6. The second joint (between link2 and link3) should be named Y and move
prismatically along the Y axis.
7. The third joint (between link3 and link4) should be named Rz and move
rotationally around the Z axis.
9. Add a TOOLFRAME to link4, located on the ground between the front wheels
(pick fr1 frame from the Objects Tree).
10. Test the (inverse) kinematics and reset them to HOME when done.
12. Right click the crawler_top_user## in the Object Tree and select Display Only
.
14. Create two empty links.
15. Add the bed geometry to link2
16. The one joint (between link1 and link2) should be named lift and move
prismatically along the Z axis.
Defining Fork Lift Kinematics
Warning:
There is no usable data for a forklift in the training data. These steps are here for reference.
1. Follow the same basic process described for the crawler, except use forklift
geometry (minus the fork).
2. Follow the same basic process described for the crawler_top, except use forklift
fork geometry.
Defining Overhead Crane Kinematics
Note:
If you are not sure what the kinematics should look like, open crane2_demo and Robot
Jog it. Delete it from the study when finished.

1. Right clickCrane2_user## in the Object Tree and select Display Only .
3. Create a frame on the top of the crane top (Modeling -> Create Frame ).
4. Shift it down in the Z 10 feet using Placement Manipulator .
5. Create four empty links.
6. Add all the geometry from the crane2_user## (not top) to link2
7. Add all the geometry from the crane2_user## (top) to link3.
8. Add the fr1 frame to link4.
9. The first joint (between link1 and link2) should be named X and move
prismatically along the X axis (0,0,0) – (10,0,0)
10. The second joint (between link2 and link3) should be named Y and move
prismatically along the Y axis. (0,0,0) – (0,10,0)
11. The third joint (between link3 and link4) should be named z and move
prismatically along the Z axis. (0,0,0) – (0,0,10)
12. Add limits to the joints?
14. Add a TOOLFRAME to link4, located on the fr1 frame
15. Test the (inverse) kinematics and reset them to HOME when done.
16. Click File —> eMServer Selective Update , select Operations, and Click
[OK].
Defining another Type of Crane Kinematics
Note:
If you are not sure what the kinematics should look like, open crane1_demo and Robot

Note:
In this case, we will create hook as a separate device with one linear joint that we will
mount to the end of the crane to give us to type of flexibility we want during simulation.

1. Right click crane1_user## in the Object Tree and select Display Only .
3. Define the kinematics as shown in the demo object or as desired.
4. Add a TOOLFRAME to the last link.
[OK].

Defining (Regular) Lift Assist Kinematics
Note:
If you are not sure what the kinematics should look like, open lift_assist_demo and Robot

1. Select Lift_Assist_user## in the Object Tree.
3. Define seven links as shown in the picture above
4. Joints 1, 2, and 3 are rotational using the Z-axis of the frames on the top of the arm.
5. Joint 4 is rotational and Joint 5 is linear along the Z-axis
Note:
This robot can be used in conjunction with the human (follow the weld operation of
the lift assist).

6. Add a TOOLFRAME to link4.
[OK].
Defining (Special) Lift Assist Kinematics
Note:
If you are not sure what the kinematics should look like, open top_lift_assist_demo.cojt
and Robot Jog it. Delete it from the study when finished.

1. Right click top_lift_assist_user1 in the Object Tree and select Display Only .
3. The first two joints are prismatic along the X-axis and Y-axis.
4. Joints 3, 4, and 5 are rotational using the Z-axis of the frames on the top of the arm.
5. Joint 6 is rotational and Joint 7 is linear along the Z-axis
Note:
This robot can be used in conjunction with the human (follow the weld operation of
the lift assist).
6. Add a TOOLFRAME to link4.

[OK].

OTHER SELECTED MODELING & KINEMATICS TOPICS
Activity: Sample Rail Creation Overview
The objective of this activity is to create a simple rail.
Open a new prototype for the rail

Define the Rail Geometry
Place the carriage on one end of the rail
Define the links and Joints
Open a new prototype for the rail
1. The same project should still be opened from the previous activity.
2. Right click on temp study and select Load in Standard Mode .
3. No, don’t store changes to the study.
5. In the New Resource window, select ToolPrototype.
6. Click [OK].
8. Name it rail1_user## (Replace ## with your user id to the end of the name for
training purposes).
Define the Rail Geometry
Note:
The geometry for the rail could be created in a CAD system, such as NX. However, the
kinematics should be defined in Process Simulate.
Note:
It can consist of two boxes. One is the rail track and the other is the carriage that carries the
robot along the track.
Example: Dimensions:
1. Rail 15,000 x 800 x 1000 (box )

2. Carriage 800 x 100 x 1000 (box )

Place the carriage on one end of the rail
1. Use what you've learned to place the carriage on one end of the rail.
Define the links and Joints
1. After creating the links, define the rail as a kinematic device having a single
prismatic joint (J1) to move the rail along the track.
1. From the Object Tree, select your rail1_user##.


Instructor Demo: Other Slider Cranks including RPRR Offset Slider
The objective of this activity is to look at an example of kinematic motion of various cranks
and defining the kinematics using the Kinematics RPRR offset slider.
Insert the various crank object examples

Look at the Joint Functions and Jog the Device
Start Modeling the RPRR Slider with Offset
Define the crank for the RPRR Slider with Offset
Insert the various crank object examples
1. The same project and study should still be opened from the previous activity.
2. Select Modeling —> Insert Component from File .
3. Browse and select these COJTs from the
.\sysroot\libraries\model_kinematics\more_kin folder: rrrp.cojt, prrr.cojt,
rprr_offset.cojt, prrr_offset.cojt, rprr_offset_geo.cojt, and rrrp_offset.cojt.
Note:
rprr_offset_geo.cojt does not have any kinematics. We will add them later in this
activity.

5. Use Fast Placement to move the objects so that they are not overlapping.
Look at the Joint Functions and Jog the Device
1. Joint Jog one of the crank objects.

2. Open the Kinematics Editor window for one of the crank objects.
Note:
Look at the functions on the joints using the Joint Kinematics Functions
button on the Kinematics Editor toolbar.
Start Modeling the RPRR Slider with Offset
1. Select the rprr_offset_geo object in the Graphic Viewer or Object Tree.

3. Select Yes.
4. Right click the rprr_offset_geo object and select Display Only .
5. Right click the rprr_offset_geo object and select Zoom to Selection .
Define the crank for the RPRR Slider with Offset

3. Click Next.
Link Name Correlation to Linkage Diagram

gray entity Fixed Link
green entity Input Link
red entity Coupler Link
blue entity Output Link
4. On the Slider Crank Joints window, click one of the three points on the Linkage
Diagram and pick the equivalent point in the Graphic Viewer
Point Location
po7 Between Fixed Link and Input Link
po8 Between Input Link and Coupler Link
po9 Between Coupler Link and Output Link

Note:
A triangle is drawn in the Graphic Viewer between the three points.
5. Click Next.
6. Check With offset.
7. In the Graphic Viewer for the From point, pick the end of line_3 sticking out of the
green input link.
8. In the Slider Crank Joints window, pick in the To point field.
9. In the Graphic Viewer for the To point, pick the end of line_3 sticking out of the
yellow coupler link.
10. Click Next.
11. On the Slider Crank Joints window, click the first link (Fixed Link).
12. On the Slider Crank Joints window, click Existing Link.

13. Pick the equivalent link in drop down. DO NOT RECREATE THE LINKS.
14. Repeat this process for the other three links.
15. Click Finish. The kinematic tree is defined.

Instructor Demo: Implementing Joint Logic with Functions (Optional
Activity)
The objective of this activity is to look at an example of kinematic motion added to a weld
gun. In this example the upper arm until a certain limit before the bottom arm begins to
move.
Instructor opens Gun Geo Advanced

Joint jog the gun
Look at the Kinematic Joint Functions
Instructor opens Gun Geo Advanced
Warning:
This is not a student activity.
2. Load the gun geo advanced study from the model kinematics study folder.
Note:
Students could use the temp study and insert the gun funobject into it. However,
they should not save any changes to this object, since the whole class is looking at
the same gun .COJT.
Joint jog the gun
1. Joint Jog the gun.
Note:
Look at the functions on the joints using the Joint Kinematics Functions button on the
Kinematics Editor toolbar.
1. Open the Kinematics Editor window for this gun.

2. J1 is an independent joint (so there’s no function)
3. J2 function: (((D(j1)<=41.275)*(.005497*D(j1)))+((D(j1)>41.275)*(.2269)))
Note:
J2 NOTE:
o Expression1 is D(j1)<=41.275: If prismatic joint j1 is less than or equal to

41.275, then evaluate to 1 else evaluate to 0.
o Expression2 is .005497*D(j1): prismatic joint j1 times 0.005497
o Expression3 is D(j1)>41.275: If prismatic joint j1 is greater than 41.275,
then evaluate to 1 else evaluate to 0.
o Expression4 is 0.2269
o J2’s Logic: Multiply expression1 times expression2 plus expression3
times expression4: This means that j2 will depend on expression2 for its
joint value when j1 is less than or equal to 41.275, but will depend on
expression4 when j1 is greater than 41.275.
4. J3 function: ((D(j1)>41.275)*((-.004810)*(D(j1)-41.275)))
Note:
J3 NOTE:
o Expression1 is D(j1)>41.275: If prismatic joint j1 is greater than 41.275,

then evaluate to 1 else evaluate to 0.
o Expression2 is -.004810)*(D(j1)-41.275): prismatic joint j1 minus 41.275
times -0.004810
o J3’s Logic: Multiply expression1 times expression2. This means that j3
will always have a value of zero unless j1 is greater than 41.275
5. J4 function: (((D(j1)<=41.275)*((-.003145)*D(j1)))+((D(j1)>41.275)*((-.1298)+((-
.002806)*(D(j1)-41.275)))))

Note:
J4 NOTE:
o Expression1 is D(j1)<=41.275
o Expression2 is (-.003145)*D(j1)
o Expression3 is D(j1)>41.275
o Expression4 is (-.1298)+ ((-.002806)*(D(j1)-41.275)))
o J4’s Logic: Multiply expression1 times expression2 plus expression3
times expression4. This means that j4 will depend on expression2 for its
joint value when j1 is less than or equal to 41.275, but will depend on
expression4 when j1 is greater than 41.275.

Instructor Demo: Kinematics Following a Surface (Optional Activity)
The objective of this activity is to look at an example of kinematic motion that follows a
surface defined by a mathematical function.
Insert the surface tracker object

Joint jog the gun
Insert the surface tracker object
2. Select Modeling —> Insert Component from File .
3. Browse and select the surfacetracker.cojt (CAM Motion Example) object from the
.\sysroot\Libraries\model_kinematics\more_kin folder.
4. Click Open.
Note:
It is OK for the .COJT filename to be different than the name shown in Process
Simulate. They are two different attributes of the object.
5. Right click the CAM Motion Example (surface tracker) object and select Display
Only .

Joint jog the gun
1. Joint Jog the CAM Motion Example (surface tracker) object.
1. Select the CAM Motion Example (surface tracker) object.

3. Open the Kinematics Editor window for the surface tracker object.

4. Select the Z joint.
5. From the Kinematics Editor window, select Joint Kinematics Functions .
6. Click Close
7. Click Close
8. Select the CAM Motion Example (surface tracker) object.
9. Select Modeling —> Reload Component .
10. Select Yes,

Instructor Demo: Examine the Train Joint
The objective of this activity is to examine the trainj. There is an example object named
trainj available for examination. It has all of the functions defined and works properly.
Steps for the Train Joint
Steps for the Train Joint
2. Insert the trainj.cojt from the .\sysroot\libraries\modeling_kineamtics\functions
folder and begin modeling it.
3. Right click the trainj object and select Display Only .
4. Begin modeling it.

5. Jog the joints of the trainj and see how it works.
7. Edit each of the joints and look at the functions. Using the Kinematics Editor, look
at the functions defined for the cpin joint on this device.
8. Follow the same process to look at the function for the barpin joint.
9. Open and jog some of the other train related objects.

Instructor Demo: Examine the Cam Joint
The objective of this activity is to examine the camfinalj. There is an example object
named camfinalj available for examination. It has all of the functions defined and works
properly.
Steps for the cam joint object
Steps for the cam joint object
2. Insert the camfinal.cojt from the
.\sysroot\libraries\modeling_kineamtics\functions folder and begin modeling it.
3. Right click the camfinal object and select Display Only .
4. Begin modeling it.

5. Jog the joints and see how it works.
7. Edit each of the joints and look at the functions. Using the Kinematics Editor, look
at the functions defined for the first joint on this device.
8. Open and jog some of the other cam related objects.

Activity: Setting up Compound Equipment
The objective of this activity is to setup some compound equipment.
Create the first part of the Robot and Rail Equipment

Create the second part of the Robot and Rail Equipment
Place the robot on the rail
Attach it to the Rail
Set it up as an external axis and finish up
Create the first part of the Robot and Rail Equipment

2. Load in Standard Mode an empty study such as the tempstudy RobcadStudy.
3. In the Navigation Tree, browse into the Libraries collection.
4. Right click the Resource Library and select Navigation Tree .
5. Browse into the Modeling and Kinematics library.
6. Right click the compound_equipment library and select Check Out and
click [OK].
7. Right click the compound_equipment library and select New .
8. In the New window for EquipmentPrototype name, enter Rail and click [OK].
9. Right click the compound_equipment library and select Check In and click
[OK].
Note:
This will allow others to check out this library.
10. Right click the Rail EquipmentPrototype and select Check Out and click [OK].
Note:
This will allow you to continue editing your EquipmentPrototype.
11. In the Navigation Tree displaying the Resource Library , drag and drop the
e_carriage_l and e_rail_l25 resource prototypes (from the
compound_equipment2 library) unto the Rail equipment prototype.

Create the second part of the Robot and Rail Equipment
1. Right click the compound_equipment library and select New .

2. In the New window for EquipmentPrototype name, enter Robot and Rail user##
and click [OK].
3. Right click the compound_equipment library and select Check In and click
[OK].
Note:
This will allow others to check out this library.
4. Right click the Robot and Rail EquipmentPrototype and select Check Out and
click [OK].
Note:
This will allow you to continue editing your EquipmentPrototype.
5. In the Navigation Tree drag and drop the Rail equipment prototype onto the Robot
and Raill equipment prototype.
6. In the Navigation Tree, drag and drop the real_robot robot (from the robots
library) onto the Robot and Rail equipment prototype.
7. Drag and drop the Robot and Rail user## object from the compound_equipment
library to the Graphic Viewer.
Place the robot on the rail

1. Select Modeling —> Set Modeling Scope and click [OK].
2. In the Object Tree, select the Rail.
3. Select View —> Display .
4. Right click the Robot and Rail user## equipment instance. in the Object Tree and
select Display Only .
5. Right click the real_robot and select Relocate .
6. Pick the magenta frame on the rail's carriage and click Apply and Close.
Attach it to the Rail
1. In the Object Tree, select the Robot and Rail user## equipment instance.

3. Click Create Link , click [OK], and Close.
4. Click Create Link , click [OK], and Close.
5. Drag a joint between the two links just created and click [OK].
Note:
The root of the compound equipment must contain some type of kinematic
information (one joint at minimum) in order to be able to store the attachment of
objects within it. Now when you end modeling this object, it will prompt you for the
location to store the new .COJT.
6. Select the real_robot.

7. Select Modeling —> Attach .
8. Change the Pick Level to Entity .

9. Select on the geometry of the e_carriange_l (the k1 link should be selected).
10. Select [OK].
11. Change the Pick Level to Component .
Set it up as an external axis and finish up
1. Right click the real_robot and select Configuration, Properties, and Settings —>
Robot Properties .
2. In the Robot Properties window, select the External Axes tab.
3. Click Add, select e_carriage_l for the Device, and click [OK].
Note:
j1 is already selected as the Joint.
4. Click Close.
5. Select the Robot and Rail user##.
6. Select Modeling —> End Modeling .
7. In the Save Component As window, browse into the Libraries —>
Model_kinematics —> compound_equipment folder.
8. Enter CompEquip_User## for the name and click Save.
9. Select File —> eMServer Selective Update and click [OK].

Note:
Equipment instantiation is performed the same way as the instantiation of any other
object in the Resource library

GENERAL ROBOTICS
Activity: Creating a New Study (Again)
The objective of this activity is to create another study.

Create a new RobcadStudy in the Line ## studyfolder
1. Select File —> Close Project.

2. When prompted: ―You are about to close the porject. Do you wish to updae
eMServer?‖ selectNo.
4. From the Open Project window, select the Basics Project — user## project (where
## is the user number assigned to your by the instructor).
5. Click [OK].
1. In the Navigation Tree, expand the Studies StudyFolder.

eMS User ID StudyFolder

administrator Line 0
user1 Line 1
user2 Line 2
user3 Line 3
user4 Line 4
user5 Line 5
user6 Line 6
etc... etc...
user8 Line 8
user9 Line 9

3. Right click your Line ## StudyFolder and select Check out
4. Select with Hierarchy (This is one of the rare times we will use Check out with
Hierarchy).
5. Click [OK].
6. Expand your Line ## study folder.
Create a new RobcadStudy in the Line ## studyfolder
1. Right click on your Line ## StudyFolder and select New .

2. From the New window, check the checkbox for RobcadStudy .
3. Rename it to Study2.
4. Click [OK].
5. Drag and drop the Operation Tree CompoundOperation onto the study. Expand the
tree under the study.
Note:
Normally you would not add the entire operation tree to a study. Normally it would
be a smaller chunk of related processes and resources.
6. Close all the Navigation Tree viewers except for the original one.
1. Right click the Study2 RobcadStudy and select Load in Standard Mode .

Activity: Training Data Overview
The objective of this activity is to load and examine two studies created at the Scenario
(study) level. This is the most common level for every day Process Simulate use.
Start Process Simulate

Define your working folder
Load the “station22” Scenario (study)
Load the “station02” Scenario (study)
Load the “pnp” Scenario (study)
Load the “arc multi axis”Scenario (study)
Start Process Simulate
2. Login using your instructor assigned user id.
3. Click [OK].
4. Open the Robotics Sim Begin (user##) project (where ## is the user number
assigned by the instructor).
5. Click [OK].
Define your working folder

1. In the Navigation Tree of Robotics Sim Begin (user##) , browse into the
Working Folders. collection.
2. Select the User## folder, where ## is the user number assigned to you by your
instructor.
3. Right click it and select Check Out .
4. Click [OK].
Load the ―station22‖ Scenario (study)

etc…).
4. From the Navigation Tree, expand into your mount_wp studyfolder.
5. Right click station22 and select Load in Standard Mode .
6. Examine the Scenario (study).
Load the ―station02‖ Scenario (study)
1. Expand into the Processing studyfolder.

2. Expand into your Line## (where ## is your assigned user number).
3. Right click station02 study and select Load in Standard Mode .

Load the ―pnp‖ Scenario (study)
1. Expand into the Other Selected studyfolder.

2. Right click pnp and select Load in Standard Mode .
Load the ―arc multi axis‖Scenario (study)
1. Expand into the Other Selected studyfolder.

2. Right click arc multi axis and select Load in Standard Mode .

SPOT WELDING APPLICATIONS
Activity: Viewing Spot Mfg Features in Process Simulate
The objective of this activity is to view spot manufacturing features in Process Simulate.
Load the Station02 Study

Open the Mfg Viewer
View some of the attributes of the weld locations
1. Process Simulate should already be started, and you may have already opened the
Robotics Sim Begin (user##) project , and loaded thestation02 study. If so, skip to
step 3.
Note:
this would only be the case if you were following the instructor's demo.
2. If you are NOT already in the Robotics Sim Begin (user##) project with the
station02 study loaded:
o Select File —> Close Project, if a different one is open.
o Select Robotics Sim Begin (user##) and click [OK].
o In the Navigation Tree displaying theRobotics Sim Begin (user##) project,
browse to the Studies studyfolder.
o Browse to the Line ## studyfolder , where ## is the user number assigned
to you by the instructor.
o If not already checked out, right click the Line ## studyfolder and select
Check Out .
o Check Check Out with Hierarchy, and Click [OK].
o Browse into the processing studyfolder.
o Right click the station02 study and select Load in Standard Mode .
Open the Mfg Viewer
1. From the Process Simulate Object Tree, select a part and chooseView —> Zoom to
Selection .
2. Notice the Mfg Features in the Graphic Viewer.

3. Select View -> Viewers -> Mfg Viewer.
4. In the Mfg Viewer, click the down arrow to the right of the Filter and verify
WeldPoint is selected.
5. Notice the Mfg Features in the Mfg Viewer.
1. In the Mfg Viewer, click Customize .

2. In the Field Selection window, select Projection Indication and Assignment
indication attributes under Mfg Viewer Fields and move them to the Available
Fields list.
3. In the Field Selection window, select the desired attributes under WeldPoint and
click to move them to the Show properties in following order list.
4. Click [OK].

Activity: Projecting Spot Mfg Features
The objective of this activity is to project the weld locations we have created onto the
workpiece and orient them roughly to avoid collision with the workpiece.
Start Projecting Spot Mfg Features
Start Projecting Spot Mfg Features
Note:
By projecting the Spot Mfg Features onto its related parts, we will get a robotic simulative
operation, where each spot will be represented as a location operation.
1. Continue in Process Simulate from where the last activity left off.
Note:
The station02 study should be loaded from the Processing studyfolder .
2. From the Operations Tree, expand into station02 and click the display status square
for the pink WeldOperation 1 simulative operation, if it is not currently displayed.
Note:
A dotted line is shown in the Graphic Viewer which represents the order of the Mfg
Features in simulative operation.
3. Select the pink WeldOperation 1 simulative operation.

4. Select Weld -> Spot —> Project Weld Points .

Note:

The default approach and perpendicular axis are defined and can be modified by
either clicking Options or by selectingTools -> Options and select the Weld
tab.
5. Check Project on approximation only.
Note:
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.
6. Click Project and Click [OK].
Note:
Notice that each location has a blue check mark next to it in the Project Weld Points
window, meaning that the projection was successful.
Note:
Constraint − weld locations must be on the surface and perpendicular to it. They
will be used to determine the orientation of the weld gun when approaching or at
this location.
7. Click Close.

Activity: Adjusting a Weld Path
The objective of this activity is to edit the weld path of locations from the previous activity
and jog a weld gun along it.
Graphically label the locations

Reorder the locations in the path
Get the first approximation (guess) of a gun
Orient the weld location approach vector
Align the orientations of the other weld locations to this one
Simulate the gun along the path
Update the database
Graphically label the locations

2. From the Operations Tree, pick the first location in the pink WeldOperation 1
simulative operation.
3. Hold down the [Shift] key and pick the last location in the path.
4. Select Tools -> Notes -> Object Notes .

5. Place the notes into non-overlapping positions by dragging and dropping them in
the Graphic Viewer.

Reorder the locations in the path
1. From the Operations Tree, right click the pink WeldOperation 1 simulative
operation and select Set Current Operation .
Note:
If the Sequence Editor is not shown, select View —> Viewers —> Sequence
Editor.
2. From the Sequence Editor, right click on nothing and select Tree Filters Editor.
3. In the Tree Filters Editor window, check all three unchecked boxes.
4. Click [OK].
5. From the Sequence Editor, expand the pink WeldOperation 1 simulative operation
to show all the locations.

6. Looking at the Graphic Viewer: Drag and drop the locations on the Sequence Editor
(in between other locations) so that they are in sequential order from right to left
(i.e. starting with e254 and ending with e278).
Get the first approximation (guess) of a gun
1. On the Operations Tree, right click on the pink WeldOperation 1 simulative

operation and select Operation Properties .
2. In the Operation Properties window, select the Process tab.
3. Pick in the Gun field.
Note:
We will NOT select the robot at this time. This will occur in a later topic.
4. Pick the gun on the robot sitting near the top of the car door (named gun1).
Note:
Do not select gun1_2. That is for the other robot and weld operation.
5. Click [OK].
Orient the weld location approach vector
1. Select the first location in the pink WeldOperation 1 simulative operation (i.e.
e254).
2. Select Weld -> Rotate Locations . A temporary gun is placed at the selected
location.

3. Rotate the weld location around the Z-axis (as shown above).
Note:
Constraint − the approach of the gun must be modified to avoid collisions.
Note:
While the Rotate Location window is open, the gun is attached to the weld location.
This command rotates the weld location NOT the gun. When the location is rotated,
the gun will follow.
4. Close the Rotate Location window.
Align the orientations of the other weld locations to this one

2. Select Weld -> Align Locations .
3. For Align Selected Locations to, pick the location you just rotated (i.e. e254).

Note:
This command aligns all orientations while maintaining the perpendicular constraint
of the weld locations.
Note:
Weld locations for Selected Locations list can also be selected with a pick window.
4. In the Align Locations window, Click [OK].
Simulate the gun along the path
Note:
Watch the gun simulating and imagine the robot attached. Does this orientation for
the gun make sense? Are there any sharp changes in orientation (i.e. flips) ?
2. Click Jump Simulation to Start .

3. In the Sequence Editor, click Zoom to Fit .
Note:
Originally there was no time associated to these location operations. However,

based on the gun time (no robot motion yet) a time has been assigned to the
locations.
Update the database

2. Select Parts, Operations, and Resources.

3. Click [OK].
4. Click [OK].

Activity: Gun Shank Validation
The objective of this activity is to create cross-sections of the weld gun at various spot
welds to check for clearance and validate the gun for this process.
Get a gun and put it at a weld location

Create and place the cutting box on weld location(s)
Show side view of multi-section (line them up)
Identify a section on the workpiece
Store the multi-section as an object
Get a gun and put it at a weld location
Note:
The Scenario (study) should contain a pink WeldOperation 1 simulative operation,

and product related to the path.

3. Select Weld -> Multi Sections .
4. Look for collisions (i.e. an X beside the weld in the Locations list).
Create and place the cutting box on weld location(s)

1. In the MultiSections window, click Expand Dialog .
2. Verify that Show Cutting Box of Selected Section and Show Gun are checked.
3. In the MultiSections window, double click on a weld location in the Locations list.
Note:
The gun is shown in the Graphic Viewer of the MultiSections window at the
location; and a transparent cutting box and gun are shown in the main Graphic
Viewer at the location.
4. Modify the dimensions of the cutting box to define rough volume of gun by clicking
Fit all Cutting Boxes to Gun .
5. Modify the dimensions of the cutting box to be a 2D section by entering new values
from the keyboard to adjust dimensions: Click on one of the current values.
6. In the Cutting Box Dimensions window for Y Dimension, enter -1 for the Low and
1 for the High value.
7. Make the other four values 20 mm larger.
8. Click [OK].

9. Notice how the cutting box shape has changed, as well as the resulting sections.
Note:
The MultiSections window forms sections according to the cutting−box parameters.

It produces a section for each location displayed in the Locations list.
Show side view of multi-section (line them up)
1. From the MultiSections window, click Show section side view .

2. Zoom in the area around the gun tips.
Identify a section on the workpiece
1. From the MultiSections window, click another location from the Locations list.

Note:
The frame representing the location is highlighted in magenta and the section plane
is moved in the main Graphic Viewer to the selected location.
2. The gun is jumped to that location in the Graphic Viewer and MultiSections window
if the location is double clicked.
Note:
It is possible, based on gun overlay, to modify the shank (in Process Simulate
modeling or by sending a .JT of the sections to the gun designer in another CAD
system) OR choose another gun that is appropriate for this particular process.
Store the multi-section as an object
1. From the MultiSections window for Store Sections, click All Sections as one
Component.
Note:
The output of this command can be either a .JT or .COJT, depending on what was
set for the File Format using the Settings button of the MultiSections window.
2. Click Save as.

3. In the Save Component As window, browse to the .\sysroot\sections\user##
folder.
4. Click Save.

Note:
A JT file is created in a .COJT folder which contains all sections shown in the
MultiSections window.
5. From the MultiSections window, click Close.

Activity: Using Weld Distribution Center (with Automatic Approach
Angle)
In this activity, you learn how to use the Weld Distribution Center with automatic approach
angle.
Locate a Spot Weld Operation

Open and Setup the Weld Distribution Center
Weld Distribution Center Settings and Filters
Using the Pie Chart and Automatic Approach Angle in Weld Distribution Center
Locate a Spot Weld Operation
1. Continue using the same Scenario (study).
Note:
Need to have a spot weld simulative operation with projected locations.
2. Save your changes to the Scenario (study) back to the database, if you haven't
already.
Note:
Ideally with the command you would select welds from several robot's paths.
Open and Setup the Weld Distribution Center
1. Select Weld —> Weld Distribution Center and wait for a few seconds.

2. In the Weld Distribution Center window, click Configure Attributes List .
3. In the Weld Distribution Center — Properties Customization window, expand
WeldPoint.
4. Select WPMWPForce.
5. Click Add .
6. Click [OK].
Note:
If a weld force had been assigned to these weld Manufacturing Features, it would
show here.
Weld Distribution Center Settings and Filters
1. Click Settings .

2. In the Settings window, click Apply Automatic Approach Angle on Assignment.
3. Click [OK].
4. In the Weld Distribution Center window, click the down arrow to the right of
Filter .

5. Look at the list of available filters.
Using the Pie Chart and Automatic Approach Angle in Weld Distribution Center
1. In the Weld Distribution Center, pick the first weld .
Note:
You could change the assignment of a weld from one robot (weld operation) to
another by checking the unchecked checkbox for the weld (under the desired weld
operation)
2. Hold down the [Shift] key.

3. Pick the last weld.
4. Release the [Shift] key
5. Select Automatic Approach Angle .
6. Pick a single weld
7. Select Open Pie Chart .
Note:
Currently the pie chart shows white because a robot has not been assigned to this
weld location yet.
8. In the Location Pie Chart window, check the checkbox for Opened Gun.
9. Move the slider to manually adjust the location orientation.
10. Undo your changes here by clicking Reset.

11. Click Close to close the Location Pie Chart window.
12. Close the Weld Distribution Center window.

Activity: Putting the Gripper on the Robot (for Ped. Welding)
The objective of this activity is to prepare for pedestal welding.
Load your Station22

Measure the thickness of the spacer
Mount the gripper to the robot
Attach the endspacer (one way) to the gripper fixed link
Update the database
Load your Station22
1. From the Navigation Tree, expand into the Studies studyfolder.

2. Expand into your Line## studyfolder, where ## is the user number assigned to
you by your instructor.
3. Check Out your assigned studyfolder with hierarchy, if it is not already.
4. Expand into the mount wp studyfolder.
5. Right click station22 and select Load in Standard Mode .
Measure the thickness of the spacer
1. In Process Simulate, select Tools -> Measurements -> PTP Distance .

2. For the First Object, select the edge of the spacer touching the robot.
3. For the Second Object, select the opposite end of the spacer.

4. Write down the X distance. (i.e. 95.5 mm).
5. Close the Point to Point Distance window.
Mount the gripper to the robot
Note:
The mount command places the mounted object, attaches it to the TOOLFRAME of the
robot, and sets the robot TCPF to the predefined position and orientation on the mounted
object.
Caution:
Notice that we are mounting the gripper to the robot, not the spacer. The spacer will be
attached to the gripper.

2. Select Kinematics -> Mount Tool .
3. In the Mount Tool window for the Tool, select the gripper.
4. For the Frame on the tool, select fr4.
5. For the Frame on the robot, select TOOLFRAME (the default).
Note:
The Mount Tool command is designed to do at least three things: move the tool
into position, attach the tool to the robot TOOLFRAME, and move the robot

TCPF to the pre-defined TCP position and orientation in the tool. However, if the
tool is already in position (and don't want the Mount Tool command to move it,
pick the same frame for the Mounted Tool: Frame and Mounting Tool: Frame.
6. Click Frame by 6 values to the right of the Frame on the robot prompt.
7. Figure out the increased X value by distance measured in the last step (i.e. 1830 +
95.5 = 1925.5). And type that value in.
Note:
It is X because this user interface enters and displays information according to the
Working Frame axes.
8. In the Location window, Click [OK].

Attach the endspacer (one way) to the gripper fixed link
1. Pick the endspacer.

2. Select Modeling -> Attach .
3. (In the Attach window, click One way).
4. For the To Object, select (the fr1 frame of) the gripper.
5. Click [OK].
Tip:
Only the gripper should be mounted to the robot tool frame. All spacers should be
attached to the gripper.

Update the database

2. Make sure that at least Operations is selected.

3. Click [OK].
4. Click [OK].
Note:
In the next activity we will attach the station22 product assembly to the gripper
using a gripper operation. Eventually, this is a tree of what our attachments
(including the tool mount) should be in this Scenario (study):

Activity: Get/Put the Part in the Fixture
The objective of this activity is to create a pick and place path (operation).
Create a new Pick and Place operation

Add a location to the path just created before the first location
Add a location after the last location
Make separate pickup and drop off paths
Sequence the operations
Add a pause event and play the simulation
Reset the simulation and update the database
Create a new Pick and Place operation

2. From the Operation Tree, right click station22 and select Set Current Operation
.
5. Pick station22 from the Operation Tree and release the [Ctrl] key
6. Select Operations -> New Operation —> New Pick and Place Operation .
7. For Pick pose, select st41_clse.
8. For the Place pose, select st41_pick_opn.
9. Pick the frame just below the part for both the Pick and the Place location (it is part
of the fixture).
10. Click [OK]. Operation s420a_PNP_Op1 is created.

Add a location to the path just created before the first location
1. On the Operations Tree, click the pick location.

2. Select Operations -> Path Editing -> Add Location Before .
3. Right click the robot and select Home.
Add a location after the last location
1. On the Operations Tree, click the place location.

2. Select Operations -> Path Editing -> Add Location After .
3. Right click the robot and select Home .
4. Close Robot Jog window.
Make separate pickup and drop off paths
1. On the Operations Tree, drag and drop s420a_PNP_Op1 onto station22 with the
[Ctrl] key depressed.
2. Name one copy Pick up and the other Drop off.
3. Delete the place location from the Pick up operation.
4. Delete the pick location from the Drop off operation.
Sequence the operations
1. In the Sequence Editor, select Pick up.

2. Hold down the [Ctrl] key and select WeldOperation and then Drop off.
4. Click Link .
5. Right click on station22 and select Reorder by Links.
Add a pause event and play the simulation
1. On the Gantt chart of the Sequence Editor, right click on the end of the Pick up
operation and select Pause Event.
2. Enter 0 seconds Before End of Task.

3. Click [OK].
4. From the Sequence Editor, click Play Simulation Forward . The robot should
start at home, move into the fixture, pick up the part, and return to home pose.


4. Click [OK].
5. Click [OK].

Activity: Creating a Rough Mounted Workpiece Path
The objective of this activity is to learn how to rough in the path.
Prepare the mounted workpiece data

Project the MFG features into locations
Associate the locations to the welding frame on the sw40d
Play the simulation
Check reachability
Jump the robot to the reachable locations
Prepare the mounted workpiece data

2. From the Sequence Editor, click Play Simulation Forward to simulate the path.
The robot should start at home, move into the fixture, pick up the part, and return to
home pose.
Project the MFG features into locations
1. From the Operations Tree, click the display status square for the pink
WeldOperation simulative operation.
2. Select the pink WeldOperation simulative operation.
3. Select Weld -> Spot —> Project Weld Points .
Note:
The default approach and perpendicular axis are defined and can be modified by
either clicking Options or by selectingTools -> Options and select the Weld
tab.
4. Click Project on Approximation only.

5. Click Project.
6. Click [OK], and Close.
Associate the locations to the welding frame on the sw40d
Note:
The locations we just created are mounted workpiece locations. So we need to associate the
locations with the welding frame on the sw40d.
1. From the Operations Tree, right click the pink WeldOperation simulative
operation and select Operation Properties .
2. From the Properties window, select the Process tab.
3. For Robot select the S420a robot.
4. For Gun select the green sw40d (i.e. not the gripper).
5. Check the External TCP checkbox.
6. Click [OK].
7. The icon for the weld operation changes (because External TCP was checked).
Play the simulation
1. From the Sequence Editor, click Jump Simulation to Start the simulation
2. Click Play Simulation Forward the simulation. (It pauses after the pickup).
3. Click Play Simulation Forward again.
4. Close the error window.
5. Click Jump Simulation to Start . (We will fix the path in the next activity).
Check reachability
1. Click Play Simulation Forward to move the simulation to the pause event.
3. Select Kinematics -> Reach Test .
5. Look at which locations are blue (fully reachable), yellow (partially reachable), and
red (not reachable).
6. Close the Reach Test window.
Jump the robot to the reachable locations
Note:
Jump the robot to the reachable locations to see how they look (i.e. is the sheetmetal part
colliding with the sw40d) ?

2. Select Kinematics -> Jump to Location to start jump to location Mode).
3. On the Operations Tree, pick each of the locations in order.
4. Select Kinematics -> Jump to Location to end jump to location Mode.
5. Notice that all four locations will need to have changes made to them.
6. Jump Simulation to Start the simulation. (We will fix the path in the next
activity).
7. If the robot does not return to his HOME pose, right click it and select Home .
8. If the product assembly does not go back to its proper start position select
station_22 from the Parts folder of the Object Tree and chooseTools —>
Placement —> Restore Design Relative Location .
9. Click Play Simulation Forward to move the simulation to the pause event.

Activity: Orient the Locations
The objective of this activity is to orient the locations.
Get a better location orientation

Use the pie chart command to verify that the location is reachable
Align the rest of the locations and play the simulation
Get a better location orientation

2. Select location wp4 in the pink WeldOperation simulative operation.
3. Select Weld -> Rotate Locations .

Note:
A shadow of the sw40d may be placed at the location (and the robot will not move)
if only the ped. gun is associated to the weld operation. If both the ped. gun and
robot are associated to the weld operation, then the robot will move to the ped gun.

4. Rotate the weld location (using the yellow arc of the manipulator frame) so that the
sw40d is on the opposite side of the part as the robot.
5. Close the Rotate Location window.
Use the pie chart command to verify that the location is reachable
1. Select location wp5 in the pink WeldOperation simulative operation.

2. Select Weld -> Pie Chart .
Note:
Closed Gun should not be checked.

3. In the Location Pie Chart window, move the slider below the pie left and right until
the longer axis (X-axis) is in the blue (reachable) area of the pie.
4. Close the window.
Note:
This type of reach check considers the reach envelope of the robot, but not
collisions between the part and the sw40d.
Note:

The Rotate Interactively tool considers the collisions between the part and the
sw40d, but the reach envelope of the robot would not be considered.
Align the rest of the locations and play the simulation
Note:
We used one technique to fix the alignment of wp4 and another for wp5. In this case, align
the rest of the locations in the pink WeldOperation simulative operation to match our wp4
reference location.

2. Select Weld -> Align Locations .
3. For Align Selected Locations to, pick the wp4 location you just rotated.
4. Click [OK].
5. Perform the reach test again.
7. From the Gantt chart of the Sequence Editor, right click the pause event and select
Delete .

8. Click Play Simulation Forward .

4. Click [OK].
5. Click [OK].

Activity: Weld Gun Search
The objective of this activity is to use the Weld Gun Search tool in Spot. It is a step-by-
step wizard that guides the user to find the optimum gun for welding.

Start Gun Search
Use weld guns from the resource library
Check if the guns collide
Define the gun search options
Display gun search results
Save the gun results to an Excel file
Insert the resulting gun into the Scenario (study)
1. Process Simulate should already be started, the Robotics Sim Begin (user##)
opened, and the station02 study loaded. If so, skip to step 3.
2. If you are NOT already in Robotics Sim Begin (user##) with the station02 study
loaded:
o Select File —> Close Project, if a different one is open.
o Select Robotics Sim Begin and Click [OK].
o In the Navigation Tree of Robotics Sim Begin (user##), browse to the
Studies studyfolder.
o Browse to the Line ## Study Folder , where ## is the user number
assigned to you by the instructor.
o If not already checked out, right click the Line ## studyfolder and select
Check Out .
o Check Check Out with Hierarchy, and Click [OK].
o Browse into the processing studyfolder.
o Right click the station02 study and select Load in Standard Mode .

Start Gun Search
1. Select Weld -> Geometric Gun Search .
2. In the Geometric Gun Search window, select Next.

3. Select the pink WeldOperation 1 simulative operation from the Operation Tree
that we have used during the first part of class.
4. In the Geometric Gun Search — Targets window, select Next.
Use weld guns from the resource library
1. In the Geometric Gun Search — Select Guns window, select Library from the
Select guns from drop-down.
2. Browse into Resource Library and Robot Tools and Guns and select the
Spotweld Guns library.
Note:
If you have a ResourceLibrary* that is checked out, ignore it for now. This library
contains the new objects that you created in the modeling activities.
3. Click Use .

Note:
Lists of guns can be stored or loaded for later use by clicking either Load Gun Set
or Store Gun Set .
4. Click Next.
Check if the guns collide
Note:
Parts or tooling can be selected for checking the guns against. Gun poses that will be used
at each location can be chosen.
1. From the Object Tree, select the product assemblies being welded. In this case the
parts are surf_part and door_frame.

2. In the Geometric Gun Search — Collision Check window, click Next.
Define the gun search options
1. In the Geometric Gun Search — Options window, uncheck Closed and select Semi-
Open.
2. Check Check gun flipped around approach axis.
3. Check Rotate Gun Around Perpendicular Axis.
4. Enter an Angle of Rotation of 30 degrees.
5. Enter 2 for the Number of steps.

6. Click Next.
Display gun search results
In the Geometric Gun Search — Search window, click Search.

Note:
The picture above is for reference only. Your results may be different. The description of
how to define a resource prototype as a gun is described in the earlier in this course.
Save the gun results to an Excel file
1. Geometric Gun Search — Search window, click Save to File .

2. In the Save As window, browse into the .\sysroot\Documents folder.
3. Name the file according to your user id and Scenario (study) name (i.e.
user##_M11LH_gun).

4. Click Save.
Insert the resulting gun into the Scenario (study)
1. Check the checkboxes for all non-colliding (suitable) weld guns (i.e. ).
2. Click Insert Guns .
3. Click [OK].
Note:
The following guns are inserted into at the origin of the study. (The picture below
shows the guns spread out, when in reality they will be in a big pile at the origin)
4. Click Close to close the Geometric Gun Search window.

5. If you wanted to switch which gun is used, you should fist unmount (Kinematics —
> Unmount Tool) the existing gun on the robot then mount (Kinematics —>
Mount Tool) the new gun. However, we will not do that in this activity.

Instructor Demo: Simulating Robots with Servo Guns
The objective of this activity is to load an existing cell and simulate a robot with servo
guns.
Load the cables servo demo Scenario (study)

Play and reset the simulation
Load the cables servo demo Scenario (study)

2. From the Navigation Tree, expand into the Studies studyfolder.
3. Expand into your Line## Study Folder , where ## is the user number assigned
to you by your instructor.
Note:
In this case the demo can, and should, only be checked out and performed by the
instructor.
4. Check out your assigned studyfolder with hierarchy, if it is not already.

5. Expand into the Other selected studyfolder.
6. Right click cables servo demo and select Load in Standard Mode .
Play and reset the simulation
Note:
The guns in this Scenario (study) are servo guns.
1. In the Operation Tree, right click on cables_servo Demo and select Set Current
Operation .
2. From the Sequence Editor, clickPlay Simulation Forward .
3. Click Jump Simulation to Start it.

Activity: Working with Servo Guns
The objective of this activity is to work with servo guns.
Load the cables servo Scenario (study)

Set the servo gun as an external axis of the robot
Move the robot in front of the location to its left (lo1)
Assign the robot to the path
Assign external values for a location
Simulate it in the Path Editor
Look at the external axis value for the gun in the Path Editor
Update the database
Load the cables servo Scenario (study)

3. Expand into your Line## Study Folder , where ## is the user number assigned to
6. Right click cables servo and select Load in Standard Mode .
7. Right click in the Graphic Viewer and select Display All.
8. Zoom to an area: Hold down the [Alt[ key and draw a box around the r120_3 robot
and its gun (the only robot with an orange gun next to it)
9. Pick an object in the field of the view and select View —> Graphic Viewer —>
View Center .

1. Right click the r120_3 robot and select Joint Jog .

2. Notice the main joint of the servo gun is not shown.
Note:
The main joint of a servo gun, also designated the dynamic or active arm, is
controlled by an electric motor; mounting a servo gun on a robot makes the main
joint an external axis of the robot.
Set the servo gun as an external axis of the robot
1. Select the r120_3 robot.

2. Select Kinematics -> Robot Properties .
Note:
This button can also be found on the right click of a robot.
3. In the Robot Properties window, click the External Axis tab.

4. Notice the servo gun joint does not show.
5. Click the Settings tab.
6. From the Robot Properties window, click Mount Tool .

Note:
The same Mount Tool command can be accessed from the Robot Properties
window, the Kinematics menu, Kinematics toolbar, or the robot right click.
7. Pick the gun for this robot.

8. For the Frame on the gun, select the mtg frame.
10. Click the External Axes tab again. Notice the servo gun joint does show.
Note:
If it does not show, close and reopen the Robot Properties window again.
11. In the Robot Properties window, click Close.
Move the robot in front of the location to its left (lo1)
1. Right click the robot and select Joint Jog .

2. Notice the main joint of the servo gun is shown.

3. From the Joint Jog window, jog external joint j1 (srtc_u0181_l1).
4. Notice the main point of the servo gun moves.
Tip:
Leave the Joint Jog window open throughout this activity and do not reset this joint
value at this time.
Assign the robot to the path
1. From the Operations Tree, browse and right click pa3 and select Operation
Properties .
2. In the Properties window, click the Process tab.
3. Select the r120_3 robot.
4. click [OK]
Assign external values for a location
1. From the Operations Tree, browse and select the first location of pa3 (r3pounce).
2. Select Kinematics -> Set External Axes Values .

3. In the Set External Axes Values window, check the Approach Value checkbox.
Note:
The current value for the external axis joint is automatically copied from the Joint
Jog window to the Approach Value field in the Set External Axes Values window.
4. In the Joint Jog window, move the slider for the j1 (srtc_u0181_l1) joint to a
different value.
Note:
In this case we want to have a different value for the external axis when
approaching and departing from this location.
5. In the Set External Axes Values window, check the Depart Value checkbox.
Note:
The current value for the external axis joint is automatically copied from the Joint
Jog window to the Depart Value field in the Set External Axes Values window.
Note:
You can also, just type the desired value into this field. Or if several locations need
the same value you can copy and paste the value to the other fields (using right click

copy/paste or [Ctrl]-[C] / [Ctrl]-[V]). Finally, the Follow Mode and Get
Current Joint Value can be used as well.
6. In the Set External Axes Values window, Click [OK].

7. Click Next Location .
8. Enter the Approach Value and Depart Value for this location using the desired
technique.
9. Repeat for two or three locations
Simulate it in the Path Editor
1. In the Operations Tree, select the pa3 simulative operation

2. From the Path Editor, click Add Operations to Editor .
Note:
Another way to add a path to the Path Editor is to drag and drop it here from the
Operations Tree.
3. Click Play Simulation Forward .

Look at the external axis value for the gun in the Path Editor
1. On the Path Editor, click Customize Columns .

2. In the Customize Columns window in the Available columns list, expand into the
General group of attributes.
3. Select Depart External Axes Values and External Axes Values and click Add.
Note:
This list of attributes can be saved and loaded for later use using these buttons:
and .
4. In the Customize Columns window in the Available columns list, expand into the
General group of attributes.
5. Add any other desired columns such as Joint Speed, Motion Type, and Zone.
6. Click [OK].

7. Scroll to the right and locate the Depart External Axes Values or External Axes
Values columns.
8. Mouse over the pencil icon in the Depart External Axes Values or External Axes
Values columns to see the external axis joint values for each location.
Update the database


3. Click [OK].
4. Click [OK].
MATERIAL HANDLING APPLICATIONS
Activity: Pick and Place (Material Handling) Setup
The objective of this activity is to setup the pick and place (material handling) simulation.
Load the PNP Study

Mount the gripper to the robot using the Mount Tool window
Duplicate the boxes
Update the database
Load the PNP Study

From the Navigation Tree, expand into the Studies collection.
Expand into your Line## Study Folder where ## is the user number assigned to
Check out your assigned studyfolder with hierarchy, if not already checked
out.
Expand into the other selected studyfolder.
Right click pnp and select Load in Standard Mode .
Right click in the Graphic Viewer and select Display All .
Mount the gripper to the robot using the Mount Tool window

2. Select Kinematics -> Mount Tool .
3. In the Mount Tool window for the Tool, select the box gripper.
4. For the Frame on the tool, select mnt.
5. For the Frame on the robot, select TOOLFRAME.
Duplicate the boxes
1. With the robot facing you (and the container in front of the robot), pick the box on
the left conveyor. Notice it is named box24x24x12_left1.
2. With the robot facing you (and the container in front of the robot), pick the box on
the right conveyor. Notice it is named box24x24x12_right1.
3. Pick the box24x24x12_left1.
5. Pick the box24x24x12_right1.
Note:
In the WKP215 course (for intermediate users) we will describe how to create
appearances of the parts so that copies do not need to be created and managed. We
will also use logic to determine the next path instead of the hard coded sequence
described here. But, hey, you've got to start somewhere.
8. In the Duplicate Objects window for Number along X, enter 2.

9. In the Duplicate Objects window for X spacing, enter 0.
10. Click [OK].
Note:

This make another copy of the boxes in their current position.
11. From the Object Tree, rename the left box duplicate to box24x24x12_left2.
12. From the Object Tree, rename the right box duplicate to box24x24x12_right2.
13. From the Object Tree, blank box24x24x12_left2.
14. From the Object Tree, blank box24x24x12_right2.
Update the database

2. Make sure that Parts, Operations, and Resources are selected.
3. Click [OK].
4. Click [OK].

Activity: Create the Basic (PNP) Process
The objective of this activity is to create a basic collection of pick and place paths
(operation) for one box from the left and one from the right.
Create a new Pick and Place operation for the left box
Check Reachability
Again, make separate pickup and drop off paths
Stick the part to the gripper
Add a location before/after the pick (left1) location
Add a location before/after the place (drop left bottom) location
Sequence the operations for the first pass
Simulate the pnp path so far
Rotate the Place location and its approach/retract locations
Create a new Pick and Place operation for the left box

4. In the Operation Tree, pick pnp.
6. Select Operations -> New Operation —> New Pick and Place Operation .
7. For Pick pose, select CLOSE.
8. For the Place pose, select OPEN.
10. For Pick, choose the part on the left

12. For Place, choose near the middle of the left third of the bottom.

13. Click [OK] to create operation kawasaki_uz100_PNP_Op1.
Check Reachability
1. Select the container.

3. Pick the location in the container.
5. Right click the highlighted objects and select Placement Manipulator.
7. Select Kinematics —> Reach Test.
8. Pick the kawasaki_uz100_PNP_Op1 simulative operation.
9. In the Graphic Viewer, grab the X axis of the Manipulator Frame and drag it
toward the robot until the place location gets a blue check in the Reach Test
window.
10. Close the Placement Manipulator window and the Reach Test window.

Again, make separate pickup and drop off paths
1. On the Operations Tree, drag and drop kawasaki_uz100_PNP_Op1 onto pnp with
the [Ctrl] key depressed.
2. Name one copy kawasaki_uz100_pick_left1 and the other
kawasaki_uz100_drop_left_bottom.
3. Delete the place location from the kawasaki_uz100_pick_left1 operation.
4. Delete the pick location from the kawasaki_uz100_drop_left_bottom operation.
Stick the part to the gripper
1. In the Operation Tree, right click kawasaki_uz100_pick_left1 and select Set

Current Operation .
Tip:
As long as you don't jump the simulation to the beginning, the attachment will
remain.
Add a location before/after the pick (left1) location
1. On the Operations Tree, click the pick location.

3. In the Robot Jog window, click Z.
4. Enter 600 and press [Enter].
Note:
600 mm approximately equal to 24 inches.

6. On the Operations Tree, click the via location.
7. Drag and drop it on kawasaki_uz100_pick_left1 with the [Ctrl] key depressed.
Add a location before/after the place (drop left bottom) location
1. On the Operations Tree, click the place location.

3. In the Robot Jog window, click Z.
6. Drag and drop it on kawasaki_uz100_drop_left_bottom with the [Ctrl] key
depressed.
Sequence the operations for the first pass
1. In the Operation Tree, right click pnp and select New Compound Operation.
2. In the New Compound Operation window for Name, enter FirstPass.
3. Move the two robotic operations into the FirstPass compound operation.
4. In the Operation Tree, right click pnp and select Set Current Operation .
5. Click [OK] to reset the simulation.
6. In the Sequence Editor, select kawasaki_uz100_pick_left1.
7. Hold down the [Ctrl] key and select kawasaki_uz100_drop_left_bottom.
9. Click Link .
10. In the Sequence Editor, right click first pass and select Reorder by Links.
Simulate the pnp path so far
pick up the box and put it into the container.
Note:
Notice that when the robot puts the box into the container, it collides with side of
the box. (You can step the simulation backwards or setup and turn on collision
detection to see it). This problem can be easily solved by rotating the place location
(and its approach/retract locations) 90 degrees. We will do this in the next step.

2. Click Jump Simulation to Start the simulation.
Rotate the Place location and its approach/retract locations
1. On the Operations Tree, pick all three locations in the

kawasaki_uz100_drop_left_bottom simulative operation with the [Ctrl] key
depressed.
Note:
A simulative operation is a generic term for the operations created by Process

Simulate to represent a simulation. In this case the simulative operation is a robot
operation.
2. Select Tools —> Placement —> Placement Manipulator .

3. In the Placement Manipulator window, click Rz.
5. Click Close
pick up the box and put it into the container. This time the place location is rotated
90 degrees.



4. Click [OK].
5. Click [OK].

Activity: Stacking Boxes
The objective of this activity is to build on the results of the previous activity. After this
activity we will have 2 rows or 2 boxes in he container.
Create a new Pick operation for the right box

Move the path's locations to the right side
Create a new Place operation for the right box
Move the path's locations to stack the box on the left top
Farther sequence the operations of the first pass
Add Display Events
Create a new Pick operation for the right box

3. Drag and drop the kawasaki_uz100_pick_left1 to the FirstPass with the [Ctrl] key
depressed.
4. Rename the duplicate operation to kawasaki_uz100_pick_right1.
Move the path's locations to the right side

kawasaki_uz100_pick_right1 simulative operation with the [Ctrl] key depressed.
Note:

operation.
2. Select Tools —> Placement —> Relocate .

4. Pick in the From frame field.

5. Choose the Pick location for the part on the left.
6. Pick in the To frame field.

7. Choose the part on the right
8. Click Apply and Close
Create a new Place operation for the right box
1. Drag and drop the kawasaki_uz100_drop_left_bottom to the FirstPass with the

[Ctrl] key depressed.
2. Rename the duplicate operation to kawasaki_uz100_drop_left_top.
Move the path's locations to stack the box on the left top

kawasaki_uz100_drop_left_top simulative operation with the [Ctrl] key
depressed.
Note:

operation.

3. Change the Pick Intent to Snap.
4. In the Placement Manipulator window, click Z.

5. Enter 304.8 and press [Enter].
Note:
This number was found by measuring the height of the box.
6. Click Close
Farther sequence the operations of the first pass
1. In the Sequence Editor, select kawasaki_uz100_drop_left_bottom.

2. Hold down the [Ctrl] key and select kawasaki_uz100_pick_right1 and
kawasaki_uz100_drop_left_top.
4. Click Link .

5. Click Jump Simulation to Start , if needed.
pick up the each box and stack them in the container.
Add Display Events
1. Reset the simulation.

2. If not blanked already: from the Object Tree blank box24x24x12_left2 and
box24x24x12_right2
3. on the Gantt chart of the Sequence Editor, right click on the end of the FirstPass
compound operation and select Display Event.
4. For the Display Event window, pick the box24x24x12_left2 and
box24x24x12_right2 objects from the Object Tree.
5. For the Start Time, enter 0 seconds Before End of Task
6. Click [OK].


4. Click [OK].
5. Click [OK].

Activity: Doing the Second Pass (Optional Activity)
The objective of this activity is to create a process for the second stack of boxes.
Create a new Pick and Place operations for the second set of boxes
Move the Place operations for the second stack
Sequence the operations of the second pass
Simulate the first and second pass
Create a new Pick and Place operations for the second set of boxes

3. Drag and drop the FirstPass to the pnp with the [Ctrl] key depressed.
4. Rename the duplicate operation to SecondPass.
Move the Place operations for the second stack
1. On the Operations Tree, browse into the SecondPass.

kawasaki_uz100_drop_right_top and all three locations in the
kawasaki_uz100_drop_right_bottom simulative operations with the [Ctrl] key
depressed.
Note:

operation.

5. In the Placement Manipulator window, click Y.

6. Enter –800 and press [Enter].
Note:

To put the stack for the second pass in the other half of the box
7. Click Close
Sequence the operations of the second pass
1. In the Sequence Editor, select FirstPass.

2. Hold down the [Ctrl] key and select SecondPass.
4. Click Link .
Simulate the first and second pass
1. Click Jump Simulation to Start , if needed.

2. From the Sequence Editor, clickPlay Simulation Forward . The robot should
pick up the each box and stack them in the container.


4. Click [OK].
5. Click [OK].

CONTINUOUS APPLICATIONS
Activity: Using Continuous Feature Operations
The objective of this activity is to use continuous feature operations.
Create a new Continuous Feature Operation

Assign a Continuous Mfg to the Continuous Feature Operation
Now reload the arc 7th axis Scenario (study)
Look at the Continuous Mfg in the MFG Tree
Associate the robot and tool (arc weld gun) to the Continuous Feature
Compare the orientation of assigned TCPF with the parameters for locations that will be
created
Begin creating the continuous seam and continuous seam locations
Flip the locations
Update the database
Create a new Continuous Feature Operation
1. In the Navigation Tree, browse into the Process and Plant collection.
2. Right click the Robotics operation tree and select Navigation Tree .
3. In the new Navigation Tree (2), browse into your Line## area (where ## is the user
number assigned to you by your instructor) and locate the arc 7th axis station under
Other Selected.

4. Check out your arc 7th axis station, if it is not already.
5. Right click it and select New .
6. Check the checkbox for ContinuousFeatureOperation.
7. Click [OK].
8. Expand arc 7th axis to show the new ContinuousFeatureOperation.
Assign a Continuous Mfg to the Continuous Feature Operation
1. In the original Navigation Tree, browse into the Welds collection.

2. Right click the Continuous MfgLibrary and select Navigation Tree.
Note:
The Continuous MFG has a geometric line associated to it. It will be the basis for
the path generated from the Continuous Feature Operation that it is associated to.
3. In the new Navigation Tree (3), drag and drop the 7a1 continuous Mfg feature in
the library onto the new ContinuousFeatureOperation.
4. Rename it to Continuous MFG Operation.
5. Close the two new Navigation Tree viewers.
Now reload the arc 7th axis Scenario (study)
1. Now reload the arc 7th axis Scenario (study) from the Other selected
studyfolder.
3. Check out your assigned studyfolder with hierarchy, if it isn't already.

5. Right click arc 7th axis (not demo) and select Load in Standard Mode .
Look at the Continuous Mfg in the MFG Tree
1. In Process Simulate, notice the Mfg Features in the Graphic Viewer.

2. Select View -> Viewers -> Mfg Viewer.
3. In the Mfg Viewer, click the down arrow to the right of the Filter and select
ContinuousMfg.
4. Notice the Mfg Features in the Mfg Viewer.
1. In the Mfg Viewer, click Customize .

2. In the Field Selection window, select Projection Indication and Assignment
indication attributes under Mfg Viewer Fields and move them to the Available
Fields list.
3. Click [OK].
Associate the robot and tool (arc weld gun) to the Continuous Feature
1. In the Operations Tree, right click on the Continuous Feature Operation and
select Operation Properties .
2. In the Properties window, click the Process tab.
3. Click in the Robot field, and select the other robot (the one not used by the spot
simulation).

4. Click [OK].
Compare the orientation of assigned TCPF with the parameters for locations that will be
created

2. In the Options window, click the Continuous tab.
Note:

Notice that the setup for continuous MFG projection is on a different tab than the
spot weld project setup (located on the Weld tab of the Options window).
3. For thePermitted Deviation Angle (Normal), enter 360 degrees.

4. Click [OK].
Begin creating the continuous seam and continuous seam locations
1. In the Operations Tree, select the Continuous Feature Operation.

2. Select Weld -> Continuous -> Project Continuous MFG Features .
Note:
o Maximal Segment Length – Maximum allowable distance between two

location created when projecting a Continuous MFG Feature.
o Maximal Tolerance – Maximum allowable distance between a location and
the curve that defines the seam geometry.
3. For Maximal Segment Length, enter 3000.
4. Check Project on approximation only.

5. Click Project.

6. Close the Project Continuous Mfgs window.
7. Look at the results in the Graphic Viewer and Operations Tree.
Note:
One continuous seam operation is created for each continuous MFG feature
assigned to the continuous MFG feature operation. The continuous seam operation
contains continuous seam location operations (the number of which was determined
by the length of the geometry assigned to the MFG feature and its curvature).
Flip the locations
1. In the Operation Tree, select ls1 (the first continuous mfg location).
2. Hold down the [Ctr] key and select ls2 (the second continuous mfg location)
4. Select Weld —> Flip Locations —> Flip Locations on Surface .
Note:
We will mount the gun on the robot, put the robot on the rail, and check robot reach
later in this course.
Update the database


3. Click [OK].
4. Click [OK].

Activity: Creating Arc MFGs for the Whitehouse Part
The objective of this activity is to create the Mfg Features needed in order to create the
continuous Mfg features to be used for arc weld seams
Load the ―arc multi axis‖ Scenario (study)

Get the view setup to create the arc MFG feature
Create the Geometry for Arc Continuous Mfg Feature
Create the Arc Continuous Mfg Feature
Load the ―arc multi axis‖ Scenario (study)
Note:
Now perform the activity by first loading the arc multi axis Scenario (study) from the
other selected studyfolder.
1. From the Navigation Tree, expand into the Studies collection.

5. Right click arc multi axis (not demo) and select Load in Standard Mode .
6. Select View -> Display All .

Get the view setup to create the arc MFG feature
1. In the Objects Tree, expand into the Parts and Resources folders.

2. From the Parts folder, select the FRONT_whitehouse_weldpart part in the
Arc multi axis compoundPart (the product assembly sitting on the positioner).
4. From the Resources folder, select the st_gun3_30 gun (the arc weld torch at the
end of the robot's wrist) in the Arc multi axis compoundResource.
6. Select View —> Display Only .
7. Pick off the objects to deselect them.
8. In the Graphic Viewer (or Object Tree), right click on the
FRONT_whitehouse_weldpart part (the curved part in the assembly on the
positioner) and select Zoom to Selection .
Create the Geometry for Arc Continuous Mfg Feature
Note:
More is described on modeling objects earlier in this in the course.
1. Select the FRONT_whitehouse_weldpart part, if it is not already selected.

2. Change your view point so that you are looking at the bottom of the part.
Note:
This can be done by hold down the right and middle mouse buttons and moving
your hand in a circle; or by clicking the [down arrow] key about three times.
3. Zoom in on the bottom edge of the part.
Note:
This can be down by holding down the middle button and moving the mouse to the
right; or by holding down the [Alt] key and drawing a zoom window with the left
mouse button.

5. Change the Pick Level to Entity.
7. Select Modeling —> Create 2D —> Curve on Borders .

8. In the Curve on Borders window for Name, enter
Front_Whitehouse_ArcSeams_user##.
9. In the Curve on Borders window, pick the Entity field.
10. For Entity, pick the bottom face of the solid not near an edge.

11. Click Preview.
Warning:
If the curve is not created along the bottom face of this solid, pick it again and click
Preview.
12. Click [OK].

Note:
The new Front_Whitehouse_ArcSeams_user## curve is created in the

FRONT_whitehouse weldpart. However, we will not store this change
permanently in this part. Instead, we will store this geometry into a separate .COJT
related to a continuous MFG feature (in the next page of this activity).
Note:
In this activity we used the Modeling —> Create 2D —> Intersection Curve
command to create the curve. Other commands could have also been used to create
the curve. Or the curves can be created in a CAD system, converted to a .COJT, and
associated to an existing MFG feature.
Create the Arc Continuous Mfg Feature
1. From the Object Tree or Graphic Viewer, select the

Front_Whitehouse_ArcSeams_user## curve.
2. Select Weld —> Continuous —> Create Continuous Mfg from Curve .
3. In the Create Continuous Mfg from Curve window, pick the Assign to part field.
4. Pick the BOTTOM_whitehouse_weldpart part from the Object Tree.
Note:
When we create the arc weld seam the FRONT part will be the side wall and
BOTTOM part will be the bottom wall. We derived the curve from an edge of the
FRONT part. Therefore, it is suggested to associate the MFG feature containing the
curve with the BOTTOM part. Eventually we will associate both parts with the
MFG feature, however the MFG will move only with the assigned part.
5. For 3D folder location, click Browse and select the .\sysroot\Libraries\mfgs

folder.
Note:
In production, the exact folder name could be anything under the system root folder.
However, you should create a standard for what to name the MFG features and
where they should be placed.

6. Click [OK].
Note:
This command will create a new .JT file (in a .COJT folder) that will contain this
curve. This .COJT will be associated to a new MFG feature which will be shown in
the MFG Viewer. After executing this command we can either delete this curve
from the original part (FRONT_whitehouse_weldpart) or just reload the original
part. We will do this later.
7. To see the Mfg Feature just created, select View —> Viewers —> Mfg Viewer.
8. Continue to the next whitehouse part activity on creating a debur MFG feature.

Activity: Creating Debur MFGs for the Whitehouse Part
continuous Mfg features to be used for debur paths. A similar process could be followed to
create glue paths.
Create the Geometry for Debur Continuous Mfg Feature

Create the Debur Continuous Mfg Feature
Create the Geometry for Debur Continuous Mfg Feature
Note:
1. Continue from where the last whitehouse part activity left off.
2. Change your view point so that you are looking at the top of the part.
Note:
your hand in a circle; or by clicking the [up arrow] key about three times.

Note:
We are still modeling the part from the previous activity and the Pick Level is still
set to Entity.
4. Select Modeling —> Create 2D —> Curve on Borders .

5. In the Curve on Borders window for Name, enter
Front_Whitehouse_Debur_user##.
6. In the Curve on Borders window, pick the Entity field.
7. For Entity, pick the top face of the solid not near an edge.

8. Click Preview.
Warning:
If the curve is not created along the front face of this solid, pick it again and click
Preview.
9. Click [OK].
Note:
The new Front_Whitehouse_Debur_user## curve is created in the

FRONT_whitehouse weldpart. However, we will not store this change
permanently in this part. Instead, we will store this geometry into a separate .COJT
related to a continuous MFG feature (in the next page of this activity).

Note:
In this activity we used the Modeling —> Create 2D —> Intersection Curve
command to create the curve. Other commands could have also been used to create
the curve. Or the curves can be created in a CAD system, converted to a .COJT, and
associated to an existing MFG feature.
Create the Debur Continuous Mfg Feature

Front_Whitehouse_Debur_user## curve.
4. Pick the FRONT_whitehouse_weldpart part.
Note:
In this case the MFG feature will only be associated with one part (not like the arc
weld seam that is associated to two parts).

folder.
Note:

6. Click [OK].
Note:
8. Continue to the next whitehouse part activity to create the Paint MFGs.

Activity: Creating Paint MFGs for the Whitehouse Part
continuous Mfg features to be used for paint paths.
Create the Geometry for Paint Continuous Mfg Feature

Create the Paint Continuous Mfg Feature
Reload the FRONT whitehouse weldpart
Update the database
Create the Geometry for Paint Continuous Mfg Feature
Note:
1. Continue from where the last whitehouse part activity left off.
2. From the Mfg Viewer, blank both MFG features by clicking their display status
squares .
Note:
Later in this activity we want to pick the curves of the

FRONT_whitehouse_weldpart part not of the MFG features.
3. Change your view point so that you are looking at the top of the part.
Note:
your hand in a circle; or by clicking the [down arrow] key about one time.
Note:
We are still modeling the FRONT_whitehouse_weldpart part from the previous

activity and the Pick Level is still set to Entity and the Pick Intent is set to Snap.
4. Select Model —> Create 2D —> Split Curve on Intersection .

5. From the Graphic Viewer, pick the Front_Whitehouse_ArcSeams_user## (the
curve along the bottom edge of the part).
6. In the Split Curve on Intersection window, select Split point.
7. Select the lower left corner of the front face of the FRONT_whitehouse_weldpart.

9. Click [OK].
Note:
The Front_Whitehouse_ArcSeams_user## curve is deleted and the

Front_Whitehouse_ArcSeams_user##_1 straight line and
Front_Whitehouse_ArcSeams_user##_2 curve are created.

10. Follow the same process to split the Front_Whitehouse_ArcSeams_user##_2
curve again. This time for the Split point, pick the lower right corner of the front
face of the FRONT_whitehouse_weldpart
Note:
The Front_Whitehouse_ArcSeams_user##_2 curve is deleted and the

Front_Whitehouse_ArcSeams_user##_2_1 and
Front_Whitehouse_ArcSeams_user##_2_2 curves are created. We will use the
curve across the front of the part.
11. Select Front_Whitehouse_ArcSeams_user##_2_1 curve, press [F2], and change

the name of this curve to Front_Whitehouse_Paint_user##.
12. Select the Front_Whitehouse_Paint_user## curve.
13. Select Modeling —> Duplicate Objects.
14. In the Duplicate Objects window for Number along Z, enter 3.
15. In the Duplicate Objects window for Z Spacing, enter 50.
16. Click Preview.
17. Click [OK].
Note:

The new Front_Whitehouse_Paint_user##_1 and
Front_Whitehouse_Paint_user##_2 curves are created in the
FRONT_whitehouse_weldpart only along the front face. However, we will not
store this change permanently in this part. Instead, we will store this geometry into a
separate .COJT related to a continuous MFG feature (in the next page of this
activity).
Note:
In this activity we just copied the same curve across the part. Another option would
have been to create a box that is bigger than the part, move one of its faces to the
desired position on the part and then use the Modeling —> Create 2D —>
Intersection Curve command to create the curve. Or the curves can be created
in a CAD system, converted to a .COJT, and associated to an existing MFG feature.
Create the Paint Continuous Mfg Feature

Front_Whitehouse_Paint_user##_1 curve.
Front_Whitehouse_Paint_user##_2 curve.
7. Pick the FRONT_whitehouse_weldpart part.
Note:
In this case the MFG feature will only be associated with one part (not like the arc
weld seam that is associated to two parts).

folder.
Note:

9. Click [OK].
Note:

Reload the FRONT whitehouse weldpart
2. Select the FRONT_whitehouse_weldpart.

3. Select Modeling —> Reload Component .
Note:
This command will undo all changes made to this object since that last time it was
saved.
4. Click Yes.
Update the database


3. Click [OK].
4. Click [OK] again.

Activity: Creating Arc Seams for the Whitehouse part (using Project Arc
Seam)
The objective of this activity is to create seams using the MFG Features created in the
previous activity.
Setup Continuous Features

Set the Start Point and Direction
Create the simulative operation and seam
Split off the seam along the bottom front edge
Update the database
Setup Continuous Features

2. Select Tools —> Options.
3. In the Options window, click the Continuous tab.
4. For the Movement Vector, select Y.

5. Click [OK].
Set the Start Point and Direction

1. From the Mfg Viewer, select the Front_Whitehouse_ArcSeams_user## Mfg
feature.
2. Select View —> Display Only .
3. Select Weld —> Continuous —> Indicate Seam Start .
4. In the Indicate Seam Start window, pick in the Start point field.
5. For Start Point, pick in the Graphic Viewer in the lower left corner of the
Front_Whitehouse_ArcSeams_user##_Mfg Mfg feature.
Note:
A red point is shown at the pick point
6. In the Indicate Seam Start window, pick in the Via direction point field.
7. For Via direction point, pick a point in the Graphic Viewer about half way across
the bottom edge of the front of the Front_Whitehouse_ArcSeams_user##_Mfg
Mfg feature.
Note:
A blue point is shown at the pick point

8. Click [OK].
Create the simulative operation and seam
Note:
A simulative operation is a generic term for the operations created by Process Simulate to
represent a simulation. In this case the simulative operation is a robot operation.
1. From the Object Tree, display the BOTTOM_whitehouse_weldpart and

FRONT_whitehouse_weldpart parts by clicking its display status square .
3. From the Mfg Viewer, select the Front_Whitehouse_ArcSeams_user##_Mfg Mfg

feature.
4. Hold down the [Ctrl] key and select Arc multi axis in the Operation Tree.
6. Select Operations —> New Operation —> New Continuous Feature Operation
.
7. For Name, enter Front_ArcSeams_Op.
8. Click [OK].
Note:
An ―empty‖ (but special) compound operation is created named

Front_ArcSeams_Op.

9. Right click the FRONT_whitehouse_weldpart and select Placement
Manipulator.
10. In the Placement Manipulator window, pick Z, enter —0.2 and press [Enter].
11. Click Close.
12. From the Operations Tree, select the pink Front_ArcSeams_Op simulative
operation.
13. Select Weld —> Continuous —> Project Arc Seam .
14. In the Project Arc Seam window, expand below the
Front_Whitehouse_ArcSeams_user##_Mfg MFG feature.
15. Pick on the Front_Whitehouse_ArcSeams_user##_Mfg MFG feature and click

Edit Mfg Feature data .

16. In the Edit Mfg Feature Data window, pick the Side part field.
17. From the Object Tree or Graphic Viewer, pick the FRONT_whitehouse_weldpart.
Note:
If you have selected the wrong parts for the Base part or Side part, click Swap
Parts . By default the Base part is the part that is assigned to the MFG feature.
This is the part that controls the placement of the MFG feature. To change the
assigned part (before opening the Project Arc Seam window), select Weld —>
Assign Parts.
18. Click [OK] to close the Edit Mfg Feature Data window.
19. Verify the General Arc Alignment Parameters are as desired.
Note:
We will keep the defaults in this case. However, in production you may want to
change them in order to push or drag the arc torch.
20. Click Project.

21. Click Close.

Split off the seam along the bottom front edge
1. Select Weld —> Continuous —> Split Seam Operation .

2. In the Split Seam Operation window for Operation, select the
Front_Whitehouse_ArcSeams_user##_Mfg_op just created, (where ## is the user
number assigned to you by your instructor).
3. For Split location, pick the location along the bottom front edge on the opposite
end from the start point (on the right).

Note:
The split location will be added to both seams resulting from the split.
4. Click [OK].
Note:
Now there are two seams in the Front_ArcSeams_Op.
Update the database


3. Click [OK].
4. Click [OK].


WKP115S Activities PDF

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WKP115S-Process Simulate Basic

2 WKP115S-Process Simulate Basic Robotic Simulation

3 WKP115S-Process Simulate Basic Robotic Simulation

4 WKP115S-Process Simulate Basic Robotic Simulation

5 WKP115S-Process Simulate Basic Robotic Simulation

Activity: Starting Process Simulate and Opening the Basic Project

Login to database using your eMS user ID

Login to database using your eMS user ID

2. Double click on the Process Simulate desktop icon.

3. Login (using your eMS database login ID) with no password.

User Type eMS User ID

7 WKP115S-Process Simulate Basic Robotic Simulation

Open your Basics Project

8 WKP115S-Process Simulate Basic Robotic Simulation

Set the background color to black

Set the background color to black

1. In Process Simulate, select Tools -> Options.

9 WKP115S-Process Simulate Basic Robotic Simulation

Set the mouse movement mode to Continuous

10 WKP115S-Process Simulate Basic Robotic Simulation

1. In the Options window, select the Graphic Viewer tab.

2. Select Continuous viewing to change the Process Simulate graphics manipulation

Check the system root settings

11 WKP115S-Process Simulate Basic Robotic Simulation

2. Click [OK] to close the Options window.

12 WKP115S-Process Simulate Basic Robotic Simulation

The objective of this activity is to create a high-level Operation Tree.

Create the top level of the Operation Tree (1)

Create the top level of the Operation Tree (1)

1. Expand the Basics Project — user## project.

8. In the New window, click [OK].

13 WKP115S-Process Simulate Basic Robotic Simulation

Add two stations to it (to hold their operations)

5. In the New window, click [OK].

14 WKP115S-Process Simulate Basic Robotic Simulation

The objective of this activity is to create a high-level Resource Tree.

Create the top level of the Resource Tree (2)

Create the top level of the Resource Tree (2)

7. In the New window, click [OK].

15 WKP115S-Process Simulate Basic Robotic Simulation

Add two stations to it (to hold their resources)

5. In the New window, click [OK].

16 WKP115S-Process Simulate Basic Robotic Simulation

The objective of this activity is to associate the structures together.

Resource Assignment: Associate the Resource Tree and Operation Tree

Resource Assignment: Associate the Resource Tree and Operation Tree

Normally we would not do the assignment at the top level. .

1. Unpin the Sequence Editor viewer to make more room.

17 WKP115S-Process Simulate Basic Robotic Simulation

Adding Resources to the Resource Tree

18 WKP115S-Process Simulate Basic Robotic Simulation

Look at the Object Types

Look at the Object Types

1. Look through the folders of the Navigation Tree viewer.

19 WKP115S-Process Simulate Basic Robotic Simulation

Open the Part Library using the Navigation Tree viewer

Open the Part Library using the Navigation Tree viewer

Look at a Part Prototype’s properties

1. Right click a PartPrototype object in the PartLibrary and select Properties .

20 WKP115S-Process Simulate Basic Robotic Simulation

Use the magnifying glass to see the instance/prototype relationship

Look at a Part Instance’s properties

21 WKP115S-Process Simulate Basic Robotic Simulation