Large assembly handling in Pro/Engineer

@ Tetra Pak

Fredrik LagoTetra Pak

Peter GustafssonCIROX Consulting

Agenda

~ 30 min• What is a large assembly?• Application areas• Large Assembly Approach

@ Tetra Pak

~ 15 min• Tips & Tricks &

General good practice

A large assembly…

No such definition exists! All above correct.

–has more than XX (unique) parts and YY subassemblies– take more than XX minutes to load– take more than X GB of disk-space–consumes more than X MB of RAM-memory– take more than XX minutes to check out from Intralink–…

Tetra Pak rule of thumb: Large assembly > C-group

What is a large assembly?

Symptoms

Graphics–Repainting of screen takes forever–Viewing and navigation is almost impossibleTime–Regeneration –Retrievel in Pro/E–Check-out from INTRALINK (>1 hour)File-size (on disk)

Most criticalRAM memory–Pro/E OS memory limit

Operating SystemWindows single process limitation

Tetra Pak 2005Win32 + Pro/E 32bit– XTOP limited to ≈ 1,7 GB

Win32 + ”tweak” + Pro/E32– XP tweak ≈ 3 GB

http://support.microsoft.com/kb/316739/EN-US/http://support.microsoft.com/default.aspx?scid=kb;en-us;Q319043

– Physical memory (RAM) > 2GB recommended

Win64XP + Pro/E64 (from M160)– 18.4 Billions GB theoretical limit for 64-bit system!

Application areas

Application areas

Priority 1

Drawings– Safety Sign drawings

(legal requirement)– Installation- and ”footprint”-drawings

Simulations–Mechanism, Mechanica etc– Interface and interference checks (B-group to B-group)Visualization–Rendered images–Real-time renderingsOther

Background

Background

Tetra Pak MachinePart Count >10 000Part # Count > 5 000Typically 5-7 B-groups

8-12 C0-groups5-15 C1-groups3-5 C2-groups

Yields ~ 2000-3000 Pro/E assembly-files

Mechanical Designers~ 450 active Pro/E users~ 20 independent design teams with total responsibility

Large Assembly Method -LAM

Toolchest

• Family tables• Interchange groups• Accelerator files• Layout• Envelope• Zone• Substitute• Simplified representation• Graphics representation• Geometry representation

Variant handling

Top down design

Reduction of necessary information

• Skeleton• Copy geometry• Publish geometry• Inheritance features• Snapshot drawing views• Drawing view manager• Component display• “dumb” parts• Shrinkwrap• …

Top Down Design

Detailing

Memory reduction

Large Assembly ApproachCombined Top Down / Bottom Up

Simplified rep (Bottom up)– Definition rules to filter and reduce complexity

Shrinkwrap (Bottom up)– Associative– Surface subset– Defined on C-level

General structure (Top Down)– Parallell ”help assembly” used to define and control assembly

structure– Template for variant handling

Interchange groups (Top Down)– Container for variants and lightweight groups

LAM cont.OPGL- Operational Guidelines

General structure (Top Down)– Assembly structure without detailed

components– Parallell ”help assembly”– Template for variant handling– Reference parts (similar to skeleton)

LAM cont.OPGL- Operational Guidelines

Interchange Groups– ”Collector” for variants and

lightweight groups

LAM cont.OPGL- Operational Guidelines

Simplified representationDefault reps

•Master•Geometry •Graphics

Gra

ph

ics

Geo

metr

y

View only

No modification or re-define

Modify possible

No create or re-define

Measure

Create / Redifine

Analyse

Modify

Mast

er

• On-Demand Simplified Rep• Set config option to enable referencing to

geometry reps in drawingsallow_refs_to_geom_reps_in_drw = yes

* Based on Tetra Pak data

25 % reduction*

18 % reduction*

Simplified representationDefinition rules

•Rulebased way of selecting and filtering components•Rules can be added to each other

Used in LAM to reduce assemblies before Shrinkwrap models are exported

Warning!Never use in combination with ‘substitute’Instead ‘Copy Snapshot’

5 good start value

Turn off if strange behavior

ShrinkwrapReplacement of assembly by part

Two types:Shrinkwrap model‘Save as’ to create part

– Two definitions;Surface subset (recommended)Merged solid

Shrinkwrap feature‘Insert shared data’ to create part

– Only ‘Surface subset’– Associative

(can be updated)

Shrinkwrap‘Surface subset’ vs ‘Merged solid’

37 % diff.

1469028-53.asm

Memory [MB]

Peak Memory [MB]

VM Memory [MB]

File size[MB]

Time

No_Ref 182 182 178 50s

Shrinkwrapquality 10

solid merge 108 143 108 10,2 5s

surface subset 79 83 79 1,45 4s

703 % diff.

Surface subset– faster creation– less memory consumption– much smaller file size– QLT HLR on drawing– Inteference check OK

25 sec178,80387444388Quality 10

20 sec104,42273311274Quality 9

16 sec55,96195219195Quality 8

6 sec30,38149165149Quality 7

5 sec18,04125134125Quality 6

4 sec9,69107112107Quality 5

4 sec4,42949594Quality 4

4 sec2,57888988Quality 3

3 sec0,78818183Quality 2

3 sec0,53808179Quality 1

shrinkwrap no_refsurface subset

9 min115611621162no_ref

Retrieval Time

File Size [MB]

VM Memory [MB]

Peak Memory [MB]

Memory [MB]

Shrinkwrap Surface SubsetShrinkwrap

Cont.

90 %

67 %

Tips & Tricks

Tips & TricksGraphics

Turn off ‘selection highlighting’– Model Tree– Layer Tree

Turn off ’preselection highlighting’– Preferences

Strict use of layers– Hide all items

Turn off Datums in ’Display WhileSpinning’ to enhance navigation performance

Tips & TricksDrawing mode

Set line display of all views to Wireframe when detailingthe drawing

Turn off display of views, which are not needed for the moment (erase and resume views)

Drawing Representation Tool(similar to simplified representation in assembly mode)

QLT HLR(Quilt Hidden Line removal)

auto_regen_view = noallow_refs_to_geom_reps_in_drw = Yes

Tips & TricksDrawing mode

Set line display of all views to Wireframe when detailingthe drawing

Turn off display of views, which are not needed for the moment (erase and resume views)

Drawing Representation Tool(similar to simplified representation in assembly mode)

QLT HLR(Quilt Hidden Line removal)

auto_regen_view = noallow_refs_to_geom_reps_in_drw = Yes

Tips & TricksGeneral

• Avoid assembly features(based on family table, create hidden copies)

• Avoid ‘automatic intersection’ for assembly features(adds extra calculations)

• retain_display_memory = yes(makes it smoother to switch windows)

• open_simlified_rep_default = YES or [Rep Name] (Force use of simplified representation)

Summary

Recomendations & General Good Practice

– Agree on which goal to target (performance, time, memory handling, file-size etc)– Make sure your assemblies are ”healthy” (MODELCHECK)– Focus on control of external references– Define common mounting rules (PTC Top Down, skeleton)– General LAM rule: Only carry dataset into session necessary for completing

design task

– Geometry Rep

– Open_Rep_By_Default = YES or [Rep Name]

– On Demand Simplified Rep & Definition Rules

– Pre-define ‘Assem_Only’ Simp Rep in start assembly

– Establish internal agreement of acceptable shrinkwrap quality level

– Standardize settings and create mapkeys– Break down shrinkwrap output on rather low level

(similar to lowest assembly level)

Questions