PS Standalone (eMServerCompatible) BasicRoboticSimulation PDF

SIEMENS
Process Simulate
Standalone
(eMServer
Compatible) Basic
Robotic Simulation
Student Guide
January 2017
MT45115 ‒ version 13.1
MT45115-S-131
Tecnomatix copyright, proprietary, and restricted rights notice
Proprietary and restricted rights notice

This software and related documentation are proprietary to Siemens Product Lifecycle
Management Software 2 (IL) Ltd.
© 2017 Siemens Product Lifecycle Management Software Inc.
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2 Process Simulate Standalone (eMServer Compatible) Basic Robotic Simulation Student Guide MT45115-S-131
Contents
Tecnomatix copyright, proprietary, and restricted rights notice . . . . . . . . . . . . . . . . . . . . . 2
Basic robotic simulation course overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TR45115 prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TR45115 audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Learning tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Basic concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Training introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Introduction to the training manual structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Basic methodology and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Basic definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
What is Process Simulate? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
What is a simulation? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Typical Process Simulate inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Typical Process Simulate outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
The four basic object types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Typical Process Simulate usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Starting Process Simulate Standalone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Starting and exiting Process Simulate Standalone . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Using the welcome page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Introduction to the graphical user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Basic options setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Data structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Examining object types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Basic object types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
The prototype and instance relationship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Libraries of parts, and resources (prototypes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Instance basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Creating a study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Introduction to studies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Process Simulate introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Process Simulate basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Introduction to the graphical user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Status and title bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Viewer area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Process Simulate viewer overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
MT45115-S-131 Process Simulate Standalone (eMServer Compatible) Basic Robotic Simulation Student Guide 3
Contents
Contents
Viewer overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

Operation Tree viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Object Tree viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Object Tree viewer nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Review questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Customizing the user configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Customizing the Quick Access Toolbar and ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Adding commands to the Quick Access Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Customizing the ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Customizing the right-click menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Resetting and Saving Customizations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Window layout management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Window layout basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Docked and floating viewers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
On demand window viewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
Save/restore window layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
Process Simulate Standalone environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Working with viewers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Graphic Viewer overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Object Tree basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Right-click menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Working with groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Review questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Graphic Viewer setup and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Graphic Viewer control overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Finding the view control menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Graphics background options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Mouse movement options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Rotation methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
View control with the mouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
View control with a space mouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Basic viewing command usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Customizing the mouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Entity selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Highlighting and Selecting in the Graphic Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Selection techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Pick Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Toggling detailed or united representation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Viewing and selecting PMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Contents
Introduction to selection filters (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Selection filter basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Introduction to Display By Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Display by type basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Available types for Display by Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Measurement and units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Changing units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Linear measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Creating dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Graphical visualization and performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Graphical visualization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Toggling all objects’ visualization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Specific object visualization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Graphical visualization setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Stereo visualization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Dynamic clipping overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Overview of performance options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Add a fancy graphics background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Texture Maps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Point Clouds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Begin using point clouds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Optionally, manage point clouds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Additional commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Window manipulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Toolbar manipulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Searching for objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Expand to selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Collapse to selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Display tooltips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Display or hide the floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Accessing online help and release notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Quick Help Topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Online help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Release notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
Placement commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Introduction to placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Overview of the placement tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Contents
Contents
Introduction to Fast Placement and Restore Object Initial Position . . . . . . . . . . . . . . . . . . . . . 3-4

Fast Placement usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Changing selection behavior and creating frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Setting pick intent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Setting pick level refresher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Basic techniques for creating frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Advanced techniques for creating frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Introduction to Placement Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Reference frame definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Placement Manipulator basic options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Placement Manipulator advanced options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Introduction to Relocate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Relocate command overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Basic Relocate command usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Advanced Relocate command usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Quick introduction to kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fundamentals of kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Kinematics basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
General kinematics usage commands (part 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Creating device operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
General kinematics usage commands (part 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Inverse kinematics review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Principles of inverse kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
How is inverse kinematics like the Relocate command? . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Direct kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Inverse kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Level of kinematic inverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Using inverse kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Joint jog basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Robot jog basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Creating a basic robotic path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Contents
Process Simulate analysis tools and study data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Study data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Study data storage in the system root . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Study data administrative note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Creating and using snapshots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Snapshot usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Using the Markup Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Markup Editor usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Markup Editor toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Adding text in the Graphic Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Graphic Viewer text usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Storing pictures of the study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Introduction to collision detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Do I use this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Collision detection basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Collision Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Collision sets (list pairs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Rules of thumb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Selection toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
More on collision detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Collision introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Configuring Level of Detection Granularity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Collision detection and near miss setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Collision report level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Factors that affect collision detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Collision factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Cutting sections with section planes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Basic section cutting usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Section plane alignment tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Cutting sections with section volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
More section cutting usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Using cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Basics of cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Contents
Contents
Creating cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

Advanced cable parameters and settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Recording Process Simulate simulations to an .AVI file and 3D HTML . . . . . . . . . . . . . . . . . 5-48
Do I use this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Record a Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Simulation Time Interval and Videos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Create 3D HTML output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Other selected basic topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Using Process Simulate Standalone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Ways of using Process Simulate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Creating a new PSZ (no database) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Creating a new PSZ that can update a eMS database in the future . . . . . . . . . . . . . . . . . . 6-3
Process Simulate Standalone - eMS compatible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Files used in Process Simulate Standalone - eMS compatible . . . . . . . . . . . . . . . . . . . . . 6-5
Client system root . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Importing CAD files in Process Simulate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Updating back to the eMS database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Selected Process Simulate features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Modeling basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Overview of Process Simulate basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Starting out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Process Simulate basic modeling tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Modeling and kinematics functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Pick Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Setting pick intent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
More modeling topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Modeling concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Modeling overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Modeling methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Solid modeling overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Other notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Solid creating with primitives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Solid Creation Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Using wireframe to create solids (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Wireframe basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Modeling gun shanks (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Tools used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Contents
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Modeling a more complex object (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Tools used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Using the working frame to build . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Ways of creating and placing objects in modeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Kinematics basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Kinematics background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Kinematics background basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Basic kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Attributes of a kinematic joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Methodology to define a kinematic device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Creating and editing in the kinematic editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Kinematics basics summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Joint dependency basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Introduction to joint dependency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Description of joint dependencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Kinematic functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Introduction to kinematic cranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Crank basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
First draw the kinematic tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Links and joints cranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Crank types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Four bar cranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Slider crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Using three point cranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Kinematic branching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Branching basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Robot tool example of kinematic branching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Defining speed and acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Speed and acceleration basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Copying prototypes vs. instances of objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Defining an object as a tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Tool definition basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Tool definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
How do I define a gun for searching? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Pose definition basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Contents
Contents
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Adding kinematics to a simple robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Simple robot kinematics basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Inverse kinematics device creation and usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Inverse kinematics definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Robot jog basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Inverse kinematics description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
Other selected modeling and kinematics topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Rails, gantries, and positioners (external axis) definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

External axis definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
More kinematic branching and cranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Complete kinematic basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Working with the main branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Example of a parallel pantograph (or four bar linkage) . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Example of a non-parallel pantograph (or four bar linkage) . . . . . . . . . . . . . . . . . . . . . . . 9-5
Example of a prismatic screw (or slider linkage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
RRRP slider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
PRRR slider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
PRRR offset slider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
RPRR offset slider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
RRRP offset slider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Variable joint limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Introduction to variable joint limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Variable joint limits graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Defining variable joint limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
More on kinematic functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Function basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Process Simulate function definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Implementation notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Train joint function example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Train joint basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Defining the train joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Cam joint function example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Cam joint basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Defining the cam joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Compound equipment (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
Compound equipment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
Contents
Equipment basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32

Kinematic coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Global and local attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
Setting up dual arm and cooperative robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
More topics (not covered in class) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
Advanced kinematic definitions (MotionParameters.e file) . . . . . . . . . . . . . . . . . . . . . . . 9-37
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
General robotics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Robotics overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Robotics introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Robotics applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
High-level robotics flow charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Simulation Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Creating a study (again) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Activity: Creating a new study (again) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Create a new study in a project folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Save the study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Review questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Manufacturing feature representation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Manufacturing feature types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Viewing manufacturing features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Sources for discrete manufacturing features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Importing weld points or rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Sources for continuous manufacturing features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Using auto save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Spot welding applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Spot welding primer (optional topic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Spot welding basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Designing a spot-welding line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Design targets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Process methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Basic principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Strategic planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Projecting spot manufacturing features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
Sources for basic manufacturing feature orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Weld location constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Projecting weld locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Editing a weld path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Contents
Contents
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Modifying the weld location orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Deleting and unassigning weld locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17
Multi sections and gun cloud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19
Steps for creating multi sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19
Gun cloud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21
Weld distribution center (WDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23
Weld Distribution Center overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24
WDC primary functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-25
WDC settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28
Process methodology, revisited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-31
Robotic principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-31
The process: From least constraints to most constraints . . . . . . . . . . . . . . . . . . . . . . . 11-31
Overview of gripper creation (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34
Discussion of steps to add poses to an object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34
Define an object as a gripper (discussion only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34
Study setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36
Setting up the study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-37
Mount tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-37
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-37
Material handling (pick and place) operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40
Pick and place basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40
Creating a rough mounted workpiece (pedestal welding) path . . . . . . . . . . . . . . . . . . . . . . 11-41
Introduction to pedestal welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-41
External TCP usage differences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-42
Setting up a mounted workpiece path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-42
Robotic reach test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43
Jumping to a location basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-46
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-47
Orienting workpiece locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-49
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-49
Steps to orienting the locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-49
Using the pie chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-50
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-51
Introduction to weld gun search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-53
Geometric gun search basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-53
Contents
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-54
Servo guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-55
Servo gun usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-55
Servo gun definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-56
Define an object as a servo gun (discussion only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-56
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-56
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-59
Drilling and riveting applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Overview of drilling and riveting applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

Drilling and riveting (fastening) overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Creating drill/rivet manufacturing features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Create drilling and riveting operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Do I use this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Weld location constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
Projecting weld locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11
Waypoints and the Waypoint Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12
Do I use this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12
Navigating waypoints in the Waypoint Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12
Setting up waypoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15
Working with waypoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
Material handling applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Do I use this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

Overview of gripper creation (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Discussion of steps to add poses to an object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Define an object as a gripper (discussion only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Material handling study setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Setting up the material handling study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Material handling (pick and place) operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
Pick and place basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10
Arc-weld continuous feature applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Overview of arc-weld robotic applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

Arc weld basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
Contents
Contents
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
Arc-weld continuous manufacturing features and operations . . . . . . . . . . . . . . . . . . . . . . . . 14-8
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8
Creating Arc-weld continuous operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8
Using Continuous Process Generator for arc-welding . . . . . . . . . . . . . . . . . . . . . . . . . 14-10
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
Creating paths from continuous manufacturing features . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
Continuous location constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
Projecting arc-weld continuous manufacturing features . . . . . . . . . . . . . . . . . . . . . . . . 14-14
Arc-weld projection tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16
Automatically setting the location attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
Seventh axis and more (external axis usage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
External axis basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-20
External axes usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-21
Add 7th axis to a robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-21
More external axis commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22
Smooth rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-23
Creating and editing more arc-weld continuous manufacturing feature paths . . . . . . . . . . . . 14-24
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-24
Verifying location orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-25
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-27
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
Paint continuous feature applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Overview of paint continuous robotic applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2

Painting basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
Setting up paint brushes and meshes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Do I use this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Overview of paint coverage simulation setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Paint brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8
Meshes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
Creating and projecting paint manufacturing features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
Creating paint continuous operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
Using Continuous Process Generator for painting . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Continuous location constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15
Creating appropriate brush geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18
Modifying paint continuous manufacturing features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-19
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-19
Using the Location Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-19
Contents
Using Insert Location Inside Seam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-21

Using Split Seam Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-22
Using the Teach Pendant to start/stop painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-23
Paint trigger tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-23
Additional (paint) robot tracking tools (discussion) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-24
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-28
Simulating paint coverage and more . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-30
Do I use this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-30
Overview of the paint coverage simulation process . . . . . . . . . . . . . . . . . . . . . . . . . . 15-30
Simulation of paint coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-30
Paint coverage settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-31
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-31
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-32
Other continuous feature applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

Overview of other continuous robotic applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2
More continuous robotic applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-5
Creating other types of continuous manufacturing features . . . . . . . . . . . . . . . . . . . . . . . . . 16-6
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6
Steps to create a continuous feature operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-7
Continuous location constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-8
General continuous manufacturing feature creation tools . . . . . . . . . . . . . . . . . . . . . . . 16-9
Common modeling commands used to create manufacturing features . . . . . . . . . . . . . . 16-9
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-10
Projecting other types of continuous manufacturing features . . . . . . . . . . . . . . . . . . . . . . . 16-11
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-11
Projecting general continuous manufacturing features . . . . . . . . . . . . . . . . . . . . . . . . 16-11
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-13
Modifying other types of continuous manufacturing features . . . . . . . . . . . . . . . . . . . . . . . 16-14
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-14
Using the Location Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-14
Using Insert Location Inside Seam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-16
Using Split Seam Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17
Water jet specific commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-18
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-21
Final steps for robotic path development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1

Test robot’s reachability to the locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Robotic reach basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Robotic reach test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4
Smart Place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-8
Smart Place modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-10
Robot Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-10
Contents
Contents
Jumping and moving to a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-12

Create and measure a TCP Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-12
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-13
Dynamic and static collision detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-16
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-16
Collision basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-16
Collision Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-17
Dynamic collision report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-18
Editing location attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-20
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-20
Basic location attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-21
Overview of techniques to edit location attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-23
Path Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-23
Custom columns in the Path Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-23
Quickly set multiple location attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-24
Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-25
Apply Path Template Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-26
Rename Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-27
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-28
Introduction to path modification (via locations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-30
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-30
Path modification basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-30
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-31
Via location creation tools Location creation tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-33
Do I use this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-33
Location creation basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-34
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-35
Location modification commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-37
Via location modification basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-37
Automatic Approach Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-38
Modifying locations using the Path Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-39
Path segment simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-40
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-40
Path modification tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-42
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-42
Path modification tools basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-42
Automatic Path Planner (APP) for robot paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-44
Automatic Path Planner (APP) robot settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-45
Modifying paths using operation properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-46
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-46
Additional path creation tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-49
Overview of path creation tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-49
Replicate an arc seam operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-50
Contents
Replicate a continuous seam operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-52

Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-53
Introduction to adding OLP commands to locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-56
Steps for driving devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-56
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-56
Multiple robot simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-57
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-57
Working with hard and soft limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-58
Hard limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-58
Soft limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-58
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-59
Robotic swept volumes and interference zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-61
Process Simulate swept volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-61
Process Simulate interference volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-63
Process Simulate inference zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-66
Use create 2D outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-67
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-68
Adding events to a sequence of simulative operations . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-69
Introduction to events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-69
Additional event types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-71
Event basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-71
The attach command versus the attach event . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-72
Global and local attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-73
Emphasize events versus emphasize presentation modes . . . . . . . . . . . . . . . . . . . . . 17-73
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-75
Putting it all together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-77
Where do you go from here? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-78
Final notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-78
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-79
Basic robotics optional topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Manually creating arc-weld manufacturing features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Creating manufacturing features manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Dual arm and coordinated motion applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Setting up dual arm and coordinated motion robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Dual arm and coordinated motion basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Creating a new concurrent robotic operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Creating sequences of simulative operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Process Simulate sequence of operations organization . . . . . . . . . . . . . . . . . . . . . . . . A-10
Types of simulative operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Review of the process structure hierarchy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Creating compound operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Creating and linking compound operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Contents
Contents
Creating a robotic sequence (method 1 and 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14

Creating a robotic sequence (method 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14
Creating a robotic sequence (method 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14
Comparing methods of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14
Creating and updating spot-welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16
Sources for discrete manufacturing features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16
Creating weld points (in Process Simulate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17
Multi-assign weld points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17
Automatic weld point assign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-18
Update weld locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-19
Creating robotic paths from NC paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21
Using CLS Upload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21
Overview of the robotic tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24
Robotics tools basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24
Adjust location orientation to full reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-26
Arc continuous positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-26
Attach seam locations to part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-29
Convert to via location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30
Convert to weld location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30
Create seam operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-31
Create a scheduler operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-31
Define gun main joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-32
Insert seam location after . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-33
Mark current rail value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-33
Rail Jog with Locked TCPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-34
Set gantry positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-34
Shift locations by TCP offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-36
Shift rail value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-37
Smooth circular motions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-37
Smooth rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-38
Other robotics features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-40
Do I do this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-40
Spot-weld quality report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-41
Creating weld points (in Process Simulate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-45
Multi-assign weld points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-46
Automatic weld point assign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-46
Update weld locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-48
Unified collision settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-48
Flip location on solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-50
Supported CAD formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-51
Cell and component preview images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-52
Selected intermediate and advanced robotics topics (More topics not covered in the basic
robotics course) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-54
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-55
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1
Basic robotic simulation course overview
Course description
The Process Simulate on Basic Robotics Simulation course provides step-by-step instruction on how
to use Process Simulate to create robotic simulations.
Course objectives
Learn about:
• Basic Environment
o Study creation
o Creating sequences of simulative operations
o Collision detection
o Section cutting
o Video and picture output
• Defining kinematic devices
• Defining and simulating robotic spot-welding

o Pneumatic and servo gun definition and usage
o Ped. welding and Gun on robot path development
• Defining and simulating robotic continuous applications

o Arc-welding and grinding path development
• Defining and simulating robotic material handling

o Gripper definition and usage
Basic
Basic robotic
robotic simulation
simulation course
course overview
overview
o Pick and place path development
• And More
o Multi-robot simulation (for example interference zones)
o Swept volumes, 7th axis, etc.
Basic robotic simulation course overview
TR45115 prerequisites
• Students should be skilled in the use of a mouse in windows-based systems.
• Previous experience with a 3D system is recommended.
• A basic knowledge of robotics is suggested.
TR45115 audience
This course is intended for individuals who want to become knowledgeable on the creation of basic
robotic simulations using Process Simulate Standalone.
Learning tracks
Learning tracks for the Tecnomatix application are found on the Siemens PLM Software training
website: training.industrysoftware.automation.siemens.com/index.cfm
Related Courses
• TR45101 – Process Simulate Standalone (eMServer Compatible) Part Flow Simulation
• TR45106 – Process Simulate Standalone (eMServer Compatible) Human Simulation
• TR45115 – Process Simulate Standalone (eMServer Compatible) Basic Robotic Simulation
• TR45215 – Process Simulate Standalone (eMServer Compatible) Intermediate Robotics
• TR45315 – Process Simulate Standalone (eMServer Compatible) Advanced Robotics
Lesson 1: Basic concepts
Purpose
To provide an introduction to Process Simulate Standalone.
Objectives
After you complete this chapter, you should be familiar with:

• The basic concepts of Process Simulate Standalone is discussed.
• Window Management, study objects, and basic options is discussed.
• The concept of prototype and instances.
• The concepts of System Root, projects, libraries, and objects is introduced.
MT45115-S-131 Process Simulate Standalone (eMServer Compatible) Basic Robotic Simulation Student Guide 1-1
Lesson
Lesson 1: 1: BasicBasic concepts
concepts
Training introduction
Purpose
In this topic, you learn about the basic training manual structure.
Objectives
After you complete this topic, you should be able to:

• Know the basic training manual structure
Introduction to the training manual structure

The training manual is designed for a classroom containing one to nine students and an instructor.
The course starts out using simple, basic data. Later, there are three data that can be
used: Automotive, Airplane, or Structural. In cases where there is a data choice, the
activity includes the name of the choice:
Activity Name Prefix Description

Automotive Refers to an automotive assembly process
Airplane Refers to an airplane maintenance process
Refers to a large structure (skyscraper or
Structure
ship) general assembly process
1-2 Process Simulate Standalone (eMServer Compatible) Basic Robotic Simulation Student Guide MT45115-S-131
Basic concepts
Basic methodology and purpose

Purpose
This student guide begins by giving an overview of the overall goal of this class, depicted in this topic.
Objectives
After you complete this lesson, you should be able to:

• Understand basic definitions.
• Get an overview of Process Simulate.
• Understand the typical Process Simulate usage.
Basic definitions
eBOP is an electronic bill of process. It is made up of four primary objects: Product, Operations,
Resources, and Manufacturing Features.
Product – refers to the object that is produced from the manufacturing process described in the eBOP.
Operations – refers to the sequence of steps that is performed to produce the product.
Resources – refers to the objects such as machines, tools, and workers—within a manufacturing
plant—that performs the operations to produce the product.
Manufacturing Features – Manufacturing features are used to represent special relationships
between several parts. Some examples of manufacturing features are robotic paths moving along
a part such as painting or arc-welding, weld spots and datums.
What is Process Simulate?

Tecnomatix offers a suite of engineering study tools known collectively as Process Simulate. This
suite includes Process Simulate Human, Process Simulate Robotics, Process Simulate Assembler
(Flow Paths), and more.
Process Simulate is a dynamic environment that facilitates concept verification, as well as assembly
and serviceability studies, by enabling an engineer to conveniently:
Lesson
concepts
Here are a few examples why you may want to use these parts of Process Simulate:
• Basic tasks including modeling and kinematics
o Intuitive and native Windows environment tool
o Navigate your data and play simulations
o Layout objects in a study and setup how you visualize them
o Create or modify the components needed to perform a study (for example 3D modeling of
kinematics for tooling and robots)
o Check collisions and clearances dynamically between simulated objects
o Create videos, pictures, and labels
• Human simulation
o Perform human reach checks and ergonomic studies to desired situations.
o Develop human simulations
o Check collisions and clearances dynamically for tools, robot arms and the human hand.
o Perform serviceability studies of the assembly.
o Determine how to service a specified part of the assembly.
• Robotic path simulation, PLC simulation, and off-line programming

o Dynamic 3D robot simulation
o Perform robotic reach checks to desired locations.
Basic concepts
o Develop and download robotic processes and paths (including logic)
o Model PLC logic and signals as well as connect to existing PLCs
o Support for industrial robots from a vast array of vendors (such as ABB, Comau, Duerr,
Fanuc, IGM, Kawasaki, Kuka, Nachi, NC, Reis, Staubli, Trallfa, and Yaskawa)
o Accurate cycle time calculation using realistic robot simulation (RRS)
o Upload robot programs from the shop floor
o Customizable robot specific abilities
• Part and resource flow simulation

o Verify the feasibility of a product assembly.
o Develop a path for assembly and the disassembly of parts.
What is a simulation?
• Simulation is a very general term that can mean something different to different people,
depending on your background
Here is a wooden mechanical horse simulator from World War I.
• In general:
o Simulation is the imitation of some real thing or process.
o It usually entails representing certain key characteristics or behaviors of a system.
• Computer Simulations:
o A computer simulation is an attempt to model a real-life or hypothetical situation on a
computer so that you can study it and see how it works.
o Just about anything can be simulated on a computer, but usually there is a question that
needs to be answered (or results verified).
Lesson
concepts
• In this system, you create assembly process verification simulations. Many other types of
simulation are NOT performed (for example rain, corrosion, crane force loading, etc.).
Typical Process Simulate inputs

1. Product linked to the Process structure (Optional)
2. Process (Required).
3. Plant inked to the Process structure (Optional).
Basic concepts
Typical Process Simulate outputs
Simulations:
1. Sequencing product assembly / disassembly
2. Robotic reachability, cycle time, and controls logic
3. Human reachability, ergonomics, and standard time
And More:
• An entire product process structure properly sequenced for collision free assembly or
disassembly.
• Ergonomic analysis and reports
• Time analysis
• Robotic path analysis
• Collision analysis
• Robotic programs
• Reach envelopes
• Robot controller interaction
• Etc.
Lesson
concepts
The four basic object types

Process Simulate software coordinates four basic types of objects: parts, operations, resources,
and manufacturing features.
1. Parts are the pieces that make up the manufactured product.

• The part tree lists all of the parts of the final product as a hierarchical model that depicts how
the parts relate to one another in the completed product.
2. Operations are the actions performed in order to manufacture the product.

• The operation tree lists all of the operations and describes the order in which they is
performed.
3. Resources are the factory facilities that perform the operations on the parts; these
include assembly lines, zones, stations, workcells, tools, and fixtures.
• The resource tree lists the workers, robots, tools, and fixtures. It also describes the order and
placement of the resources as well.
4. Manufacturing features Manufacturing features are used to represent special

relationships between several parts. Examples of a manufacturing feature are weld spots, PLP
(datums), and curves representing robotic paths that follow the contour of the part such as
arc-welds, painting, grinding, etc. This object type is generally used by robotic users.
Typical Process Simulate usage

This training manual is divided into the following sections and follows the displayed basic use case.
Basic concepts
1. Opening a New Study
Product, operation, and resource trees, which represent a desired smaller area of the complete
project, are loaded into the simulation environment.
2. Creating and Modifying Simulative Operations
Paths are developed for the assembly parts in order to determine if the assembly can be
effectively assembled and disassembled. You can use the commands in the Path menu and/or
Placement toolbox to create a path for each part in the assembly.
3. Sequencing Simulative Operations
A sequence combines separate operations into an entire assembly process. This process defines
individual operations for the currently displayed assembly, combines them into a sequence of
operations, and simulates then in sequence. The purpose of these commands is to demonstrate
and verify the feasibility of a complete assembly procedure in the dynamic simulated environment,
and to produce a detailed assembly report.
4. Analyzing Simulative Operations
Collision list pairs and set clearances are created using the Collision viewer, and are checked
during the movement of the parts along their paths.
Lesson
concepts
The simulative operation is then simulated. These commands affect motion along the path, either
continuously from the beginning to the end, or as single steps between locations. When desired,
the simulation can be halted and then restarted in either the forward or the reverse direction. The
simulation may begin at any location or at any time. The simulation can be stopped when one of
the collision or clearance conditions is violated.
The path can be edited at problematic locations to obtain a more optimized path. The last step
in this process is the verification of all locations where an assembly part violates a predefined
clearance along the path, and the determination of where minimum clearances are reached
along the path.
5. Outputting Deliverables
Process Simulate provides various outputs for the engineer. The following outputs constitute
documentation of fault conditions, which can be used as a means of communication with the
designers:
• A report of the collision and clearance violations along the path.
• A report of the path or paths that were developed for the assembly parts.
• A movie of the simulation, in .AVI format.
Basic concepts
Starting Process Simulate Standalone

Purpose
In this lesson, you learn ways to start Process Simulate Standalone.
Objectives

• Start and exit Process Simulate Standalone
• Welcome Page
Starting and exiting Process Simulate Standalone

No matter which method is used, the resulting data is the same.
Before you begin:
• Your system administrator must install and configure the Process Simulate Standalone software
and desired robot controllers.
More details and import formats are mentioned at the end of this course and in the
Process Simulate Standalone install guide.
• Your application administrator should import the desired data, such as product and resource
libraries, into the system (for example in .COJT format) .
More details and import formats are mentioned at the end of this course.
Ways to start Process Simulate Standalone:

• Method 1: Using Microsoft Windows Explorer, browse into a folder containing a .psz file and
double-click it.
• Method 2: Click the Process Simulate Standalone icon on your Microsoft Windows
desktop
• Method 3: Choose Start→Programs→Tecnomatix→Engineering Applications→Process

Simulate Standalone
Ways to exit Process Simulate Standalone:
• Choose File→Exit .
Lesson
concepts
Using the welcome page

The Welcome Page is displayed when you open the software. It can be used to:
• Open and create new .
• Select recently used
• See “What’s New” descriptions and videos.
• Set Process Simulate options.
• Access Process Simulate social media.
• You can set the system root return to the system root used by a study that was opened.
You can open the Welcome Page later from the ribbon by choosing Home tab→Viewers
group→Welcome Page .
Introduction to the graphical user interface

Process Simulate uses an results-oriented interface similar to Microsoft Windows applications.
This means that you must first choose the object(s) that you would like to work on, after which the
relevant options become available.
Basic concepts
Commands can be accessed from the following places:
• Ribbon — The ribbon is located along the top of the Process Simulate window and contains tabs
of commands. For example, File, Home, and View.
• Quick access toolbar — You can customize this toolbar to contain shortcuts to commands
available on the ribbon.
• Right-click context menus — You display menus with context specific commands by
right-clicking different types of objects.
• Graphic Viewer Toolbar — You always have access to these important graphic commands.
It can be moved within the Graphic Viewer.
• Quick Toolbars — Small quick toolbars are shown when you press the Space bar in the Graphic
Viewer.
Lesson
concepts
Activities
In the Starting Process Simulate Standalone section, do the following activities:
• Starting and exiting Process Simulate Standalone
Basic concepts
Basic options setup

Purpose
In this topic, you learn some basic options setup.
More details is provided about the data structure in a later topic.
Objectives

• Know the basic data structure.
• Set and view basic options.
Data structure
Projects:
A project is a folder which typically contains studies (.psz files).
Studies:
Studies reference 3D data from components (.COJT).
It contains several folders of components (.COJT). Resource and part prototypes are instanced from
these libraries. Studies are made from instances of these prototypes.
Component:
A component (.COJT) is the physical 3D object found in a cell. It is a part or resource prototype
either constructed using Process Simulate modeling commands or imported from a CAD system.
Components are stored as folders (containing .JT files) under the System Root.
Activities
In the Basic Options Setup section, do the following activity:
• Setting and viewing basic options
Lesson
concepts
Examining object types

Purpose
In this topic, you learn about the basic object types found in Process Simulate.
Other object types is described later in this course.
Objectives
• Examine the basic object types that are available.
Basic object types

Process Simulate accommodates a large variety of object types. An unique icon associated with
each object type identifies it in the tree view containing the type. The table below lists and briefly
describes most of these object types, and shows the icon that corresponds to each object type.
Icon Type Representation

Study Folder A folder containing everything in the cell.
A built in folder found in the Object Tree that is used to group objects
Folder
based on their type.
Part A single part.
Compound part An assembly comprising one or more parts or subassemblies.
A single operation.
Operation Other icons for a single operation can be shown based on the
operation type. you discuss more on this later.
Compound
An operation comprising one or more sub operations.
operation
A single resource.
Resource Other icons for a single resource can be shown based on the
assigned resource type including Container , Robot ,
Table , and Gun . you discuss more on this later.
Compound
A collection of one or more resources.
resource
New objects can only be created under the objects that they are related to. For example
a compound part can only be created under a compound part, or the Parts folder of the
Object Tree. A compound resource can only be created under a compound resource,
or the Resources folder of the Object Tree. An operation can only be created under a
compound operation or the operations root of the Operation Tree.
Basic concepts
Process Simulate supplies a variety of icons to depict standard resource types (robots,
fixtures, guns, etc.); however, these icons can be customized and new icon types can
be added.
Activities
In the Examining Object Types section, do the following activities:
• Examine the object types that are available
Lesson
concepts
The prototype and instance relationship
Purpose
In this topic, you learn what a prototype and instance is.
Objectives
• Understand the prototype and instance relationship.
Libraries of parts, and resources (prototypes)
Libraries are repositories of standard parts, and of resources; they facilitate and standardize the
planning process. The libraries may be built from imported data, and they may be edited as desired
from within Process Simulate.
Libraries are any folder under the Libraries folder of the system root.
Instance basics
The objects depicted on this page are for discussion only and are not part of the data
found in the training. Once you understand the concept of the prototypes and instances
described on this page, you can look at the data (which is more complex).
The information shown here is generic and can be applied to parts and resources.
An instance is a usage of a part or resource (prototype). It is a unique object that physically exists
in the plant, whereas a prototype that does not have an instance in a product or plant structure is
merely conceptual (not yet purchased).
For example: you have a product assembly that contains a metal plate and two bolts. The Product
Tree would look like this in Process Simulate:
The library contains a COJT for each unique object which you refer as the prototype. In this case one
Plate and one Bolt. The product tree describes the hierarchy, part position, and number of each part
prototype in the product assembly. The Plate in the library is linked to the plate in the product tree.
The Bolt in the library is linked to both bolts in the product tree. So the parts in the product tree are
called instances of the part prototype. Whenever a change is made to the attributes (for example
geometry) of the part prototype, the instances also reflect that change.
Basic concepts
Creating a study
Purpose
In this topic, you learn to create an empty study.
For other activities in class, you use pre-existing studies.
Objectives
• Know about studies.
• Create a new study.
Do I do this?
Most tasks you perform in Process Simulate, begin by making a study.
In the open study, you may decide to layout the components.
Lesson
concepts
Introduction to studies
You look at data using viewers. Viewers can be opened from the Screen Layout group of the View
tab ribbon.
The viewers (under the Viewers button such as Object Tree, Operation Tree, etc.). Changes
made in these viewers are stored in the memory of the user's computer and do not affect the psz
file until you specifically choose to save the file.
Basic concepts
Ways of loading studies
A study is also known as a .psz file. Opening a study (.psz file), also loads data from the referenced
components (.cojt) from under the system root. The study contains references to a subset of data
from in a project. (Usually just one manufacturing area).
Studies can be loaded in two different modes. Although both modes have a lot of functionality in
common, there are specific actions of Process Simulate that can only be carried out in one mode or
the other.
• From the Welcome page, select a study from the Recent Studies list.
The Welcome page can be opened by choosing Welcome Page from the Home
tab of the ribbon.
• From the Welcome page, select a study from the Open in Standard Mode list.
• From the Welcome page, select a study from the Open in Line Simulation Mode list.
This command is discussed in the TR42215 Process Simulate on eMS Intermediate

Robotics course.
• From the ribbon choose File→Recent Studies and select a study from the list.
• Select a study and then from the ribbon choose File→Study →Load in Standard Mode
• Select a study and then from the ribbon choose File→Study →Load in Line Simulation
Mode .
This command is discussed in the TR42215 Process Simulate on eMS Intermediate

Robotics course.
• Select a study and then from the Quick access toolbar, choose Open Study
• Select a study and then from the Quick access toolbar, choose Open in Line Simulation
Mode
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concepts
This command is discussed in the TR45215 Process Simulate Standalone Intermediate

Robotics course.
Study mode use cases
After loading a study in one mode, it can be easily switched to other mode to complete specific
actions. It takes less time to switch modes than to reload the study in the other mode.
• From the ribbon, choose Home tab→Study group→Standard Mode
o Add product data
o Create and validate path reachability
o etc.
• From the ribbon, choose Home tab→Study group→Line Simulation Mode
This command is discussed in the course
o Validate controls logic
o Check for reachability and collision problems
o etc.
Activities
In the Creating a Study section, do the following activities:
• Creating a new study
Basic concepts
Process Simulate introduction

Purpose
In this topic, you get an introduction to Process Simulate
Objectives

• Know a little bit about Process Simulate.
• Use some Process Simulate commands
• Identify the status and title bar areas.
• Identify the viewer area.
Process Simulate basics

Selected list of Process Simulate uses:
• The Process Simulate product is used to plan and validate manufacturing processes.
• It is a hierarchical processing tool that links product data with manufacturing resources and
operations. This results in an integrated framework for a complete production-engineering
process.
• As a system for top-down (or bottom-up creation), modification and navigation of process data,
Process Simulate coordinates, and simplify the task of process planning and validation.
• It integrates manufacturing process planning, analysis, validation, and optimization.
• Process Simulate is an integral part of Siemens PLM Software Manufacturing applications.
Process Simulate uses an object-oriented interface similar to other Windows-type applications.

options required become available.
Introduction to the graphical user interface

Process Simulate uses an results-oriented interface similar to Microsoft Windows applications.
relevant options become available.
Commands can be accessed from the following places:
• Ribbon — The ribbon is located along the top of the Process Simulate window and contains tabs
of commands. For example, File, Home, and View.
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• Quick access toolbar — You can customize this toolbar to contain shortcuts to commands
available on the ribbon.
• Right-click context menus — You display menus with context specific commands by
right-clicking different types of objects.
• Graphic Viewer Toolbar — You always have access to these important graphic commands.
It can be moved within the Graphic Viewer.
• Quick Toolbars — Small quick toolbars are shown when you press the Space bar in the Graphic
Viewer.
Basic concepts
Status and title bars

• Title Bar — The title bar is located at the very top of the Process Simulate window. It displays the
version of Process Simulate and the name of the study that is currently opened.
• Status Bar — The status bar is located at the very bottom of the Process Simulate window. It
displays the status of the last executed command, the systems readiness to execute the next
command, and the currently selected object.
To configure what is shown on the Status Bar, right-click it and choose the desired
options. For example: , Study Mode, , , Pick Coordinate.
Viewer area
The viewer area takes up most of the Process Simulate window. The next topic is completely
dedicated to it.
Lesson
concepts
Process Simulate viewer overview

Purpose
In this topic, you get an overview of the viewers in this system.
Objectives

• Use the Operation Tree viewer
• Use the Object Tree viewer
Viewer overview
All of these can be opened from the ribbon. Choose View tab→Screen Layout group→Viewers
1. Collision Viewer - Used to setup 3D collision checking for the loaded scene and display the
results (covered in this course)
2. Logical Collections Tree – Used to display the In-Process Assembly tree (covered in this course)
3. Material Flow Viewer — This viewer is related to event-based simulation and is not covered in
this course (covered in the .
4. MFG Viewer – Used to view and edit information for manufacturing features (for example weld
spots, PLPs, continuous MFGs, etc.) (covered in the TR45115 Process Simulate Standalone
Basic Robotic Simulation course).
5. Modules Viewer — This viewer is related to event-based simulation and is not covered in this
course (covered in the TR45215 Process Simulate Standalone Intermediate Robotics (CEE)
course).
6. Object Tree – Provides a structural view of product, plant, and other non-process objects
(covered in this course)
7. Operation Tree – Used to view the process structure and related simulative operations (covered
in this course
8. Path Editor – Used to view and edit the operations/simulation paths
9. Sequence Editor – Used to view and edit the process structure (initially covered in this course)
Basic concepts
10. Signal Viewer — This viewer is related to event-based simulation and is not covered in this
course (covered in the TR45215 Process Simulate Standalone Intermediate Robotics (CEE)
course).
11. Simulation Panel — This viewer is related to event-based simulation and is not covered in
this course (covered in the TR45215 Process Simulate Standalone Intermediate Robotics
(CEE) course).
12. Snapshot Editor – Used to view, edit, and use snapshots. (covered in this course)
These viewers can also be opened from the View tab of the ribbon:
1. Relations Viewer – Used to view database relationships between the currently selected
object and other objects in the scene.
2. Properties — lists the attributes of the selected database object (covered in all courses).
3. Open New Window Opens another Graphic Viewer.
Operation Tree viewer

The hierarchy of process, operations, activities, and simulative operations required to produce the
target product (for example Process A contains operation B and operation C. This means that
Process A includes operation B and operation C).
The Gantt chart (Sequence Editor) should be used to view the order (or sequence) of the operations.
The operations plan is a logical structure; it starts with a single, all-inclusive operation (e.g., Plant,
Line, Zone, Station), and expands to include specific operations. Each operation in the hierarchy
points both to the parts or subassemblies upon which the operation is performed as they flow in and
out of the operation, and also to the resources that the operation utilizes.
An operation is the central object in the database that connects product-manufacturing resources
together in an integrated process.
Process Simulate provides several views of the Operation Plan: tree views and Gantt view (Sequence
Editor). The Operation Tree view shows the hierarchy of individual operations that constitute the
operation plan. This tree view does not show or imply dependencies between operations.
To open the Operation Tree viewer:
• From ribbon, choose View tab→Screen Layout group→Viewers , and then select
Operation Tree.
To close the Operation Tree viewer:
Lesson
concepts
• Click Close in the right-hand corner of the viewer.
Object Tree viewer

The Object Tree viewer displays a hierarchy of the elements of the currently opened study.
Displayed objects (except manufacturing features, locations, and paths) can be blanked or displayed
from the Object Tree viewer via special display status squares next to the element names. There are
several values for the display status squares:
• Blanked
• Displayed
• Partially Displayed
• No 3D data available
Objects in the tree can be selected in order to work on them.

Elements are displayed in the Object Tree viewer regardless of whether they are blanked or displayed
in the Graphic Viewer (unless a filter is applied to the Object Tree viewer).
To open the Object Tree Viewer:
• From ribbon, choose View tab→Screen Layout group→Viewers , and then select Object
Tree.
To close the Object Tree Viewer:

Object Tree viewer nodes

The Object Tree displays a listing of the current study and its contents. A is made up of objects,
frames, and paths (simulative operations).
Clicking the + icon next to a node in the tree expands it to display the next level down. Clicking the -
icon hides everything in that node except the tasks.
Main Types of Objects:
• Group
• Component
• Entity
Basic concepts
• Study Data (More on this later)
The following is a partial list of elements that can be nodes at the first or second level of the tree:
• Study
• Part (object)
• Resource (object)
• Compound Part (Group of Parts)
• Compound Resource (Group of Resources)
• Note
• Section
• Dimension
• Frame
Activities
In the Process Simulate Viewer Overview section, do the following activities:
• Browsing the Process Simulate study
Review questions
Question
Lesson
concepts
1 3 5 More than 10
Basic concepts
Customizing the user configuration

Purpose
In this topic, you learn three ways to customize the user configuration.
Objectives
• Access and use the Customize dialog box
• Reset and Save customizations.
Overview
There are three primary ways to do this:
• From the Process Simulate ribbon, choose File→Options – The contents of the Options
dialog box are discussed throughout class as needed.
• From the Process Simulate Quick access toolbar choose Customize Quick Access Toolbar
→More Commands - The Customize dialog box is used to customize the ribbon and Quick
access toolbar. It is described on the next page.
• Tecnomatix Doctor Tools menu – This menu contains options that are set before starting Process
Simulate that affect its general behavior.
The Tecnomatix Doctor is not covered in this course, but it can be started by selecting
Start→Programs→Tecnomatix→Administration Tools→Tecnomatix Doctor .
Customizing the Quick Access Toolbar and ribbon
By clicking Customize Quick Access Toolbar on the Quick access toolbar, you can:
• Change the commands in the Quick Access Toolbar
• Change the commands in the ribbon.
• Rename commands in the ribbon.
• Change the order of the tabs in the ribbon.
• Display or hide standard tabs in the ribbon.
• Define new tabs and groups in the ribbon.
• Define short-cut keys for the commands.
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• Customize the mouse configuration
Adding commands to the Quick Access Toolbar

To add any command to the Quick Access Toolbar:
1. On the Quick Access Toolbar, click Customize Quick Access Toolbar and select More
Commands.
2. On the left edge of the window, select Quick Access Toolbar.
3. For Choose commands from, select a tab such as Home or select All Commands.
4. Select the desired command in the Commands list and click Add >>.
5. Click OK.
Customizing the ribbon

To customize the ribbon:
Commands.
2. On the left edge of the window, select Customize Ribbon.
3. For Choose commands from, select All Commands.
4. (Optional) Click New Tab and rename the newly created tab.
Basic concepts
5. (Optional) Select a tab from the list and click New Group and rename the newly created group.
6. Select the desired command in the Commands list, select the command group, and click Add >>.
Built-in groups cannot be modified. However, you can add new groups to built-in tabs or custom
tabs. All tabs can be hidden.
7. Click OK.
Customizing the right-click menus

To customize the right-click menus (context menus):
Commands.
3. Move the Customize dialog box out of the way.
4. For Menus, click Customize.
The Customize dialog box opens.
5. In the Customize dialog box, click the Menu tab.
6. For Show Menus for, select a viewer you want such as Object Tree Viewer.
7. For Select context menu, select object type specific right-click menu you want such as Object
Context Menu.
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concepts
The related right-click (context menu) shows.
8. In the Customize dialog box, click the Commands tab.
Basic concepts
9. Drag commands from the Commands list into the displayed context menu.
10. Click Close and OK.
Resetting and Saving Customizations

To save the changes to the right-click menu:
1. From the ribbon choose View→tab Screen Layout group and select (or create) a custom layout.
Commands.
4. Click Customize and click OK.

A second Customize dialog box opens.
5. Choose the Menu tab.
6. In the second Customize, select the viewer and context menu you want.
7. Choose the Commands tab.
8. Drag a command from the Commands list into the displayed right-click menu.
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9. Click Close and OK.
10. From the ribbon choose View→tab Screen Layout group Layout Manager.
11. Select the custom layout and click Update.
12. Select Use Current, click OK, and CLOSE.
To reset the commands on the Quick Access Toolbar or ribbon:
Basic concepts
Commands.
2. On the left edge of the window, select Quick Access Toolbar or Customize Ribbon.
3. Click Reset.
Lesson
concepts
Window layout management

Purpose
In this topic, you learn about window layout management.
Objectives
• Dock and float viewers.
• Use on demand window viewing.
• Save and restore window layouts.
Window layout basics

It describes several techniques for managing the many viewer windows of Tecnomatix. Typically
these techniques are used in parallel.
• Opening and Closing Views — Viewers can be opened or closed at any time, based on need.
• Docked or Floating Viewers — Viewers can be docked or floated at any time, based on need.
• On Demand Window Viewing — All docked viewerscan be collapsed or expanded on demand,

providing more screen space for main tasks (for example Graphic View). The status of each
viewer is saved in the layout.
• Save/Restore Window Layouts — Tecnomatix window layouts can be saved and reused.
Saving a layout stores the following information and can be used to restore this information in a
later session of Tecnomatix:
o Which viewers are currently open
o Size and placement of the open viewers (If a viewer is not open, in a later session, it is
opened. However, when it is opened later it goes to predefined position stored in the layout.)
o Can save public or private layouts for all open viewers.
o Can switch between several layouts during one session.
Docked and floating viewers

To undock (float) a viewer:
• There are several methods to do the first step:
o Method 1: Click the desired tab in the viewer area. Then drag the viewer using the tab's title.
o Method 2: Double-click the tab's title.
Basic concepts
o Method 3: Click the desired tab in the viewer area. From the title area of the viewer, click
Window Position and choose Floating.
o Method 4: Click the desired tab in the viewer area. Right-click the title area of the viewer
and choose Floating.
To dock a floating viewer:
It is not recommended to leave viewers floating over the rest of your user interface to avoid
hiding important information in the software. (It’s OK to float it on your second monitor if
you have one). Otherwise you should dock them. While in this training course, you should
always keep your viewers docked to make it easier on your instructor and to help you find
the viewers easier.
• Methods to return to the previously docked position:

o Method 1: Click the desired viewer area and then double-click its title area
o Method 2: Click the desired tab in the viewer area. Right-click the title area of the viewer
and choose Docking.
• Methods to change the docking position:

o Click the desired viewer (floating or docked) then begin dragging it using the tab's title.
The viewer can now be dropped into another tab group or used to start a new
tab group.
o Shared/stacked viewer area edge method:

■ A four-way arrow indicator appears in the center of the docked viewer you are dragging
across.
■ Drag the floating viewer to one of the arrows of the four-way arrow indicator. It docks the
viewer along that edge of the viewer you are dragging across.
Lesson
concepts
■ Or drag the floating viewer across another docked viewer. The four-way indicator is now
applicable to this viewer.
o Whole viewer area edge method:

■ Single arrow indicators are shown along the middle of each edge of the Process Simulate
viewer area.
■ Drag the floating viewer to one of these indicators.
■ The viewer docks along that edge and take up the entire edge.
On demand window viewing

A viewer such as the Operation Tree can be shown “On Demand” (unpinned ). This means that
there is an icon along the left edge of the Process Simulate window named Operation Tree .
If you mouse over it, the viewer is shown. The viewer remains displayed until you are not mousing
over the Operation Tree icon or viewer.
To disable this feature and keep the Operation Tree displayed, click on the tack in the title area
of the viewer to pin it down.
Save/restore window layouts

Saving a Window Layout:
1. Open, position, and size all viewers you want as part of this layout.
2. From the Process Simulate ribbon, choose View tab→Screen Layout group→Layout Manager
. The Layout List dialog box opens.
Basic concepts
3. From the Layout List dialog box, select New.
4. In the New Layout dialog box, select Use Current for both options and click OK.
5. From the Layout List dialog box, click the name and press the F2 key to change the name.
Lesson
concepts
The list of layouts on your computer may be different.
Using a Window Layout:

When a layout is applied, it opens the viewers (including position), toolbars, and menus from the
saved layout.
1. From the Process Simulate ribbon, choose View tab. The Screen Layout group, select the
layout drop-down and choose the desired layout.
The list of layouts on your computer may be different.
2. The layout is applied to all open and successively opened viewers.
Basic concepts
Activities
In the Window Layout Management section, do the following activities:
• Docking and floating viewers
• Saving a window layout
• Using a window layout
Review questions
Question
Lesson
concepts
FALSE TRUE
Basic concepts
Summary
Subjects learned in this topic:
• Window Management, study objects, and basic options was discussed.
Lesson 2: Process Simulate Standalone environment
Purpose
To describe the Process Simulate Standalone Environment.
Objectives

• The menu and toolbar options available in Process Simulate.
• Various right-click popup menus available in Process Simulate.
• How to use the mouse to control objects displayed in the Graphic Viewer, as well as changing the
viewpoint and view center of a selected object.
• The Customize dialog box features such as adding new toolbars, adding and removing items
from existing toolbars, and modifying items in the menu bar.
• How to select and blank objects using selection filters.
• How to select and blank objects using the Display By Type dialog box.
• Discuss other functions that can be used such as resizing the Process Simulate window.
• How to perform measurements and entity selection
• The chapter finishes by discussing how to access online help for a command.
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Working with viewers
Purpose
In this topic, you learn different types of viewers available in and how to access them. It also provides
information regarding the various right-click popup menus available. you discuss the Graphic Viewer
and various tree viewers such as the Object Tree.
Objectives
• Begin using the Graphic Viewer
• Begin using the Object Tree Basics
• Begin using right-click menus
• Create and use groups.
Graphic Viewer overview

The Graphic Viewer is the 3D window showing all the current displayed elements. Pausing over an
object in the Graphic Viewer displays a tool tip containing the name of the object.
In general, 3D data displayed in the Graphic Viewer, associated to product and resources,
can be in .COJT (or .JT) or .CO format.
To open another Graphic Viewer:
• From the ribbon, choose View tab→Screen Layout group→Open New Window .
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To arrange and switch Graphic Viewers:
• From the ribbon, choose View tab→Screen Layout→Arrange Windows . Then choose
either Vertical Alignment , Horizontal Alignment , Tiled Alignment , Cascade
Alignment , or Tabbed Alignment .
• From the ribbon, choose View tab→Screen Layout group→Switch Windows . Select a
Graphic Viewer from the list to bring to the front.
To close the Graphic Viewer:

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

Clicking the + icon next to a node in the tree expands it to display the next level down. Clicking the -
icon hides everything in that node except the tasks.
The following is a partial list of elements that can be nodes at the first or second level of the resource
or part tree:
• Part A single part.
• Compound Part An assembly comprising one or more parts or subassemblies.
• Resource A single resource. (Default icon)
• Compound Resource A group comprising one or more resources.
• Robot A robot resource.
• Container A container resource.
• Human A human resource.
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Right-click menus
Right-clicking a (non-kinematic) object in the Object Tree viewer:
Displays a popup menu that contains shortcut commands and a number of options that are also
found in other menus.
• Blank — Blank the selected objects.
• Display Only — Blank all deselected objects, leaving the selected objects displayed.
• Zoom to Selection — Zoom to the selected objects (centering the displayed geometry in the
Graphic Viewer), and set the center of rotation to the geometric center of the selected objects.
• Modify Color — Enables the user to choose a new color for the currently selected object(s).
Right-clicking in the Object Tree viewer (not on a node):

The following popup menu is displayed:
• Display All — Display all entities in the Graphic Viewer.
• Toggle Display — Blank all displayed objects and display all blanked objects.
• Options — Open the Options dialog box (Same as File→Options ).
Right-clicking in the Graphic Viewer (on a non-kinematic object):

• Blank — Blank the selected objects.
• Display Only – Blank all unselected objects, leaving the selected objects displayed.
• Zoom to Selection — Zoom to the selected objects (centering their displayed geometry in
the Graphic Viewer), and set the center of rotation the geometric center of the selected objects.
• Modify Color — Enables the user to choose a new color for the currently selected object(s).
Right-clicking in the Graphic Viewer (not on an object):

• Display All — Display all entities in the Graphic Viewer.
• Toggle Display — Blank all displayed objects and display all blanked objects.
• Zoom to Fit — Zoom to the displayed objects (centering their displayed geometry in the
Graphic Viewer).
• Options – Open the Options dialog box (Same as File→Options ).
Undo / Redo:
• The Undo and the Redo commands can be used for the last action performed on a
selected object in the Graphic Viewer By selecting the command repeatedly, undo/redo can be
performed for successively earlier/later operations, as required. Unless a command is executed
that cannot be undone (which clears the undo list).
• Undo/Redo capabilities are supported for placement commands, display/hide commands, notes,
labels, color manipulations, etc.
• The Undo command can be found on the Quick access toolbar.
Users cannot undo actions after selecting Save or Delete .
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 are also be moved. Each object can also be shifted or
rotated independently of the group.
This group is stored only in the study and do not affect the original resource tree structure .
A group can contain any combination of other groups, resources, parts, .
Use groups in various Process Simulate tools to blank/display, create flow operations, create collision
pairs, export to Excel, etc. Groups enable assembly feasibility studies in early stages, even before
process is defined.
• From ribbon, choose View tab→Screen Layout group→Viewers , and then select Logical
Collections Tree
• Right-click a folder or group object in the Logical Collections Tree and choose Create Group
• Right-click a group object in the Logical Collections Tree and choose Flatten Hierarchy
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• Right-click a group object in the Logical Collections Tree and choose Replace Compounds
with Groups
• Right-click a group object in the Logical Collections Tree and choose Export Groups to
Excel
Activities
In the Working with Viewers section, do the following activities:
Perform either the Auto, Airplane, or Structural activity. Then perform the rest of the
activities with that data.
• Getting an overview of the objects in the Object Tree
• Auto — Getting an overview of the objects in the Object Tree
• Airplane — Getting an overview of the objects in the Object Tree
• Structural — Getting an overview of the objects in the Object Tree
• Object Tree basics and groups
• Using the right-click popup menu
Review questions
Question
A group cannot contain a mixture of parts and resources Groups are not selectable Groups can
contain parts and resources Groups can be hierarchical
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Graphic Viewer setup and control

Purpose
In this topic, you learn about mouse view control, view control menus, and basic Graphic Viewer setup.
Objectives
• Find the view control menus.
• Use graphics background options.
• Use mouse movement options.
• Use rotation methods.
• Control the view with the mouse.
• Control the view with the space mouse.
• Use basic view commands.
Graphic Viewer control overview

The Direct Model graphics engine is used by Siemens PLM Software applications such as
Teamcenter, RobotExpert, Process Simulate, Process Designer, and Plant Simulation. It is a set of
libraries capable of reading, writing and rendering .JT files.
Finding the view control menus
Only selected buttons is covered during this topic, while others is covered later in class
when appropriate. At this point you look at these menus from the 10,000 foot level.
There are several ways to access the view control features:

• Using the Mouse.
Moving the mouse, in conjunction with pressing the various mouse buttons allows
you to pan, zoom, and rotate.
• Using a Space Mouse (3D manipulator).
• Use the Graphic Viewer toolbar.
• Using the View tab of the ribbon.
• Using a right-click popup menu.

o Right-clicking in the Graphic Viewer (not on an object) displays the following popup menu:
• From the ribbon choose File→Options and choose the Graphic Viewer tab in the Options
dialog box. (The Performance tab is discussed in a later topic).
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Graphics background options

A different color can be selected for each of the four corners of the Graphic Viewer. the background
colors fade progressively toward the center of the viewer.
• From the ribbon choose File→Options .
• From the Options dialog box, choose the Appearance tab.
• Choose Background color.
• Choose Corners from the drop down that currently says Vertical or Solid.
• Choose a color for each corner.
• Click Preview and close the Options dialog box.
Mouse movement options

There are two mouse movement modes: direct viewing and continuous viewing:
• Direct viewing: Objects only move when you move your mouse. This is the PC default
configuration. This option is more similar to how other 3D systems manipulate the Graphic
Viewer .
• Continuous viewing: Objects continue to move at the initial speed of mouse movement. This is
the Robcad default configuration.
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These options can be set by choosing File→Options . From the Options dialog box, choose the
Graphic Viewer tab.
Rotation methods
There are two methods:
• The Walk around object (Tecnomatix method) option causes the rotation to be the same as
Robcad, RobotExpert, Process Simulate, and Process Designer.
• The Rotate object (Vis method) option rotates in the opposite direction as the Walk around
object (Tecnomatix method) method. Also the Rotate object (Vis method) allows rotating
about any axis.
o To point the Z-axis up and rotate about it: (works the same for both Walk around object
(Tecnomatix method) and Rotate object (Vis method) rotation methods)
■ From the Graphic Viewer toolbar, click any view except TOP and BOTTOM .
Notice the Z-axis of the Working Frame is pointing up.
■ Select in the Graphic Viewer.
■ Continuously click the left or right arrow keys.
o To point the Y-axis up and rotate about it: (works differently for Walk around object
(Tecnomatix method) or Rotate object (Vis method) rotation rotation methods)
■ From the Graphic Viewer toolbar, click the TOP view.
■ Continuously click the left or right arrow keys.
o To point the X-axis up and rotate about it: (works differently for Walk around object
(Tecnomatix method) or Rotate object (Vis method) rotation rotation methods)
■ From the Graphic Viewer toolbar, click the LEFT view.
o Click the down arrow key 3 times. Notice the X-axis of the Working Frame is pointing up.
o Continuously click the left or right arrow keys.
View control with the mouse

You can use the mouse to control how objects are displayed in the Graphic Viewer. The Graphic
Viewer mouse control is the same as NX. You can also switch the mouse control to work like Robcad
(and Process Simulate before version 13) or customize the mouse control the way you want. This is
discussed in the customize lesson.
The following instructions apply to a mouse with two buttons and a wheel.
If you do not have a mouse with two buttons and a wheel, use one of the other described
techniques or see the online help for information on One-Button view control.
• Mouse Wheel — Slide the mouse wheel in and out to zoom in or out of the Graphic Viewer.
Moving the mouse wheel affects the direction of the zoom. To zoom out, move the mouse wheel
toward you; to zoom in, move the mouse wheel away from you. (Also see the Setting the Mouse
Movement Mode section which follows).
• Middle (MB2) and Right (MB3) Buttons — Depress the middle and right buttons for panning
in the Graphic Viewer. Moving the mouse in any direction affects the direction panned, when
continuous viewing is set.
• Middle (MB2) Buttons — Depress the middle button to rotate the object's viewpoint in the
Graphic Viewer. Moving the mouse in any direction changes the viewpoint. The distance the
mouse moves across the screen affects the amount of rotation, when continuous viewing is set.
• Alt + Left (MB1) Mouse Button — To zoom to a specific area, hold down the Alt key and draw a
box around a small area of interest with the left mouse button.
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Other techniques to pan, zoom, and rotate:

• Left (MB1) and Middle (MB2) Buttons — Depress the left and middle buttons in the Graphic
Viewer. Move the mouse up and down to zoom in and out.
• Shift + Middle (MB2) Button — another way to pan.
• Ctrl + Middle (MB2) Button — another way to zoom.
• Alt + Middle (MB2) Button — another way to rotate.
View control with a space mouse

In order to use a Space mouse, the 3DConnexion driver must be installed and started before starting
the Tecnomatix software. Pictured below is the Space Explorer. Other models can also be used:
This tool can be used to intuitively pan, zoom, and rotate the object.
Here are the default settings:
• Pan Right/Left - nudge left and right
• Pan Up/Down - push down or pull up
• Zoom - nudge toward or away from you
• Tilt - rotate front/back
• Spin - spin around
• Roll - rotate left/right
If you have one of these you do not need to learn how to pan, zoom, and rotate with a mouse.
For more information on space mice see www.3dconnexion.com.
Basic viewing command usage

To change to a standard viewpoint:
1. From the Graphic Viewer toolbar, click the FRONT view.
2. Choose a different view from the Graphic Viewer toolbar to see how the viewpoint changes.
• From the Graphic Viewer toolbar, click the TOP view.
To change to a viewpoint that is normal to a selected point:

1. Select a point on an object in the Graphic Viewer.
2. From the Graphic Viewer toolbar, choose Normal to View Point .
To display all the entities in the Graphic Viewer:
• Right-click in the Graphic Viewer and choose Display All from the displayed popup menu.
The Display All option is also available from the Graphic Viewer toolbar.
Another option is to use the Toggle Display command which alternates the display in
the Graphic Viewer between blanked and displayed objects.
While panning in the Graphic Viewer, it is possible that all the objects are panned off the screen. To
return them to the screen, Right-click in the Graphic Viewer (not on an object), and choose Zoom To
Fit from the displayed popup menu.
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The Zoom To Fit option can also be accessed from the Graphic Viewer toolbar.
To zoom in to the Graphic Viewer:

• Press Alt while holding down the left mouse button, and draw a box around an object(s) in the
Graphic Viewer that you want to zoom in on. To zoom back out, right-click in the Graphic Viewer
(not on an object) and choose Zoom To Fit from the displayed popup menu.
To zoom in to an object in the Graphic Viewer:
Right-click an object in the Graphic Viewer, and choose Zoom To Selection from the displayed
popup menu.
To change the view center of an object:
By default, Process Simulate rotates the graphic around the 0,0,0 (world origin) coordinates of the
study. If you want to rotate the study around a different point, you must select it and hen choose View
Center command from the Graphic Viewer toolbar.
Before choosing the command, you need to first select an object in the Graphic Viewer.
1. Using one of the methods described In this topic, rotate the study in any direction and note
the center of rotation.
2. Click an entity in the Graphic Viewer. Note where the white asterisk is located.
3. Choose View Center from the Graphic Viewer toolbar.
4. Rotate the study again. The view center is now set to where the selection point is located.
Customizing the mouse

To customize the mouse:
Commands.
2. On the left edge of the window, select Customize Mouse.
3. Select the configuration you want from the Choose a mouse configuration list:
• Default — Mouse controls are similar to NX. This configuration is read only.
Some steps in the training activities assume Default is set.
• Legacy — Mouse controls are similar to Robcad and Process Simulate before version
13. This configuration is read only.
• Custom — Select your own values for the controls.
4. Click OK.
Activities
In the Graphic Viewer setup and control section, do the following activity:
• Basic Graphic Viewer controls
Review questions
Question1
Question2
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Question3
Using a Space Mouse. Hold down the left and right mouse buttons while moving the mouse in a
circle. Using the arrow keys on the keyboard. Hold down the right and middle mouse buttons while
moving the mouse in a circle. Select an object and click Zoom to Selection. Hold down the left and
right mouse buttons while moving the mouse up and down. Hold down the [Alt] key and draw a box in
the Graphic Viewer. Using a Space Mouse. Hold down the middle mouse button while moving the
mouse left and right. Objects only move when the mouse is moved. Objects continue to move at
the initial speed of mouse movement.
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Entity selection
Purpose
In this topic, you learn how to choose and view objects in the Graphic Viewer and tree viewers.
Objectives
• Use various selection and viewing techniques.
• Change the Pick Level.
• Toggle detailed or united representation.
• View and select PMI.
Highlighting and Selecting in the Graphic Viewer

• When you hover over objects in the Graphic Viewer, the objects are shown in the preview
selection color and the mouse cursor is shown with this icon .
• When you select objects in the Graphic Viewer, the objects are shown in the selection color and
the mouse cursor is shown with this icon .
You can change the Highlight preview selection and Highlight selection colors. Choose
File→Options and click the Appearance tab.
Selection techniques
It is important to remember that Process Simulate uses an object oriented interface,

meaning that you must first select what you want to manipulate, and then select the
command to be performed.
Selection Techniques:
• The Shift Key — enables you to select more than one entity in a consecutive list. Select the first
entity, then hold down the Shift key and select the last entity in the list. This key works in the tree
viewers only. selected entities are highlighted in green in the Graphic Viewer.
• The Ctrl Key — enables you to select more than one entity. Hold down the Ctrl key and select
each desired object. This key works in the tree viewers and the Graphic Viewer. selected entities
are highlighted in green in the Graphic Viewer.
• Selection Window — can be drawn in the Graphic Viewer by holding down the left mouse button
and dragging the mouse diagonally downward or upward across several displayed entities.
• Pick Level — Described in the next topic
Pick Level
Choose the Pick Level icons from the Graphic Viewer toolbar. The following options are available”
• Component — The entire object is selected when any part of it is selected.
o Whole object — with all objects only the whole object can be selected.
o Study Data — each object can be selected independently (for example a frame, cross
section, note flag, dimension, etc.).
• Entity — When selecting objects shown in united representation (the default): Only the
entity (that is, part of the whole object) is selected. Here is what can be selected:
The results of the Entity Pick Level are dependent on whether the selected object
is shown in united representation or detailed representation. Described in the next topic
o Whole Object — with non-kinematic objects only the whole object can be selected.
o Kinematic Link — On Kinematic objects, each link can be selected independently (for
example on a human, the arm and hand are separate kinematic links).
o Study Data – each object can be selected independently (for example a frame, cross section,
note flag, dimension, etc.).
o Object Frames — Frames within an object can be selected independently.
• Surface/Face — Only the selected surface (or face) of the object is selected.
• Edge — Only the selected edge of the object is selected.
The Surface/Face and Edge Pick Levels are only available when certain
Process Simulate commands are active, such as Project Arc Seam and the
various measurement commands. These Pick Levels is discussed later in this course,
only if applicable.
A short cut key to toggle between the Pick Levels is the F12 key.
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Toggling detailed or united representation

In order to improve performance in , access to individual entities (for example geometry within an
object) is limited. This is referred to as the United Representation of an object, which is the default
loading behavior for all objects.
However, in special situations, access to specific entities is required to perform a task. This is referred
to as the Detailed Representation of an object.
The Detailed Representation of an object is stored as part of the study data.
You cover several topics dedicated to scene data later in this course. For now, don't worry
about this type of data.
To temporarily access all entities of an object:

• Choose the object.
• From the ribbon, choose Modeling tab→Entity Level group→Load Entity Level .
• Pick and use the entities as desired.
• Choose the object
• From the ribbon, choose Modeling tab→Entity Level group→Load Entity LevelUnload Entity
Level .
To access specific entities of an object on a long term basis:
More is described on modeling objects later in this course.
• Start modeling the object
• Choose the desired entities and From the ribbon, choose Modeling tab→Entity Level
group→Load Entity Level Set as Preserved Objects .
• End modeling the object
Viewing and selecting PMI
According to www.wikipedia.com: Product and manufacturing information, also

abbreviated PMI, conveys non-geometric attributes in 3D computer-aided design (CAD)
and Collaborative Product Development systems necessary for manufacturing product
components or subsystems. PMI may include geometric dimensions and tolerances,
3D annotation (text) and dimensions, surface finish, and material specifications. CAD
application literature may also refer to PMI synonymously with Geometric Dimensions and
Tolerances (GD&T) or Functional Tolerancing and Annotation (FT&A).
Industry standards for defining PMI include ASME Y14.41-2003 Digital Product Data
Definition Practices and ISO 1101:2004 Geometrical Product Specifications (GPS) –
Geometrical tolerancing – Tolerances of form, orientation, location and run-out. In an effort
to unify the visualization of PMI across the different existing solutions, Adobe Systems has
released a version of the Myriad CAD font that allows to display PMI from almost any CAD
application. Similarly, Siemens PLM Software offers downloadable font sets for multiple
languages such as for Asian character sets. The ISO STEP-NC standard also handles a
wide range of PMI information.
The PMI annotation is created on the 3D CAD model, associated to edges and faces, and
can be exported into neutral formats such as Siemens JT. This information can then be
used by a number of down-stream processes. Although PMI can be used to generate
annotation on a traditional 2D drawing the data can be visualized within the 3D model by
other departments, either in the CAD/CAM system or in a 3D Product visualization tool,
such as Siemens Teamcenter Lifecycle Visualization, thus reducing the need for drawings.
Some 3D model formats enable computer-aided manufacturing software to access PMI
directly for CNC programming. The PMI also may be used by tolerance analysis and
Coordinate-measuring machine (CMM) software applications if the modeling application
permits.
By default PMI contained in a part or resource are not shown. However if you choose to load the PMI,
it is shown in the Graphic Viewer and Object Tree. It is also possible to choose, blank, display, etc.
based on the specific type of PMI. More on that in another topic.
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Displaying and Hiding all PMI for a specific part or resource:

These commands are found o the ribbon in the PMI group of the Modeling tab.
• Load PMI — Show PMI in the Graphic Viewer and Object Tree for the selected object.
There are many different types of PMI. By default all types of PMI are loaded with the
Load PMI command. However, which PMI types that are loaded can be configured
by choosing File→Options , Selecting the General tab, and clicking PMI Types.
• Unload PMI — Hide PMI in the Graphic Viewer and Object Tree for the selected object.
• PMI Character Size — Change the font size for the selected PMI.
• PMI Font — Change the font for the selected PMI.
• Grow PMI Text — Make the text larger for the selected PMI.
• Shrink PMI Text — Make the text smaller for the selected PMI.
Activities
In the Entity selection section, do the following activities:
• Selecting objects in the Graphic Viewer
• Additional methods of multiple entity selection
• Using Toggle Display
Review questions
Question
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Pick Intent Selection Criteria Modal Differentiation Pick Level
Introduction to selection filters (optional)

Purpose
In this topic, you learn about using filters to help select the desired objects.
Objectives

• Use a basic filter found on the Selection toolbar.
Selection filter basics

There are several filter tools in Process Simulate.
From the Graphic Viewer toolbar, choose Choose with Filter — Can be used to select objects
based on their type.
Selection filters available on the Graphic Viewer toolbar:
• Choose All
• Selection Type All
• Choose Type None
• Selection Type Part
• Selection Type Resources
• Selection Type Mfg
• Selection Type Weld Points
• Selection Type Path
• Selection Type Global Locations
• Selection Type Frames
• Selection Type Notes
• Selection Type Points
• Selection Type Lines/Curves
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• Selection Type Solids/Surfaces
• Selection Type PMI
Activities
In the Introduction to selection filters (optional) section, do the following activity:
• Optional — Blanking all the frames using selection filters
Review questions
Question
Select objects based on their type and perform specific commands that are shown in the toolbar of
this dialog box. Select objects based on their type and then perform any command in the system
(that is valid for the selected objects).
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Introduction to Display By Type

Purpose
In this topic, you learn about the Display By Type dialog box.
It is similar to the selection filters (described in the previous topic), but the Display By Type
dialog box is easier to use and has more functionality.
Objectives
• Use the Display by Type dialog box to blank specific types of objects.
• Use the Display by Type dialog box to blank objects by color.
Display by type basics
To open it: choose Display By Type from the Graphic Viewer toolbar.
Method 1: In the Display By Type dialog box, first select object type(s) in the dialog, then choose
a type-related action from the dialog toolbar.
• Show selected types
• Hide selected types
• Show only selected types
• Delete selected types
Method 2: In the Display By Type dialog box, first select a filter color, select partial/full, then choose
to show or hide objects fro the dialog toolbar:
• Filter by Color — Activate the color filter. Use the eye dropper to select a color from a
displayed object.
• Match — Select Partial to affect objects that contain more than the selected color. Select Full to
affect objects that contain only the selected color.
• Show All — When the color filter is active, only objects of the selected color and match are
redisplayed. Otherwise, all objects are redisplayed.
• Hide All — When the color filter is active, only objects of the selected color and match are
blanked. Otherwise, all objects are blanked.
Available types for Display by Type

• Part Appearances
• Guns
• Robots
• Human Models
• MFGs
• Dimensions
• Points
• Paths
• Locations
• Lines/Curves
• Solids/Surfaces
• Frames
• Devices
• Notes
• Labels
• Sections
• PMI
There are currently 35 PMI type filters available in Process Simulate.
Activities
In the Introduction to Display By Type section, do the following activity:
• Blanking objects using Display by Type
Review questions
Question
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Select objects based on their type and perform specific commands that are shown in the toolbar of
this dialog box. Select objects based on their type and then perform any command in the system
(that is valid for the selected objects).
Measurement and units

I
Purpose
In this topic, you learn about the relationship between the measurement tools and the current unit.
Also, you use the measurement tools found on the Graphic Viewer toolbar.
Objectives

• Change the units used.
• Perform a linear measurement.
• Create a dimension.
Changing units
In general, the results of any measurement command are shown in the current units, as set in the
File→Options menu. The default unit types are defined for data stored as numeric values
in the database.
Configurable units of measure:

• Linear: mm, cm, m, inch, ft
• Angular: deg, rad
• Mass: kg, lbs
• Time: sec, min, 1/10 min, 1/100 min, 1/1000 min, hour, day, TMU, RU, MODAPTS, SAM
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There are several industry specific time units supported by default:

• 1 minute = 10 “1/10 min”
• 1 minute = 100 “1/100 min”
• 1 minute = 1000 “1/1000 min”
• 1 minute = 0.0167 hours
• 1 minute = 0.0007 days
• 1 minute = 1666.6667 TMU (1 TMU = 1/3600 of a second). It is an abbreviation for

Time Measurement Units used by MTM
• 1 minute = 1000 RU. It is used by Work Factor
• 1 minute = 465.1163 MODAPS. It is an abbreviation for MODular Arrangement of

Predetermined Time Standards
• 1 minute = 333.3333 SAM. It is an abbreviation for Sequential Activity and Methods

analysis
The modified units are supported in the Gantt, Units tab, measurements, etc.
Linear measurement
There are several linear and angular measurement commands found in the Graphic Viewer toolbar.
These commands can be used to take a quick measurement, create a dimension, or the measurement
vale can be copied and pasted somewhere else.
• Minimal Distance — Measures the distance between two selected objects (components,
entities, edges, or faces) from the closest point on the exterior of each object.
• PTP Distance — Measures the distance between two selected points. The selected points
do not have to be on the same object.
• Linear Distance — Measures the distance between two components, entities, edges, or
faces.
• Angular Measurement — Measures the angle between two components, entities, edges,
or faces.
• Angle by 3 Points — Measures the angle between three selection points. The selection
points do not have to be on an object.
• Curve Length — Measures the length of a curve.
Creating dimensions
Using the dimension commands is kind of like using the measurement commands. However, the
measurement commands create a temporary dimension in the Graphic Viewer; while dimensions add
permanent measurements in the Graphic Viewer. you create some dimensions later in this course.
These commands are found on the Modeling tab of the ribbon under Create Dimension .
• Point-to-point Dimension — Creates a dimension to measure the point-to-point distance

between two objects.
• Minimal Distance Dimension — Creates a dimension to measure the shortest distance

between two components, entities, edges, or faces.
• Linear Dimension — Creates a dimension to measure the distance between two

components, entities, edges, or faces.
• Angular Dimension — Creates a dimension to measure the angle between two

• X-Axis Dimension — Creates a dimension to measure the distance along the X-axis
• Y-Axis Dimension — Creates a dimension to measure the distance along the Y-axis
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• Z-Axis Dimension — Creates a dimension to measure the distance along the Z-axis
• Normal to Source Curve Dimension —Creates a dimension to measure the distance in

a section normal to a section line, normal to a source curve.
• Normal to Target Curve Dimension — Creates a dimension to measure the distance

in a section normal to a section line, normal to a target curve.
• Curve Length Dimension — Creates a dimension to measure the distance the length
of a curve.
Activities
In the Measurement and units section, do the following activity:
• Relationship between measuring and units
Review questions
Question
TRUE FALSE
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Graphical visualization and performance

Purpose
In this topic, you learn about ways to modify graphical visualization of objects and graphical
performance.
Objectives
• Become aware of graphical visualization settings.
• Toggle all objects’ visualization.
• Change a specific object’s visualization.
• Set stereo visualization settings.
• Use dynamic clipping.
• Change graphical performance settings.
Graphical visualization
Graphical visualization of an object is affected by many factors such as:
• Object Specific Settings:
o Color
o Transparency
o Shading
o Textures (discussed in the next lesson)
o Displayed Entities
• Global Settings
o Lighting
o Performance Settings
Toggling all objects’ visualization

Toggling All Objects’ Visualization:
There are four display modes available:
• Shaded Mode
• Feature Lines Over Solid
• Feature Lines
• Wireframe Mode
Display modes temporarily change the visualization of all the displayed geometry in the Graphic
Viewer between shaded and feature line (also known as Hidden Line Removal) mode. There are a
few methods to do this:
• Press the F10 key (With each click of this button the display mode is changed in this order:
Shaded, Feature Lines Over Solid, Feature Lines, and then Wireframe Mode.
• From the Graphic Viewer toolbar, choose the display mode directly. For example Shaded
Mode
Specific object visualization

Changing Specific Object Visualization:
Shaded / Wirefame / Transparent — Used to permanently change the display

of a single object (or group of objects). These commands are not meant to affect all displayed
objects. There are two methods to do this:
• Right-click the desired object or objects and choose Object Viewing and then the desired mode.
• From the ribbon, choose View tab→Visibility group and then the desired mode such as
Transparent .
Graphical visualization setup
Choose File→Options . From the Options dialog box, choose the Graphics Viewer tab.
Lighting
When Second Light Source intensity is selected, you can define the intensity of a second light
source in the Graphic Viewer using the Intensity slide bar.
Feature Lines Setup
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• Feature line angle — In Wireframe Mode, Feature Lines, and Feature Lines over Solid
modes, the Graphic Viewer can draw feature lines at the border of neighboring planes when the
breaking angle between the planes is between 1 and 45 degrees. This box enables you to set
the minimum breaking angle (the default value is 35 degrees).
• Feature line width — Enables you to set the width of the feature lines between 1 to 3 pixels
(the default value is 1 pixel).
• Show silhouette in Wireframe Mode — When set, silhouette lines are visible around objects in
the Graphic Viewer in Wireframe Mode. This facilitates viewing of objects with low visibility. This
is also relevant for Feature Lines, and Feature Lines over Solid modes.
Silhouette lines are not selectable.
Stereo visualization
This information is provided as a reference, since your classroom environment, most

likely does not have this hardware.
Tecnomatix supports stereoscopic 3D viewing in the Graphics Viewer, as well as in the Multi Sections,
and Section viewers.
Prerequisites:
• Hardware that supports stereo rendering
o Monitor/projector that supports high frequency rate of at least 120Hz for Active Stereo
technology.
o Graphics card that supports stereo rendering and quad-buffer stereo mode. Contact your
graphics card manufacturer to learn whether your hardware supports stereo viewing.
o 3D glasses that support active stereo technology. For information on stereo shutter glasses,
see http://www.stereo3d.com/3dhome.htm
• Stereoscopic 3D mode should be configured for the graphics card.
• Enable stereoscopic 3D: Using the Tecnomatix Doctor , choose Tools→Enable the use of
3D stereo viewing.
Fine tuning can be done using from within Process Simulate: Choose File→Options and
choose the Stereo 3D tab.
Enabling stereo rendering can significantly impact the performance of your graphics card.
It is recommended to enable it on your hardware only for cases when you actually plan
to use 3D stereo viewing.
When Enable the use of 3D stereo viewing is selected and the Graphic Viewer displays
in stereo, the output of the following tools is in standard 2D/3D graphic viewing: Attach
File , AVI Recorder , Movie Manager , Markup Editor . Performance

may be somewhat affected.
Dynamic clipping overview
The Dynamic Clipping and Dynamic Clipping Plane Settings commands enable you to
view points of interest blocked from view by intervening objects.
In Process Simulate, the view displayed in the Graphic Viewer is the view as observed by an external
viewer located at a fixed point (known as the camera view point). Any object located between the
camera and the point of interest may partially or fully block the view. The Dynamic Clipping and
Dynamic Clipping Plane Settings options define an adjustable clipping plane which hides all
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the objects between the camera and the clipping plane. The clipping plane is always parallel to the
camera's viewing plane and objects that straddle the clipping plane are clipped (truncated).
To configure dynamic clipping:
1. From the Graphic Viewer toolbar, choose View Center to set the desired point of interest
at the center of the Graphic Viewer display.
2. From the ribbon, choose View tab→Section group→Dynamic Clipping Plane Settings .
3. In Dynamic Clipping Plane Settings dialog box, move the Clipping Plane slider between Camera
and View Center as desired.
Overview of performance options
Choose File→Options . From the Options dialog box, choose the Performance tab.
Direct Model Settings:
• Use background loading – loads newly loaded parts in the background and redraws the model
at a specified interval, instead of immediately as each part is turned on.
o Specify in seconds how frequently to update the scene in the Graphic Viewer
o A wireframe bounding box is displayed in the Graphic Viewer for parts whose geometry is
not yet loaded due to background loading.
• Fixed Frame Rate – controls the rate at which your model is redrawn in the Graphic Viewer. Use
the Fixed Frame Rate to increase or decrease the number of frames per second (FPS) that are
drawn while the view is changing.
• Memory Limit – An amount including virtual and physical memory. If you exceed the memory
limit, further part loading halts and parts not rendered in the last few frames are unloaded until
memory usage falls below the specified percentage.
• Rendering Mode – to render the Graphic Viewer contents. Results vary according to your
hardware. Machines with a server-client architecture should benefit greatly from using OpenGL
Display Lists. Other machines with sufficient memory also may achieve a significant boost in
performance. However, if your machine does not have enough memory, rendering performance
may not improve, and you should not enable the option.
OpenGL Buffer Objects allows for improved memory consumption. With this option,
loading a large amount of data into the display demands less memory with the benefit
of OpenGL rendering mode acceleration.
When loading a study that has some object JTs with units that are not in millimeters,
in some cases the application may color an object black when running a simulation
or moving the object (or another one) using the Placement Manipulator. Setting the
Rendering Mode to use OpenGL Buffer Objects prevents this from occurring.
Level of Details (LOD):

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

There are two ways to use level of details: It can affect the speed of both simulations and graphic
view manipulations.
• The Level of Details slider can be used to increase or decrease performance by changing the
precision of the displayed objects. In this way both simulation and Graphic Viewer manipulation
are affected.
• However, if Decrease Level of Detail while changing View Point is also selected, then the
lower display precision is only used during graphics view manipulations.
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• Cull parts with less than % – Specify the percentage of the Viewing dialog box that a part must
cover before the part is drawn. Parts that are less than or equal to this size are not drawn in
the Graphic Viewer .
Using Culling Percentage can reduce image quality. However, you can zoom-in to
improve the quality of the image.
Activities
In the Graphical visualization and performance section, do the following activities:
• Changing visualization performance
• Changing graphical visualization
Review questions
Question
TRUE FALSE
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Add a fancy graphics background
Purpose
In this lesson, you learn about texture maps and point clouds.
Objectives
• Use components with texture maps.
• Insert point cloud data.
Texture Maps
Object Textures
3D objects can be shown in the Graphic Viewer with object textures, if the textures were added to the
.JT file in a CAD or visualization system (for example NX or Teamcenter Visualization).
Point Clouds
In this case you want to add background graphics to your study, but do not have the 3D data. You
can scan whole factories as a cloud of points. The points in the point cloud represent the external
surface of a scanned three-dimensional object. This can be done for any 3D objects that do not take
part in the simulation, but are needed for visualization. Point database (.pod) files are specifically
designed to handle large data.
Because point cloud files are designed to represent your 3D plant background, these files are
typically massive (for example 1 GB to 8 GB are typical). They are something like three-dimensional
photography. You may find helpful to define the position of objects in a scene. The file format is used
by many systems including Bentley Pointools, Microstation, and AutoCAD. Here is an example
point cloud:
Point Clouds are not supported on virtual machines or when working in a Citrix environment.
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Point cloud basics:
• A point cloud is a single object.
• You can divide the point cloud into layers for added flexibility. For example, you might wish
to move each work station to a separate layer; this would enable you to display some work
stations and blank others.
• Point cloud files typically contain very large amounts of data. However, you can still continue
working in Process Simulate while the point cloud file loads due to the smart memory
management algorithm. This oversees memory consumption and optimally loads point cloud
data according to the point of view set by the user.
Using a point cloud is advantageous for planning engineers because:
• Scanning technology enables you to plan the manufacturing station layout based on
currently-existing data, while considering plant structure, existing resources, etc., and avoiding
problems. For example, if you wish to plan the manufacturing process for a new car model, you
can use a point cloud that represents the exact layout of the current manufacturing station as the
basis for the new line and make the necessary modifications, as opposed to providing plans that
might be inaccurate or out of date. Additionally, it is possible to update your scan periodically
and maintain your data in Process Simulate, something which is very difficult to do when using
a CAD design of the plant.
• In many cases, the manufacturing floor undergoes constant change. It is a simple process to
create a new point cloud and update the study.
Other features of point clouds:
• Change point size — Choose File→Options, click the Appearance tab, select Point
Cloud→Point Settings, and type the Pixel size.
• Set point cloud shading and emphasis colors — Choose File→Options , click the
Appearance tab, select Point Cloud→Shading, and select the shading value: RGB color,
Intensity, or RGB and Intensity.
• Check collisions with point clouds — Select it as one of the objects for a collision set. The
accuracy of collision detection results depends on point cloud density.
Not supported with point clouds:

o Collision detection between two point clouds
o All displayed objects collision detection
o Show / Hide colliding contour and Collision depth
Collision detection and near miss calculation for point cloud objects may lead to large
memory consumption and slow performance. Memory and processing requirements
vary depending on usage. The basic Process Simulate hardware requirements
may not be sufficient when working with large point cloud files. You can improve
performance by: Compute collision between small point cloud layers instead of the
entire point cloud object. Turn off Near-miss if not necessary. Working with local point
cloud files can significantly improve collision detection performance.
• Move the point cloud with the Relocate and Placement Manipulator .
• Use the section tools on point clouds.
• Show point clouds gray or blended when emphasizing geometric objects.
Either a Process Simulate Point Cloud Advanced or Process Simulate Point Cloud
View license is required to work with point clouds.
Begin using point clouds

1. Use a tool such as Bentley Pointools to create the point cloud and to remove undesired points.
2. In Process Simulate, configure a point cloud root for your point cloud paths by clicking Point
Cloud on the General tab of the Options dialog box.
3. From the Process Simulate ribbon, choose Modeling tab→Components group→Point Cloud
→Insert Point Clouds to select the .pod files you want.
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Optionally, manage point clouds
1. From the ribbon, choose Modeling tab→Components group→Point Cloud →Edit Point
Cloud to begin editing the point cloud.
A pen is added to its icon in the Object Tree to indicate that the point cloud is in edit mode.
You can only edit one point cloud at a time.
2. From the ribbon, choose Modeling tab→Components group→Point Cloud →Create

Point Cloud Layer to create some layers.
A new layer is nested under the active point cloud in the Object Tree. You can edit the layer’s
name and can create up to six layers.
3. Move points onto a layer.
a. From the ribbon, choose Modeling tab→Components group→Point Cloud →Select

Rectangle to get into a mode to select points from the edited cloud.
b. Drag the cursor over the area you wish to associate with a particular layer. When you release
the mouse button, the selected cloud points are displayed in orange.
c. Select the desired point cloud layer in the Object Tree and from the ribbon, choose Modeling
tab→Components group→Point Cloud → Move Selected Points to Layer .
4. From the ribbon, choose Modeling tab→Components group→Point Cloud →Clear

Selection
5. From the ribbon, choose Modeling tab→Components group→Point Cloud →Exit Edit
Mode to exit edit mode.
6. Set the hide/display status of the point cloud layers as needed.
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Activities
In the Add a fancy graphics background section, do the following activities:
• Use texture maps
• Use point clouds
Additional commands
Purpose
In this topic, you learn about other important, miscellaneous commands.
Objectives
• Minimize and maximize the viewers.
• Move windows and toolbars around.
• Search for objects.
• Expand the tree views to the object selected in the Graphic Viewer.
• Collapse an expanded tree view to the selected object.
• Display tooltips.
• Display or hide the floor in the Graphic Viewer.
Window manipulation
To resize Process Simulate window:
• Click Maximize to maximize Process Simulate window so that is covers the entire screen. To
restore it, click Restore Down .
• If you wish to work with other tasks not associated with Process Simulate, it is recommended that
you send Process Simulate window to the Taskbar at the bottom on the Windows desktop by
clicking Minimize . When you wish to return to Process Simulate, click Process Simulate
on the Taskbar, as shown below:
Toolbar manipulation
To Move Toolbars:
Move the toolbar by Selecting and dragging using the two vertical gray bars on the far-left edge of
the toolbar.
After a toolbar is dragged from a toolbar area it shows the toolbar name as the name of the toolbar.
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Toolbars want to “stick” to the top, bottom, left, or right edges of the viewer area.
Searching for objects

1. Continue with the same data opened in the previous activity.
2. Choose an object in the Object Tree to search below, such as the top level folder.
3. Choose Edit→Find.
4. Search for entities in the tree that contain the letters fr*
An asterisk [*] is used as a wild card in the Find dialog box. So searching for fr* locates
all objects that begin with the letters fr.
5. Choose Find Next to find the next occurrence.
6. Choose Cancel when done.
Expand to selection
To expand to selection:
When an object is selected in the Graphic Viewer, the Object Tree viewer expands and highlight the
selected object.
• This behavior can be toggled by choosing File→Options .
• In Options dialog box, choose the General tab.
• Select or deselect the check box named Expand tree to show Graphics Viewer selection.
Collapse to selection
To collapse to selection:
• Select an object in the Object Tree viewer
• Right-click on nothing
• Choose Collapse→Collapse Level.
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Display tooltips
Display Tooltips in the Graphic Viewer:
When you mouse over an object in the Graphic Viewer, a note is displayed showing its name.
• This behavior can be toggled by choosing File→Options .
• In Options dialog box, choose the Graphics Viewer tab.
• Select or deselect the check box named Display Tooltips.
Display or hide the floor

To display or hide the floor:
From the ribbon, choose View tab→Screen Layout group→Display Floor to toggle the floor
on and off.
• When the floor is displayed the menu option looks like this:
• When the floor is hidden the menu option looks like this:
From the ribbon, choose View tab→Screen Layout group→Adjust Floor . In the Adjust Floor
dialog box, click Auto Adjust to adjust the floor width and length to match the extends of the
farthest 3D objects.
To toggle between perspective and parallel viewing:
• From the ribbon, choose View tab→Orientation group→Perspective/Parallel . This changes

the view perspective in the Graphic Viewer between parallel and perspective.
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Accessing online help and release notes

Purpose
In this topic, you learn how to use the help and release notes.
Objectives
• See help in several ways.
• Use the online help.
• Find and view the release notes.
Quick Help Topics

To display the software version number:
• From the ribbon, choose File→About.
To display information about a command:

• Place the cursor on a command in the ribbon for a few seconds. A yellow tool tip is displayed
containing a short description of the icon:
To search for a command:

• On the ribbon enter part of a command or object name.
From the search results:
o See the ribbon path to the commands
o Execute a command
o Select an object from the loaded data
Online help
To access online command help by Index:
By default, the system displays the help documentation in web style (HTML) format. You
must have Java version 45 or higher installed to be able to search the help. It is advisable
to use Internet Explorer 9 (IE9) or a current version of the Firefox browser.
Users who prefer to view the help in the older CHM format can deselect the Tools→Display
Web style help option from the Tecnomatix Doctor . However, this topic assumes
the default web style help is being used.
1. If the Help dialog box is not opened: From the ribbon, choose File→Help . The help dialog
box is opened
The help dialog box is can also be accessed by pressing the F1 key.
2. In the Siemens Documentation dialog box, click Home if you are not already there.
3. In the Product area pane, click Process Simulate and then File.
4. Choose a topic from the list.
5. When you are finished, close the dialog box by clicking Close .
To access online command help by search:
1. If the Help dialog box is not opened: From the ribbon, choose File→Help . The help dialog
box is opened
The help dialog box is can also be accessed by pressing the F1 key.
2. In the Siemens Documentation dialog box, locate the Search box.
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3. Enter a single word to search for in the help. Or for multiple keywords, type the word OR between
keywords. For example standard and line.
4. Click Search .
5. Click a topic from the list. The help topic is displayed.
6. When you are finished, close the dialog box by clicking Close .
Release notes
From the Windows Start menu, choose Start→All Programs→Tecnomatix→Tecnomatix Release
Notes .
You must have Adobe Acrobat Reader installed to read the release notes.
Summary
• The menu and toolbar options available in Process Simulate were discussed.
• Various right-click popup menus available in Process Simulate.
• How to use the mouse to control objects displayed in the Graphic Viewer, as well as changing the
viewpoint and view center of a selected object was discussed.
• How to display and hide objects using the Display By Type dialog box.
• How to perform measurements and entity selection
• Discuss other functions that can be used such as resizing the Process Simulate window.
• The chapter finished by discussing how to access online help for a command.
Lesson 3: Placement commands
Purpose
To discuss placement tools provided by Process Simulate.
Objectives

• Several placement commands is used to properly position objects within studies.
Lesson
Lesson 3: 3: Placement
Placement commands
commands
Introduction to placement
Purpose
In this topic, you get an overview of the placement tools. Placement tools can be used to change the
position and orientation of product, resources, frames, etc. In the next few topics, the various tools
required to position instances are discussed.
Objectives
• Know a little bit about the placement tools.
Overview
The basic placement methodology is as follows
• Choose the desired object (or several objects using the Ctrl key).
• Use the placement commands to move the objects into the desired position.
Overview of the placement tools
In this topic, you cover the primary placement techniques available in detail. A topic is dedicated to
each. At this point you only give the names of the commands:
• Fast Placement (there is no dialog box) enables placing several objects quickly by dragging
them around the Graphic Viewer.
• The Placement Manipulator dialog box enables on-screen shifting and rotating of objects on their
X-, Y-, and Z-axes.
• The Relocate dialog box enables placing an object so that it maintains its original orientation,
place an object so that it takes on the target frame orientation, or place an object relative to
two different frames.
• Restore Object Initial Position – returns the object to its position and orientation as stored(for
example the position before placement was performed; as long as you have not saved your
changes).
Review questions
Question
Placement commands
Put Transfer Panel Place Fast Placement Placement Manipulator Relocate Restore Object Initial
Position
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Placement commands
commands
Introduction to Fast Placement and Restore Object Initial Position

Purpose
In this topic, you learn about the Fast Placement command and the Restore Object Initial
Position command.
Objectives
• Use Fast Placement and theRestore Object Initial Position .
Fast Placement usage
Fast Placement can be used on multi selections. Using fast placement for several
objects draws a bounding box which contains all the selected objects.
From the ribbon, choose Modeling tab→Layout group→Fast Placement , the left mouse
button’s function is changed to fast placement mode.
To get out of this mode, either:
• From the ribbon, choose Modeling tab→Layout group→Fast Placement. again.
• From the ribbon, choose View tab→Orientation group→Select .
• Press the Esc key.
Activities
In the Introduction to Fast Placement and Restore Object Initial Position section, do the following
activity:
• Using Fast Placement
Placement commands
Review questions
Question
Lesson
Placement commands
commands
TRUE FALSE
Placement commands
Changing selection behavior and creating frames

Purpose
In this topic, you learn how to change Pick Intent, change Pick Level, and create reference frames.
Objectives

• Set Pick Intent.
• Set Pick Level.
• Use several techniques to create frames.
Setting pick intent

Use the Pick Intent stack to choose how objects are selected in the Graphic Viewer. This can be
accessed by clicking the down arrow next to the eighth icon in the Graphic Viewer toolbar. The last
icon you select becomes the one on the top of the stack.
The Pick Intent stack contains these commands:
• Snap : The position selected is either:

o The closest mid point of an edge – select on a surface near the middle of the edge.
o An end point of an edge – select on a surface near the corner of the edge.
o The center of a face – select on the middle of an edge bounding the desired surface.
• Self-origin : This is the only Pick Intent that depends on the setting of the Pick Level. If the
Pick Level is set to Component , then the self-origin of the object is always selected, no
matter where the object is selected. If the Pick Level is set to Entity , then the self-origin of
the currently selected entity is selected.
• On Edge : The location selected is the closest point along the closest edge.
• Where Picked : The location selected is the point you selected.
A short cut key to toggle between the Pick Intent options is the F11 key.
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Setting pick level refresher

Use the Pick Level stack to choose how objects are selected in the Graphic Viewer. This can be
accessed by clicking the down arrow next to the seventh icon in the Graphic Viewer toolbar. The
last icon you select becomes the one on the top of the stack.
It was described earlier in this course. Recall that it can be set to several values such as Component
or Entity either from the Graphic Viewer toolbar or using the F12 key
The Pick Intent and Pick Level should generally be set to their default values of Snap and
Component . Unless otherwise specified, this student guide assumes that they are set this way.
The Face and Edge pick levels are only available when performing specific
commands such as projecting arc-weld manufacturing features. these two pick levels are
discussed only when applicable.
Basic techniques for creating frames

To create a frame:
1. From the ribbon choose Modeling tab→Layout group→Frame by 6 values .
2. Choose a frame creation technique, such as Frame by 6 values .
Placement commands
3. Define a location for the frame.
Techniques to create frames or define custom reference frames:

Techniques to create frames or define custom reference frames:
• Frame by 6 values
• Frame by circle center
• Frame by 3 points
• Frame between 2 points
Advanced techniques for creating frames
• Frame by 6 values :
Frame by circle center :
Lesson
Placement commands
commands
Frame by 3 points :
Frame between 2 points :
Placement commands
(1) Selecting the center of a hole: If selecting on geometry on a geometric circle or cylinder
shape, set the Pick Intent to Snap and select on or near the circle or shape to
snap to the center.
(2) Selecting the center of a cylinder: In this case, you should use Create Frame By 6
Values instead of this option.

(3) Another method to select the center of a hole or cylinder: select Create Frame by
Circle Center and select three points around the parameter of the circle. This option
is best, for geometric circles or cylinders that are so imperfect that Process Simulate does
not recognize them as such (for example a hexagon).
Activities
In the Changing selection behavior and creating frames section, do the following activity:
• Creating a frame
Review questions
Question1
Question2
Lesson
Placement commands
commands
Snag Simple Variable Snap Self Origin Where Picked On Edge Frame by 6 values Frame between 2
points Frame by 3 points Frame by circle center
Placement commands
Introduction to Placement Manipulator

In this topic, you cover
Purpose
In this topic, you learn about the Placement Manipulator command and other commands that
relate to it. The Placement Manipulator command is described in detail later In this topic.
you start by explaining the “other” commands.
Objectives

• Know the various reference frame used in this system.
• Use the basic and advanced Placement Manipulator options.
Reference frame definitions

you now learn how to use the placement commands to move instances to their proper positions. The
key to understanding and effectively working in Process Simulate lies in thoroughly understanding
the following definitions. Understanding these definitions allows you to grasp the concept behind
the placement commands.
• Point/Position — A location defined by X, Y and Z values relative to a reference frame. Position
does not possess orientation. For example: (X, Y, Z) is a point/position.
• Frame — A location having both position and orientation, that is, an axis system. The origin point
of a frame is a position. For example: (X, Y, Z, Rx, Ry, Rz) is a frame.
• World Frame — The permanent origin of the graphics space. The default position of every object
is relative to this. It does not have a graphical representation.
• Working Frame — Sits at the World Frame by default. It can be temporarily moved to any
position or orientation. It is the reference frame having red (X), green (Y), and yellow (Z) axes.
o From the ribbon, choose Modeling tab→Layout group→Set Working Frame to move it.
The small reference frame in the lower left corner of the Graphic Viewer, with the same
coloring as the Working Frame, is nothing except a visual of the Working Frame
orientation. It is useful in cases when real Working Frame is not currently visible.
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commands
• Self-Origin — An unique frame assigned to each prototype. Its position and orientation is
assigned to that of the World Frame when modeling the prototype (for example the object's origin
frame). This is the local origin of a prototype or instance, not the center of gravity.
• Geometric Center — It is the default reference frame for many commands in Process Simulate
including the placement commands.
Placement Manipulator basic options

The Placement Manipulator consists of several parts:
Translation control buttons area:
• Set the step size.
• Relative movement: After Selecting an axis, you can translate in the negative or positive
direction by the defined step size .
• Absolute movement: Type the distance for the selected axis and press Enter.
Rotation control buttons area:
• Works like the translation, except for rotation.
Frame of reference selection area:
• Can choose one of the standard reference frames from the drop down, or select anything from
the Graphic Viewer.
The Manipulator Frame:
Placement commands
Even though the actual position and orientation of the Manipulator Frame is set by the
Frame of Reference box, it always resides at the geometric center of the object.
• Grab a colored axis and drag to constrain the linear movement along that axis
• Grab a colored axis and drag to constrain the rotational movement along that axis
• Grab a white square and drag to constrain the planar movement along that plane.
Reset position and close command area:
• Click Reset to undo all positional and rotational changes to the object since the dialog box
was opened.
To undo all positional and rotational changes since the object was last saved, From the
ribbon, choose Modeling tab→Layout group→Reset Relative Location .
Placement Manipulator advanced options

The Placement Manipulator consists of several parts:
Frame of reference selection area:
• Construct or modify the position and orientation of a temporary reference frame using one of the
frame creation techniques to the right of the Frame of Reference box.
Lesson
Placement commands
commands
• Select in the Frame of Reference box and select anywhere in the Graphic Viewer or the Object
Tree.
Additional options area:
For additional options, click Expand Dialog

• Choose the desired frame of reference to view its value, or type in the desired coordinates here.
• Snap by step size works in conjunction with Step Size and dragging the Manipulator
Frame.
Activities
In the Introduction to Placement Manipulator section, do the following activities:
• Shifting and rotating instances on-screen
• Relationship between Placement Manipulator measuring and units
• Incremental shifting of objects from a reference frame
Review questions
Question
Placement commands
Can reposition the object relative to two selected frames. Can reposition the object so that it takes
on the target frame orientation. Can use the Manipulator Frame in the Graphic Viewer to rotate or
shift the object along a selected axis or plane. Can rotate or shift the object by entering relative or
absolute values.
Lesson
Placement commands
commands
Introduction to Relocate
Purpose
In this topic, you learn about the Relocate command and other related commands.
Objectives
• Use the basic and advanced Relocate options.
Relocate command overview
The Relocate command can be used to place and move objects. To access the Relocate
command, you first need to choose an object and then click Relocate on the Graphic Viewer
toolbar. The Relocate dialog box is displayed:
You can use the Relocate dialog box to do many things:

• Relocate an object relative to two frames.
• Relocate an object along one or two axes only.
• Relocate an object so that it maintains its original orientation.
• Relocate an object so that it takes on the target frame orientation.
• Create a temporary or permanent frame to display the From frame or To Frame.
• Choose to either move the object or copy it (create a new instance at the destination).
Placement commands
Many of these possibilities are discussed in detail in the following topics.
Basic Relocate command usage

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

If the Maintain orientation check box is selected, the object is moved the linear distance from the
From frame to the To frame without changing its orientation, as shown in the diagram below:
Relocating an Object So That It Takes on the Target Frame Orientation

Self-origin is the default option for the From frame. So if you only choose the To Frame, the object is
moved the linear distance from the From frame to the To Frame, and then be rotated to match the
difference between the two frames.
In other words, if the default From frame is the self-origin of the object, the object is moved and
rotated so that the self-origin of the object is superimposed on the target frame.
Lesson
Placement commands
commands
Advanced Relocate command usage

User Defined Frame and To Frames
• Construct or modify the position and orientation of a temporary reference frame using one of the
frame creation techniques to the right of the From frame and To frame boxes.
• Select in the From frame and To frame boxes and select anywhere in the Graphic Viewer or
the Object Tree.
Misc.
• The Placement Manipulator and Relocate commands can be open simultaneously for the same
object. Many parts of Process Simulate are designed to work with these two dialog boxes
opened at the same time.
Placement commands
Querying the Position and Orientation of a Frame

• Choose either the From frame or To Frame boxes in the Relocate dialog box and select on a
frame.
Click Frame to the right of either the From frame or To Frame boxes in the Relocate dialog box.
This is a printout of the current position and orientation of the selected frame.
Activities
In the Introduction to Relocate section, do the following activity:
• Relocating an object relative to two new frames
• Relocating an object relative to two existing frames
Review questions
Question
Lesson
Placement commands
commands
Can reposition the object relative to two selected frames. Can reposition the object so that it takes
on the target frame orientation. Can use the Manipulator Frame in the Graphic Viewer to rotate or
shift the object along a selected axis or plane. Can rotate or shift the object by entering relative or
absolute values.
Placement commands
Summary
• Several placement commands were used to properly position objects within studies.
Lesson 4: Quick introduction to kinematics
Purpose
To discuss kinematic basics in Process Simulate. You learn kinematics in much more detail later in
this course.
Objectives

• How to use kinematics in Process Simulate.
• How to add poses to an object instance and create device operations.
• Get some background on inverse kinematics.
• How to use a couple of techniques to move a robot.
Lesson
Lesson 4: 4: QuickQuick introduction
introduction to kinematics
to kinematics
Fundamentals of kinematics
Purpose
In this topic, you get a basic background on kinematics.
According to wikipedia.org: Kinematics (from Greek κινεῖν, kinein, to move) is the branch
of classical mechanics that describes the motion of objects without consideration of the
causes leading to the motion
Objectives
• Get a basic background in kinematics.
• Learn how to move the joints of a kinematic object.
Kinematics basics
The following is a list of definitions that are important to remember when working with kinematics:
You must be in Process Simulate modeling mode to define kinematics.
Here are some basic definitions:

• Link – (also known as a rigid body) a group of entities within an object that remain fixed, relative
to one another. In this way it is the basic non-moving segment of a kinematic chain. Default
names begin with these letters: LNK (for example LNK1, LNK2, LNK3)
• Joint – the basic moving segment of a kinematic chain. A joint consists of 2 links and an axis. It
defines the relative motion between these two links relative to the axis. Default names begin with
the letter J (for example J1, J2, J3). There are 2 types of joints.
o Revolute joint - rotates around axis
According to wikipedia.org: Rotational, or angular, kinematics is the description of

the rotation of an object
■ The positive direction of rotation around an axis is defined using the right-hand rule. The
right-hand rule is this: Make a fist and point your thumb straight up. Place your fist at the
first point and align your fist so that your thumb points straight toward the second point.
Now your fingers show the direction of rotation around the axis.
o Prismatic joint - linear movement along axis
According to wikipedia.org: Linear, or translational, kinematics is the description of

the motion in space of a point along a line.
Quick introduction to kinematics
• A kinematic tree has an order established by the relationship of the joints and links. The parent
link precedes a child link in the sequence order. When the parent link moves, the child link
follows. The parent takes the child with it.
o In a typical kinematic tree, the number of links is equal to 1 more than the number of joints.
For example: if there are 6 joints, there is 7 links.
o The kinematic chain is the simplest example of a kinematic tree. It is an open loop, string
linked mechanism. All the links, except the first, have one parent. Also all the links, except
the last, have one child.
o There is no limit to the length of a kinematic chain. Here is an example of a kinematic chain
(a simple kinematic tree)
Kinematic Tree:
The limit of six degrees of freedom only applies when defining a robot. This is
because robots require the creation of ONE inverse solution.
More is described on defining kinematics later in this course.
Also, you only briefly introduce the concepts of creating simulative operations for kinematic
devices (for example device operations and robotic operations) here. These topics are
covered more thoroughly later.
General kinematics usage commands (part 1)
The following command is located on ribbon on the Robot tab→Tool and Device group and is
covered in this lesson:
Lesson
to kinematics
• Joint Jog — You use it to drag the joints on the selected kinematic object one at a time.
When approaching the limits of a joint, the slider and Value turns light purple to signify
that you are no longer in the defined working limits. After reaching the limits, they
turn dark purple. To change the Working Limits choose File→Options and go
to the Motion tab.
to change the step size for the Value : In the Joint Jog dialog box, click Options
and enter the desired Prismatic joints step size and Rotational joints step size
Activities
In the Fundamentals of kinematics section, do the following activity:
• Jogging the joints of a simple object
Review questions
Question
Jointly jogging on the tread mill Used to validate whether the joints perform as desired Moving a
link around the joint
Lesson
to kinematics
Creating device operations

Purpose
In this topic, you learn how to define a pose (each pose contains a specific value for each joint) on
the object instance, you need start with a prototype that contains kinematics. Use Joint Jog
and Pose Editor to jog the mechanism joints to a new pose, mark the pose, and then jump
to the new pose.
Objectives

• Define kinematic poses.
• Creating a simulative operation from the poses of a kinematic device.
General kinematics usage commands (part 2)

The following kinematic related commands are discussed in this topic:
• Home — You use it to jump all joints on the selected kinematic object to the HOME pose,
where (typically) all joints have a value of zero. The Home command can be found on the
right-click menu of a kinematic object, or on the Robot tab of the ribbon.
• Pose Editor — You use it to create, edit, and apply poses for the selected kinematic
object. The Pose Editor command can be found on the right-click menu of a kinematic
object, or on the Modeling tab of the ribbon.
• New Operation →Create Device Operation — You use it to create a simulative

operation to move the target device from one pose to another pose. The Create Device
Operation command can be found on the right-click menu of a kinematic object, or on the
Operation tab of the ribbon.
This option uses direct kinematics. you discuss direct and inverse kinematics in the
next topic.
Activities
In the Creating device operations section, do the following activities:
• Defining kinematic poses
Lesson
to kinematics
• Creating a simulative operation from poses
Review questions
Question
Check In Delete Undo The Parent operation to the operation to be created The kinematic device
Lesson
to kinematics
Inverse kinematics review

Purpose
In this topic, you get a background in inverse kinematics.
A Process Simulate “robot” is any kinematic device that has the ability to perform inverse
kinematics. This can include robots, lift assists, CMMs, cranes, AGVs, forklifts, etc.
Objectives
• Know the principles of inverse kinematics.
• Know difference between direct kinematics and inverse kinematics
• Know the difference levels of kinematic inverse result.
Principles of inverse kinematics

Definitions
• Device — An object with kinematics able to move to a pose.
• Robot — A device with a TCPF at the end of the kinematic chain able to move to a pose or to a
location. It could be a robot, lift assist, CMM, forklift, etc.
• TOOLFRAME — A frame used as the default location to mount tools to the end of the robot's
kinematic tree.
• TCPF — Tool Center Point Frame. Initially positioned at the end of the kinematic chain. It is
moved to a predetermined position and orientation on a tool mounted to the end of the robot's
kinematic tree.
The TCPF refers to the frame of reference of robots and robotic resources that is
moved to target locations.
How is inverse kinematics like the Relocate command?
Inverse kinematics works kind of like the Relocate command (for placement).
Relocate with source orientation:
Putting an object from the source frame to the target frame:
• Moves the object from the source frame to the target frame
• Orientation of the object is not affected (orientation of the source frame is maintained)
Relocates with target orientation:
Putting an object from the source frame to the target frame:

• Moves the object from the source frame to the target frame.
• Orientation of the object is changed to the target frame
Direct kinematics
• Easy to do because simulation engine already knows the joint values
• Direct kinematics can be used for any kinematic device such as guns, clamps, robots, etc.
How direct kinematics work:

1. You give the simulation engine a state/pose. The state/pose contains the exact values for each
joint of the mechanism.
2. The simulation engine moves the mechanism from the current position to the destination pose
Inverse kinematics
• Takes more effort, because the destination pose must be calculated on the fly. However, this
gives more flexibility to the user.
• Only available for robots, lift assists, CMMs, cranes, AGVs, forklifts, etc.
How inverse kinematics work:

1. You give the simulation engine a location. The location contains the target position and orientation
of the TCPF of the robot.
Lesson
to kinematics
2. Internally, the simulation engine tries to put the TCPF of the robot onto the location
3. Once the simulation engine puts the TCPF on the location, it then looks at the joint values
required to reach this location
4. The simulation engine moves the mechanism from the current pose to the calculated pose which
places the TCPF of the robot on the target location.
Level of kinematic inverse

The goal is to put, with target orientation, the TCPF of the robot onto the target location (both the
position and orientation of the target location are used). This is referred to as a Full Inverse.
Sometimes it is not possible for the robot to perfectly place its TCPF onto a location. However, it
may be able to put with source orientation onto the location (only the position of the target location is
used). This is referred to as a Partial Inverse. A partial inverse can be used to get a full inverse
using special tools in Process Simulate.
In some cases, the robot may not be able to reach the location's position or orientation. This is
referred to as No Inverse. There are some tools in Process Simulate to fix this situation also.
Review questions
Question
Technical coordinate point function Test center point function Tool center point frame Refers to the
frame of reference of robots and robotic resources that is kinematically moved to a location.
Lesson
to kinematics
Using inverse kinematics

Purpose
In this topic, you use a robot model, and several kinematic tools related to robots.
Objectives
• Use Joint Jog.
• Use Robot Jog
• Create a very basic robotic path.
• Examine the kinematic tree of a robot.
Joint jog basics
Joint Jog is used to drag the joints of the selected kinematic device and its external axes (for
example servo gun or 7th axis) one at a time (Direct kinematics)
In the Steering/Poses column, a wheel shaped slider represents a rotational joint,

whereas a flat slider represents a linear joint.
Optionally, a dark purple coloring can be used to highlight a joint that is at its physical
limits, whereas a light purple color highlights joints that have reached their working limits.
To configure joint limits, use the Kinematic Properties in the Motion tab of the Options
dialog box. To configure color indications, use the Kinematic Colors in the Appearance
tab of the Options dialog box.
The joints shown in the Joints Tree column can have several overlays. Not all kinematic
devices have these overlays, depending on its kinematic definition. Later you learn how to
add this kinematic information to a device.
• Dependent joints by displaying the Dependent overlay.
• Coupled joints by displaying the Coupled overlay.
• Following and leading joints by displaying the Follow and Lead overlays.
Following joints may have multiple leading joints and leading joints may have multiple
following joints. A tooltip lists the following joints and their follow factors.
• Locked joints by displaying the Locked overlay.
• External joints are displayed with an External overlay. This topic is discussed in
more detail later in this course.
Robot jog basics
Robot Jog dialog box expander areas:
The five expander areas in this dialog box that can be Expanded to expose functionality or
Collapsed to hide it.
• Location — You can view the robot at a specific location or add locations before or after it.
• Manipulators — Move and manipulate the robot using the Manipulator Frame in the Graphic
Viewer or the controls in this area. Also, you can limit the robot to a single configuration by
checking Lock and Selecting a configuration from the Configuration list of values.
o The current position of the robot determines which configurations appear in the
Configuration list of values.
o The current robot configuration is displayed and updated continually when Lock
remains cleared.
• External Joints — You can use this area to adjust the values of the robot’s external joints (for
example servo gun joints or 7th axis) without having to access the Joint Jog dialog box. Using
Robot Jog to adjust external joint values enables you to apply lock constraints that cannot be
applied when using the Joint Jog dialog box.
• All Joints — Similar to the Joint Jog dialog box.
Lesson
to kinematics
• Coordinate Reference — You can use this area to measure the selected location's position
relative to various frames.
Robot Jog dialog modes:

There are several basic modes for the Robot Jog dialog box:
• Robot Jog (the default behavior) — the robot base is fixed to the ground or an external axis (for
example 7th axis), and TCPF can be moved anywhere kinematically possible for this robot
(Inverse Kinematics). It is also possible to jog the robot on its external axes. .
• Only Robot Jog with Locked TCPF selected — the TCPF is fixed at a location, and the
robot base can be moved anywhere along its external axes (for example 7th axis) of the robot.
• Robot Jog with Locked TCPF and Enable Robot Placement are selected — TCPF
is fixed at a location, robot base can be moved anywhere kinematically possible for this robot
(detached from external axes, if defined).
• Robot Jog with Locked TCPF and Enable Robot and Attachment Chain Placement are
selected — TCPF is fixed at a location, robot base can be moved anywhere kinematically
possible for this robot (attached external axes, if defined).
• Robot Jog with Locked Configuration — the TCPF can be moved anywhere kinematically
possible without changing the robot configuration when this is selected on the Manipulation
area of the Robot Jog dialog box.
Creating a basic robotic path
Create Generic Robotic Operation is used to create a simulative operation to move the
target device alone a path. It can be used to create a simulative operation for any inverse kinematic
device including robots, lift assists, CMMs, cranes, AGVs, forklifts, etc. To use this command select
a robot and from the ribbon choose Operation tab→Create Operation group→New Operation
→Create Generic Robotic Operation .
You can define some robot operation types, such as a weld operation, without a tool.
However, the generic robotic operation type must have a tool defined.
Initially, the TCPF is at the TOOLFRAME of the robot. When the Mount Tool
command is used to place a valid tool at the end of the robot, the TCPF of the robot jumps
to the TCP frame of the mounted tool (the default position). The TCPF position on tool
affects the robot’s ability to reach them, so changing the TCPF’s position for a specific
location may cause it to become unreachable. To use this command select a robot and
from the ribbon choose Robot tab→Tools and Device group→Mount Tool .
Lesson
to kinematics
Activities
In the Using inverse kinematics section, do the following activities:
• Examining the kinematic tree of a robot
• Making the robot move
Review questions
Question1
Question2
Move a clamp between two poses in a device operation Move a robot to locations in a path (robotic
operation) Move a clamp between two poses in a device operation Move a robot to locations in a
path (robotic operation)
Lesson
to kinematics
Summary
• How to use kinematics in Process Simulate.
• How to add poses to an object instance and create device operations.
• Got some background on inverse kinematics.
• How to use a couple of techniques to move a robot.
Lesson 5: Process Simulate analysis tools and study data
Purpose
To discuss how to use the special static and dynamic collision detection tools available in Process
Simulate, and explains how to define a section plane and use it to cut sections.
Objectives

• The different types of Study Data created in Process Simulate and stored in the system root.
• How to work with the Snapshot Editor.
• Several ways how to create markups.
• How to create notes and more.
• How to export pictures of the scene.
• The Collision Viewer and how to setup a collision set.
• How to setup collision options to fine tune the collision reporting.
• Several factors that affect collision detection results.
• How dynamic sections of objects can be cut along the YX-plane, YZ-plane, and ZX-plane of
the Working Frame.
• How to do more with dynamic sections.
• How to create an .AVI movie file of all subsequent operations effected in the Graphic Viewer
using 's AVI Recorder commands.
Lesson
Process Simulate
Simulate analysis
analysis toolstools and study
and study data data
Study data
Purpose
In this topic, you learn what are the different types of Study Data created in Process Simulate and
stored in the system root.
Objectives
• Know what is stored in the scenario data in the system root.
Study data storage in the system root
No matter what option is checked, scene data is always saved.
Study data is saved to the .psz file:
From the Quick access toolbar click Save command to save changes to the product, operation,
and resource trees as well as study data.
Examples of study data found in the Object Tree include:
• Parts — Not used in Process Designer.
• Resources — Not used in Process Designer.
• Notes — Text in the Graphic Viewer with a leader line.
• Sections — 2D plane used to cut cross-sections displayed in section viewers.
• Dimensions — Dimensions in the Graphic Viewer with a leader line.
• Labels — Text in the Graphic Viewer without a leader line associated to a specific instance.
• Frames — Also known as reference frames or coordinate systems.
• Assigned Prototypes — Not used in class
• Appearances — Ability to locate the same instance of a part in multiple locations.
• Motion Volumes — an optional solid created by the moving objects of a simulation
• Point Clouds — an optional set of data that can be imported into a study as a 3D background.
• Triggers — Used with robotic painting processes
• Cables — Used with robotic processes
• Cameras — A special view point.
Process Simulate analysis tools and study data
Examples of Study Data found elsewhere:

• Snapshots — shown in the Snapshot Editor, store a snapshot of the state of objects in the
Graphic Viewer (for example pan/zoom/rotate, blank/display, current poses, mount/unmount,
attach/detach, object position, etc.)
• Mount / Unmount of tools (or guns or grippers) on the TOOLFRAME of a robot (or on the
end of the robot wrist).
• Attach / Detach — sort of like gluing two objects together. Can be shown as an optional box in
the Object Tree.
Object attach / detach information can be shown in the Object Tree by using
Customize Columns .
• 3D File — shows the path to the .JT file related to the parts and resources.
The path to the .JT file related to the parts and resources can be shown in the Object
Tree by using Customize Columns .
• Poses of kinematic devices (for example OPEN and CLOSE pose for a fixture) created in the
context of a Study are shown in the Pose Editor.
• TCPF (Tool Center Point Frame) position/orientation of a Robot. A frame of a robot that is
superimposed on a location during robotic simulation. Shown as an entity in the Graphic Viewer
or Object Tree.
• Groups — Discussed earlier. Shown in the Logical Collections Tree.
• Collision Set — Used to setup collision detection. Shown in the Collision Viewer
• Detailed Representation (Discussed earlier in this course)
Study data administrative note

Where is Study Data stored:
Review questions
Question
Lesson
Process Simulate
Simulate analysis
and study data data
TRUE FALSE
Creating and using snapshots

Purpose
In this topic, you learn how to create and use snapshots.
Objectives
• Create and use snapshots.
Overview
To open the Snapshot Editor, from the ribbon, choose View tab→Screen Layout group→Snapshot
Editor. The Snapshot Editor displays the snapshots created from study data.
Using the Snapshot Editor, you can create a snapshot of the working cell displayed in the Graphic
Viewer. Snapshots are used to store specific views and viewing angles during your work for later
reference.
Snapshot usage
A snapshot preserves the current view of the scenario. The recorded view includes the point of view,
the location of objects and the visibility of objects. Snapshots can be useful when constructing a
current assembly or for planning future assemblies.
To create snapshots:
1. Rotate, pan, zoom, blank and display entities in the Graphic Viewer.
2. Go to the Snapshot Editor.
3. Click New Snapshot . A new snapshot of the graphic image currently displayed in the
Graphic Viewer is created with the default name Snapshot_# and the snapshot is displayed in
the upper part of the Snapshots tab.
4. You are now prompted to give it a new name. Type in the new name and press enter.
Once you have created a snapshot, you can use the Snapshot Editor to do the following:
Snapshot Editor toolbar:
Lesson
Process Simulate
Simulate analysis
and study data data
• New Snapshot - Creates a snapshot of the objects currently visible in the Graphic Viewer.
• Remove Snapshot - Deletes the selected snapshot.
• Edit Snapshot - Enables you to enter a name, type and description for the selected snapshot.
A snapshot must have an unique name. When a description is entered for the snapshot, it is
displayed next to the snapshot if the snapshot is displayed in the lower part of the Snapshots tab.
• Update Snapshot - Changes the selected snapshot to the image displayed currently in
the Graphic Viewer.
• Apply Snapshot - Replaces the image in the Graphic Viewer with the selected snapshot.
By default, only the point of view is applied but you can also choose to apply the location and
visibility of objects. Click the drop-down arrow and choose one or more from the following:
o Point of View
o Object's Visibility
o Object's Location
o Device Poses
o Object's Attachments
o Object's Color
o Object's Viewing Mode
You learn about Add Markup and Remove Markup later in this course.
Snapshot Editor right-click (on nothing in the Snapshot Editor dialog box) menu:
• List
• Small Icons
• Large Icons
• Sort Snapshots
Activities
In the Creating and using snapshots section, do the following activities:
• Creating snapshots
Review questions
Question
Lesson
Process Simulate
Simulate analysis
and study data data
FALSE TRUE
Using the Markup Editor

Purpose
In this topic, you learn how to use the Markup Editor to create markups.
Objectives
• Use the markup editor.
Overview
The Markup Editor enables you to take a snapshot of the currently displayed image in the Graphic
Viewer . The image itself cannot be modified, but labels and call-outs can be added to the snapshot.
You can print or send the snapshot by e-mail to other engineers in your organization, for example,
for consultation.
Markup Editor usage

Ways to open the Markup tool:
You have to add to the Quick access toolbar using Customize Quick Access Toolbar .
• Method 1: From the ribbon, choose Operation tab→Documentation group→Markup Editor
. This method exports the markups to a picture file in a selectable folder.
• Method 2: On the Snapshots Editor, select a snapshot, and choose Add Markup from the
Snapshot toolbar. This method stores the markups, so that they can be modified later.
Markup Editor toolbar
• Save As File — Saves the image as a .BMP or .JPG file in a specified location.
• Send Mail Message — Enables you to send the image by e-mail as an attached file.
• Print — Enables you to print the image.
Lesson
Process Simulate
Simulate analysis
and study data data
• Cut — Cuts a selected object (callout, text box or line) to the clipboard.
• Copy — Copies a selected object (callout, text box or line) to the clipboard.
• Paste — Pastes the contents of the clipboard to the Markup Editor.
• Delete — Deletes a selected object (callout, text box or line) from the Markup Editor.
• Group — Groups two or more selected objects (callout, text box or line) in the Markup Editor
into a single group and enables the objects to be manipulated together.
• Ungroup — Ungroup one or more selected groups.
• Bring to Front — Places selected objects (callout, text box or line) in front of other
deselected and overlapping objects.
• Send to Back — Places selected objects (callout, text box or line) behind other deselected
and overlapping objects.
• Select Objects — Activates Select mode, enabling you to select objects (callout, text box or
line) in the Markup Editor
• New Line — Enables you to draw a line.
• New Arrow — Enables you to draw a line with an arrowhead.
• New Rectangle — Enables you to draw a rectangle. (To make a square, hold the Shift
key while dragging).
• New Ellipse — Enables you to draw an ellipse. (To make a circle, hold the Shift key while
dragging).
• New Scribble Polygon — Enables you to draw a freeform shape.
• Add Note — Enables you to add notes to objects.
• New Text — Enables you to add text to the snapshot.
• New Text Box — Enables you to draw a text box in the snapshot.
• Fill Color — Enables you to modify the color of a selected object (callout, text box or line).
• Set Font — Enables you to change the font of text.
• Line Style — Enables you to modify the width, color and style of lines and arrows.
• Arrow Style — Enables you to modify the arrowhead style.
Activities
In the Using the Markup Editor section, do the following activity:
• Creating markups
Lesson
Process Simulate
Simulate analysis
and study data data
Adding text in the Graphic Viewer

Purpose
In this topic, you learn how to create text in the Graphic Viewer.
Objectives
• Create Graphic Viewer text such as notes and dimensions.
• Set up the note options.
Overview
Text can be added directly into the Graphic Viewer by using the note commands or the label
commands. They can be used to show attributes of objects, highlight problem areas, or add other
textual information to the view.
Graphic Viewer text usage

Text can be added directly into the Graphic Viewer using several techniques:
• Notes — Have a leader line that can be turned on and off, are associated to the study, and can
either always be the same size (irrespective of the zoom) or can be a fixed size.
• Labels — Do not have a leader line, are associated to the object, and change size when zooming
• Dimensions — As apposed to measurements, which are temporary and only one can be created
at once, dimensions are persistent in the study and many can be created at once. (Dimensions
and measurements were mentioned earlier in this course. See Measurement and units)
Notes
To work with notes:
Notes are objects that display as free text with a leader line in the Graphic Viewer and the Notes
folder of the Object Tree. From the ribbon the note commands are located under: Modeling
tab→Note group→Notes .
To setup notes:
• Note Settings — This command has two features:
o Define the Automatic Note Placement offsets.
o Define the note content. Before creating a note using Create Note or Object Notes ,
configure its content. If you do not set it, the default note content is the name of the object.
For example, to set the note content for a resource, select Resource for the note format and
then add the attributes you want.
• The color of the note background, note text, and note border and also be setup before creating
the note using File→Options (Appearance tab).
To create notes:
• Create Note — Initially, these notes show the content specified in Note Settings , but
you are prompted to change it. By default these notes do not keep their size when zooming in
and out. You can only create one note at once.
• Object Notes — These notes show the content specified in Note Settings . By default
these notes keep their size when zooming in and out. You can create multiple notes at once.
• Location Notes — These notes contain the name, position, and orientation of the selected
object relative to the working frame. By default these notes keep their size when zooming in and
out. You can create multiple notes at once. The note text automatically updates if there is a
change to the object’s name,the object's location, or the working frame location.
To modify notes:
• Edit Note — Used to change what/where the leader line points, the note name,note content,
add/remove the leader line, keep/do not keep note size when zooming, and change font size.
• Toggle Note Visibility — Change the note from displaying its content to displaying a flag.
• Automatic Note Placement — Apply the note placement define in Note Settings to
the selected notes.
• Update Object Notes
• The color of the note background can also be modified using Modify Color .
Labels
To work with labels:
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Labels are objects that display as free text in the Graphic Viewer and the Labels folder of the
Object Tree. There are many options to define the formatting for a note. From the ribbon the label
commands are located under: Modeling tab→Note group→Labels .
To setup labels:
• The color of the label background, note label, and label border and also be setup before creating
the note using File→Options (Appearance tab).
To create labels:
• Object Labels — These labels show the name of the object. Labels do not keep their size
when zooming in and out. You can create multiple labels at once.
• Create Label — Initially, these labels show the name of the object, but you are prompted
to change it. Labels do not keep their size when zooming in and out. You can only create one
label at once.
To modify labels:
• Modify Label
• The color of the label background can also be modified using Modify Color .
Dimensions
To work with dimensions:

Dimensions are objects that display as free text in the Graphic Viewer and the Dimensions
folder of the Object Tree. From the ribbon the dimension commands are located under: Modeling
tab→Note group→Create Dimension .
Types of dimensions:
• Point-to-point Dimension — Creates a dimension to measure the point-to-point distance

• Minimal Distance Dimension — Creates a dimension to measure the shortest distance

between two components, entities, edges, or faces.
• Linear Dimension — Creates a dimension to measure the distance between two

• Angular Dimension — Creates a dimension to measure the angle between two

• X-Axis Dimension — Creates a dimension to measure the distance along the X-axis
• Y-Axis Dimension — Creates a dimension to measure the distance along the Y-axis
• Z-Axis Dimension — Creates a dimension to measure the distance along the Z-axis
• Normal to Source Curve Dimension — Creates a dimension to measure the distance in

a section normal to a section line, normal to a source curve.
• Normal to Target Curve Dimension — Creates a dimension to measure the distance

in a section normal to a section line, normal to a target curve.
• Curve Length Dimension — Creates a dimension to measure the length of a curve.
Selected attributes of dimensions:
• Dimensions can be hidden or displayed from the Dimensions folder of the Object Tree.
• The dimensions are stored with the study data.
• Process Simulate dynamically updates the dimension values when users move the measured
objects to new locations in the Graphic Viewer.
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Activities
In the Adding text in the Graphic Viewer section, do the following activities:
• Setting the note options
• Creating notes in the Graphic Viewer
• Creating dimensions in the Graphic Viewer
Review questions
Question
With Edit Viewer, Properties With ball pen, pencil With Notes, Dimensions, Labels
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Storing pictures of the study

Purpose
In this topic, you learn how to output pictures of the Graphic Viewer contents.
Objectives

• Output the Graphic Viewer to a file or printer.
Overview
Static images of studies can be created in .BMP, .JPEG, .GIF or .TIFF format.
Output types may vary based on the image output command used.
Activities
In the Storing pictures of the study section, do the following activities:
• Outputting the Graphic Viewer to a file or printer
Introduction to collision detection

Purpose
In this topic, you learn about how to setup and use collision detection.
Objectives
• Know some of the basic concepts of collision detection.
• Use the Collision Viewer.
• Define a collision set (list pair) and fast collision sets.
• Know rules of thumb when using collision detection.
Overview
Tecnomatix collision detection tools can temporally change the colors of objects in the Graphic
Viewer and the Collision Viewer.
Do I use this?
Collision detection basics

There are three levels of detection granularity:
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• Near Miss — Objects are highlighted in yellow if they come within a predefined clearance
envelope of each other
• Collision Contact — Objects can optionally be highlighted in red if they are touching each other
(or orange if near miss detection is activated).
• Collision Penetration — Objects are highlighted in red if they exceed the allowed penetration
depth with each other.
Valid values for Allowed Penetration Value are between 0 and 5 mm.
Collision detection types:

• Dynamic collisions — Collisions that occur during a simulation or while objects are being placed.
• Static collisions — Collisions that are occurring without moving the objects.
Collision options:
When a collision occurs the object’s color is always changed to red in the Graphic Viewer and the
Collision Viewer. Optionally a simulation can be stopped when a collision is detected and/or a sound
is played at regular intervals while in a collision state.
Collision Viewer
The Collision Viewer displays all current occurring collisions, near misses and contacts. It enables
you to define, detect and view collisions in the data currently displayed in the Graphic Viewer, as
well as view collision reports.
To open the Collision Viewer:
• From the ribbon, choose View tab→Screen Layout group→Collision Viewer.
To close the Collision Viewer:

Collision Viewer panes:

The Collision Viewer is composed of several panes:
• The first pane contains an editor for creating and managing collision sets. It can be closed or
opened by selecting Show/Hide Collision Sets .
• The second pane displays collision results and includes collision viewing options. Two basic
options from the second pane of the collision viewer:
o Show/Hide Collision Sets — Shows or hides the collision set editing pane of the
Collision Viewer.
o Collision Mode On/Off — Activates/deactivates Collision mode. Collisions are detected

only when Collision mode is on.
• The third pane (discussed in another lesson) if activated, shows additional collision details. It can
be closed or opened by selecting Show/Hide Collision Details .
• The fourth pane (discussed in another lesson) if activated, shows a contour (curves) representing
where the objects are colliding. It can be closed or opened by selecting Show/Hide Contour
View .
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.
The first pane of the Collision Viewer includes the following options:
• New Collision Set — Define which objects are in the two lists of a collision set. The resulting
collision set is displayed in the left pane of the Collision Viewer and can be renamed there.
• Remove Collision Set — Delete of a previously created collision set.
• Edit Collision Set — Change the content of a previously created collision set.
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• Fast Collision — Create a new collision set quickly based on the selected objects.
This collision set is displayed in the left pane of the Collision Viewer under the name
fast_collision_set. The collision set created with this option is a self set, which means that all
the objects within the set are checked for collision against each other. Only one fast collision set
may exist in a study. If you create another one, it replaces the previous fast collision set.
• Emphasize Collision Set — A toggle used to emphasize the selected collision set in blue
and yellow in the Graphic Viewer.
• All Displayed Objects — When selected, it checks for collisions between all objects displayed in
the Graphic Viewer. This option ignores defined collision sets. Enabling this option can have
a severe impact on system performance . It is not suggested to select the All Displayed
Objects check box.
Rules of thumb
• Manually create the collision set for tool to product assembly checks.
• Use fast collision set to check between one part and tool; or when checking collisions between
all the parts of a product assembly.
Selection toolbar
There are several filter tools in Process Simulate. One that you have not discussed
yet is the selection filters on the Graphic Viewer toolbar. Using it, you filter your
selections by various types such as: Parts, Resources, Mfg Features, Weld Points,
Paths, Global Locations, Frames, Notes, Points, Lines/Curves, Solids/Surfaces, or PMI.
Basic Usage:
• From the Graphic Viewer toolbar, choose Select with Filter .
• From the Graphic Viewer toolbar, choose one or more of the selection types.
• From the Graphic Viewer toolbar, choose Selection Type All .
Activities
In the Introduction to collision detection section, do the following activities:
• Collision Viewer and fast collision sets
• Defining collision sets (list pairs)
Review questions
Question
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TRUE FALSE
More on collision detection

Purpose
In this topic, you learn the features that enable you to detect and focus on collision areas for more
accurate analysis of collision pairs.
Objectives
• Learn more about collision detection tools.
• Configure the level of detection granularity.
• Setup near miss detection.
• Setup the collision report level
• Filter collision results.
Collision introduction
Selected options from the second pane of the collision viewer:
• Collision Options — Enables you to set default collision set options.
• Freeze Viewer — Depressing this button freezes the Collision Viewer to prevent dynamic
updating of the collision report as objects are moved in the Graphic Viewer. Click it again to
update the Collision Viewer report. This button is rarely used.
• Color Colliding Objects — Toggles the color highlighting of colliding objects to facilitate
clear viewing of colliding objects. If Show Colliding Pair is active, this function toggles the
highlighting between red/transparent blue and the original colors of the objects. Typically, this
button is always checked.
• Show/Hide Colliding Contour — Places a curve in the Graphic Viewer at the point of
collision. This button is used to isolate collision problems.
• Show Colliding Pair — Defines how the collision status of a pair of colliding objects is
displayed. This button is used to isolate collision problems:
o Color selected Pair — The selected pair is colored in the Graphic Viewer. The master object
node is colored red and the colliding object is transparent blue. All other objects are white.
o Show selected Pair Only — The selected pair is displayed in the Graphic Viewer. All other
items are not displayed.
• Export to Excel — Creates a Microsoft Excel report (CSV file) of the contents of the Collision
Viewer. For example (depending on your data this picture may look different):
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• Collision Depth — Calculates the depth of penetration of colliding objects. It uses this
information to display a vector along which to withdraw one of the colliding objects to resolve the
colliding status. This button can sometimes take a few moments to calculate.
• Filter Collision Results — Filters the collision results. Choose one of the following options.
This button is used to isolate collision problems:
o List Colliding Pairs (highlighted in red)
o List All Pairs (displays the distance between all the visible objects in the cell)
• Show hide collision details — Hides or displays the Collision Details pane in the Collision
Viewer.
The Collision Viewer can display collision details at the link and entity level, when you
use the Lowest available level option in the Collision tab.
• Show/Hide Contour View — Opens another pane on the right side of the Collision Viewer
containing selectable collision curves.
Configuring Level of Detection Granularity

Checking options for penetration and near miss affects what is shown in the Collision Viewer.
Collision setup options are found on the Collision tab of the Options dialog box and can be accessed
by either:
• Choosing File→Options and then choosing the Collision tab, or
• Clicking Collision Options in the Collision Viewer.
o Collision Near-Miss — When selected, objects selected for collision detection that are
within the near-miss envelope value are colored yellow. This value can range between
0 and 10,000 mm.
o Collision Contact — When selected, each colliding pair is checked for permitted contact (for
example a tool touching a surface). Any penetration value less than the Allowed Penetration
Value is considered in contact, but not colliding. Objects selected for collision detection that
exceed the Allowed Penetration Value are considered in a true collision.
The default Near Miss and Allowed Penetration Value are defined using the
Options dialog box. However, each Collision Set can have its own unique
value specified in the left pane of the Collision Viewer. The maximum Allowed
Penetration Value value is 5 mm.
Distinguishing the levels of detection granularity:

• Collision
o Colliding objects are marked in red
o Object in contact are marked in red (as colliding)
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o Performance: High
• Collision while contact objects are excluded

o Object in contact are excluded from the collision reports
o Performance: Mid
• Collision with near miss

o Colliding and contact objects are marked in red
o Objects in near miss are marked in yellow
o Performance: Mid
• Collision with contact and near miss

o Object in contact are marked in orange
o Objects in near miss are marked in yellow
o Performance: Low
Other collision options: You can select the Ignore wireframe entities check box to improve
performance of collision detection. This option is automatically selected when using the Automatic
Path Planner discussed later in this training.
Collision detection and near miss setup

Checking for Collisions:
In order to check for collisions: define the objects to check collisions by creating a collision set (there
are several techniques to do this) then check the Collision Mode On/Off on the Collision Viewer.
To configure what happens when a collision is detected, open the Options dialog box by right-clicking
in the Graphic Viewer, choose Options, and then choose the Collision tab.
• Stop Simulation when a Collision is Detected — Stops the current running simulation when a
collision is detected. Clicking Play Simulation Forward again continues past the collision.
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• Play a Sound when a collision is Detected — The currently selected .WAV file is played when
a collision is detected. However, the currently running simulation is not stopped.
Checking for Near Misses:

In order to check for near misses, as well as collisions: open the Options dialog box, check Check
for Collision Near-Miss, specify a near-miss value, and collision detection should be switched on.
There are two methods to specify a near miss value:
• Global (Default) Method: If a near-miss value is not defined for a pair in the Near Miss column of
the Collision Editor dialog box, the system use the global Near-Miss Default Value specified on
the Collision tab of the Options dialog box.
• Collision Set specific Method: In the left pane of the Collision Viewer, select the desired collision
set, and enter the desired Near Miss value (over riding the default).
Collision report level

This setting is affected by whether Detailed Representation is loaded for the objects in question.
There are two settings:
• Component Level — Similar to the Pick Level of Component , it is used during collision
detection to display found collisions in the Graphic Viewer and Collision Viewer.
• Lowest available level — Similar to the Pick Level of Entity , it is used during collision
detection to display found collisions in the Graphic Viewer and Collision Viewer.
The Advanced Collision Options dialog box, opened by clicking Advanced on the bottom of the
Options dialog box, is specific to robotic processes. It is discussed course.
Activities
In the More on collision detection section, do the following activities:
• Collision setup and Collision Viewer
• Filtering collision results
Review questions
Question1
Question2
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Set the Allowed Penetration Value to 5 Set the Near Miss Value to 5 Set the Allowed Penetration
Value to 5 Set the Near Miss Value to 5
Factors that affect collision detection

Purpose
In this topic, you learn factors that affect collision detection.
Objectives

• Know the factors that affect collision detection.
Collision factors
There are several factors that affect collision detection:
• Simulation Time Interval: Collision sets are only processed at the graphics update time interval
(The time interval is approximately based on time between Graphic Viewer refreshes, but the
Graphic Viewer may also need to be updated when certain motion planner events are executed).
A collision is only detected if it occurs at a time interval boundary, meaning that it is possible for a
collision to occur between updates and therefore not be detected. The smaller the interval, the
less likely it is that this occurs. This value can range between 1 (fastest) to 0.0000001 (slowest).
The default value is 0.2. This can be set by either:
o Choosing File→Options , clicking the Simulation tab, and entering a value for
Simulation Time Interval.
o Clicking Set Time Interval in the Sequence Editor and entering a value for Time.
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The display of Simulation Time Interval is affected by the Time display unit and
number of decimal places specified on the Units tab of the Options dialog box.
• Speed and Acceleration: The speed and acceleration of an object can affect the detection of
collisions. If they are very high, it may be advisable to reduce the update time interval.
o For robotic paths this can be set on each location of the path (for example set on the Path
Editor or Teach Pendant).
o For non-robotic paths this is set by specifying the duration of the operation (for example
set on the Operation Properties).
• Display/Blank: Process Simulate only detects collisions of displayed or visible parts. Collisions
involving blanked items are not detected.
o This can be done
Blanking and displaying objects is affected by the Pick Level setting.
If Freeze Viewer is depressed the collision state of objects are not updated, even
if they are blanked.
Activities
In the Factors that affect collision detection section, do the following activities:
• Instructor Demo: Factors that affect collision detection
Review questions
Question1
Question2
Simulation Time Interval. A bigger interval increases the accuracy. Magnification (Zoom) of area to
be checked. Simulation Time Interval. A smaller interval increases the accuracy. for displayed and
blanked parts. only for displayed parts.
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Process Simulate
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Cutting sections with section planes

Purpose
In this topic, you learn how to cut sections.
Objectives

• Basic Section Cutting Usage
• Optional Activity: Creating and Moving a Section Plane
• Optional Activity: More on Cutting Sections
Overview
Objects can be cut into sections along the YX-, YZ-, and ZX planes of the Working Frame, which
then appears in the Section Viewer.
Basic section cutting usage

In the ribbon the section cutting tools are located in the View tab→Section group.
Section Plane Cutting Tools:
• New Section Plane — Creates and positions a cutting plane. Imagine the part is a loaf of
bread: the result of cutting the part with this plane would be one slice of bread, one half of
the loaf, or the other half of the loaf.
• Section Manager — Enables you to create new sections.
• Section Alignment — See the next topic for more information.
• Flip Section Plane Direction — Choose which half of the loaf of bread (for example your part
that is being cut) or the other half of the loaf.
• Adjust section plane size — Changes the visualization of the section plane in the Graphic
Viewer (but does not affect the result of the section).
• Activate section — Section that is cut in the main Graphic Viewer.
• Deactivate section — Turns of the cutting of a section in the main Graphic Viewer.
• Clip section — Shows everything on the negative side of the section plane, and clips
everything on the positive side of the section plane.
• Cut section — Shows the contours of the assembly at the plane cut by the section.
• Capping — Adds definition to the cutting edge so as to know when there is space between
the parts.
• Hatching — Adds definition to the cutting edge so as to know when there is space between
the parts.
• New section viewer — Cuts the selected section in a new Section Viewer.
You can open up to five Section Viewers for the same section in order to view the
contents of the view from different angles.
• Orient View to Section Plane — Changes the view to look toward the positive Z-axis of the
plane, while the distance between the "Eye" to the view center remains unchanged.
• Show Section Contours — Displays contours in Clip mode
• Save section Contour as Component — Saves the section as a new .COJT or a .JT file.
Section plane alignment tools

From the ribbon the section plane alignment tools are located in View tab→Section group→Section
→Section Alignment .
Section Plane Alignment Tools:
• Align to X — Aligns the section plane to the YZ-plane of the Working Frame.
• Align to Y — Aligns the section plane to the XZ-plane of the Working Frame.
• Align to Z — Aligns the section plane to the XY-plane of the Working Frame.
• Align to Point — Places the origin of the plane at a selected position.
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• Align to Line between Two Points — Aligns the plane at the center of two points you
select in the Graphic Viewer.
• Align to Edge — Aligns the plane perpendicular to the point you select on a 2D object. The
orientation is set arbitrarily.
• Align to Surface — Aligns the plane normal to a selected surface with the origin of the
plane at the selected location.
• Align to View Plane — Aligns the Z-axis of the plane to the "view from"→"view to" vector and
aligns the positive Y-axis of the plane to the up vector of the camera. The position of the section
plane is not changed.
Activities
In the Cutting sections with section planes section, do the following activities:
• (Optional) Creating and moving a section plane
• (Optional) More on cutting sections
Review questions
Question
FALSE TRUE
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Process Simulate
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Cutting sections with section volumes

Purpose
In this topic, you learn how to create section volumes.
Objectives

• Do more with section cutting, including creating and moving a section volumes.
More section cutting usage

The section cutting tools are located in the View tab→Section group.
Section Volume Cutting Tools:
Many of the commands related to section planes can also be used for section volumes.
The commands listed here are specific to section volumes.
• New Section Volume — a cutting box is created and can be positioned. The results of
cutting the part with this box would be the portion of the part that is inside or outside of the box.
The edges of the 3D cutting box can be dragged to get a different size section.
The location of the cutting box (volume) is determined based on what is selected (for
example nothing selected, one object selected, or multiple objects selected)
• Clip Inside — used when creating a section volume.
• Clip Outside — used when creating a section volume.
Activities
In the Cutting sections with section volumes section, do the following activity:
• Creating and moving a section volume (Optional)
Using cables
Purpose
In this lesson, you learn how to use flexible cables.
Objectives
• Create and edit flexible cables.
• Move and simulate flexible cables.
Basics of cables
Here are a couple common scenarios that require flexible cable:
• Cables between two objects For example to simulate the twisting and bending of wiring during
manual assembly of electronic components.
• Cables on a single kinematic device: For example to simulate cables wrapping around a robot
arm.
You can create flexible cables to:
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• Represent cable hooks.
• Calculate minimum length of cables.
• Display cables as natural, smooth curves.
• Indicate excessive force exerted on cable and collisions with the environment.
Cable commands are located on the Modeling tab of the ribbon.
Cable Commands
• Create/Edit Cable — Use the Create Cable or Edit Cable dialog boxes to set the start frame,
end frame, length, radius. parameters, and cable hooks.
The Z axes of the Start and Hook frames should be on the desired cable direction
toward the End frame. The Z axis of the End frame should be on the desired cable
direction toward the Start frame.
• Regenerate Cable — Regenerates the cable with an alternative cable shape. It is

recommended to regenerate the cable in the following cases:
o Robot Jog — While performing robot jog, the system continually recalculates the cable.
However, jogging the robot too far or too fast may complicate cable recalculation causing the
cable to become "invalid".
o Move Frames — Moving cable frames may cause the cable to become "invalid".
• Cable Settings — Select whether to wrap the cables around objects during motion and
whether it should be rendered as a smooth cable.
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Cables is a separately licensed product. You must have a Process Simulate Cables
license to create new cables or to see existing ones. If you load a study with cables and
do not have a license, the cables are not shown in the Graphic Viewer, and are shown
in the Object Tree with a for the display status square.
Creating cables
Overview of creating a simple flexible cable:
Create a basic cable
1. From the ribbon, choose the Modeling tab→Layout group→Create Frame →Frame by
6 values .
2. Create a start and end frame. To make a straight cable, the two frames should have their Z-axes
pointing at each other.
3. From the ribbon, choose the Home tab→Tools group→Attachment →Attach .
4. Attach each frame to the component that you want the cable attached to.
In general, a cable cannot be attached to more than one component. However, you can create
a cable between two frames attached to two different components, as long as those two
components are attached to one component or links of that one component. For example:
• To create a wire between two components of a circuit board.
• To create a cable between a bracket attached to one part of a robot and a bracket attached
to another part of a robot.
• To create a cable between a bracket on a robot and a mounted robot tool, such as a weld gun.
5. From the ribbon, choose the Modeling tab→Cable group→Create/Edit Cable .
6. Select the start and end frames.
7. Type or calculate the length of the cable, and click OK.
Edit a cable
1. Select the cable.
2. From the ribbon, choose the Modeling tab→Cable group→Cable Settings .
3. Select the settings you want and click OK.
Advanced cable parameters and settings
(Optional) Add a cable hook
You can add cable hooks:
1. In the Create Cable or Edit Cable dialog box, expand the Hooks area.
• You can add fixed hooks to secure the cable to the robot body at selected points.
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• You create a hook by specifying the distance from the start frame and a frame to represent
the hook.
2. Click OK.
(Optional) Cable parameters
You can change many parameters of your cables:
1. In the Create Cable or Edit Cable dialog box, expand the Parameters area.
• Density — cable density in kg per meter cubed. Use it to control the weight of the cable
and affects how it reacts to gravity.
• Stiffness — the higher the value the more it resists the drag of gravity.
• Fulcrum length — the length in mm of a rigid straight cable at the cable’s fulcrums (start,
end and hooks).
• Max twist — configure the max twisting allowed as an angle in degrees per meter. For
example, if the robot TCPF rotates, you may want to allow the cable to twist twice around the
robot's arm but no more.
• Max contact force — configure the maximum force exerted on the cable in kg. For example,
if the robot arm comes into contact with the cable, you may want to limit the force exerted on
the cable to prevent damaging it.
• Min curvature — configure the minimum curvature radius for the cable in mm. Bending the
cable beyond this point may cause it damage.
• Pass near — select a frame for routing. The cable is routed in the vicinity of the selected
frame during cable creation. This is useful for example, if you wish to route the cable away
from a particular joint. This constraint is not retained when the robot moves or during
simulation. Locate the pass near frame close to the expected cable route (but never distant
from it).
• Oscillation — simulate cable oscillation. If the cable has slack, it is likely to oscillate back
and forth when the robot stops moving. You use this to set a percentage value for oscillation
to best imitate the physical cable. For example, if the physical cable has high internal friction,
this tends to dampen the oscillation, you should set a relatively low oscillation percentage
for your simulation. The fulcrum parts of the cable do not oscillate at all. This setting allows
damping of a cable’s oscillations during simulation.
2. Click OK.
(Optional) Cable settings
You can select cable settings:
1. From the ribbon, choose the Modeling tab→Cable group→Cable Settings .
2. In the Create Cable or Edit Cable dialog box,select a setting.

• Wrap around objects during motion determines whether the cable takes other visible
objects (parts and resources) into account during robot motion. When set, the cable wraps
around objects, thus avoiding collisions with them. When deselected, the cable may
penetrate objects. However when deselected, this check box improves the performance
of cable simulation.
• Smooth cable display causes cables to be displayed as natural, smooth curves. However,
even when this option is set, the simulation still performs accurate cable calculations for the
polyline cables. This means that a smooth cable may appear to slightly touch another object
causing the collision detection system to report "unwanted" collisions.
3. Click OK.
Activities
In the Using cables section, do the following activities:
• Creating, editing, and moving cables
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Recording Process Simulate simulations to an .AVI file and 3D HTML

Purpose
In this topic, you learn how to record a video of a Process Simulate simulation using the AVI
Recorder . Also, you output 3D HTML.
Objectives

• Output a simulation to an AVI file.
• Export to web (create 3D HTML)
Do I use this?
Record a Video
Use Customize Quick Access Toolbar to customize the Quick access toolbar and add the
AVI Recorder to it.
The AVI Recorder command creates a movie file of all subsequent operations effected in the
Graphic Viewer.
The Audio Video Interleaved (.AVI) format was developed by Microsoft as a special version of the
Resource Interchange File Format (.RIFF).
AVI recorder options:
• Image size can be either a preset size or set to the current size of the Graphic Viewer.
• Specify the compression technique for the video (also known as the CODEC).
CODECs in the list are based on those installed on your computer. Note that the
default ones that come with Microsoft office produce VERY poor results. If you have
a 3rd part CODEC installed (such as those included with Camtasia), those can be
selected here. If you do not have a 3rd party CODEC installed, you should select
uncompressed from the list.
While recording an .AVI file on computers with powerful graphic cards (16 MB and higher),
the Graphic Viewer may be jumpy during recording. However the resulting AVI recording
is smooth
Simulation Time Interval and Videos

Simulation time interval can affect how fast the resulting video plays your simulation.
• Selecting File→Options , choosing the Simulation tab, and entering a value for Simulation
Time Interval.
• Clicking Set Time Interval in the Sequence Editor.
The display of Simulation Time Interval is affected by the Time display unit and number
of decimal places specified on the Units tab of the Options dialog box.
Create 3D HTML output
The File→Import/Export →Export to Web command to convert 3D data and simulations

to HTML file format. You can share these with anyone using a Web browser that supports HTML5
and WebGL (for example Internet Explorer 11, Chrome 43, Safari 8, etc). In the browser It is
Lesson
Process Simulate
Simulate analysis
and study data data
possible to pan/zoom/rotate the view and play the simulation with no additional installation required.
Activities
In the Recording Process Simulate simulations to an .AVI file and 3D HTML file section, do the
following activity:
• Outputting a simulation to an .AVI file and HTML file
Summary
• The different types of Study Data created in Process Simulate and stored in the eMS database.
• How to work with the Snapshot Editor.
• Several ways how to create markups.
• How to create notes and more.
• How to export pictures of the scene.
• The Collision Viewer and how to setup a collision set.
• How to setup collision options to fine tune the collision reporting.
• Several factors that affect collision detection results.
• How dynamic sections of objects can be cut along the YX-plane, YZ-plane, and ZX-plane of
the Working Frame.
• How to do more with dynamic sections.
• How to create an .AVI movie file of all subsequent operations effected in the Graphic Viewer using
Process Simulate's AVI Recorder commands.
Lesson 6: Other selected basic topics
Purpose
To discuss other selected topics related to Process Simulate basics.
Objectives

• How to use Process Simulate Disconnected.
• Putting It All Together
• Where do you go from here
Lesson
Lesson 6: 6: OtherOther selected
selected basicbasic topics
topics
Using Process Simulate Standalone

Purpose
In this topic, you learn how to use data from Process Simulate on eMS in Process Simulate
Standalone - eMS compatible. Also Process Simulate Standalone data not originating in an eMS
database is discussed.
Objectives
• Use Process Simulate Standalone
• Save a .PSZ file from Process Simulate on eMS.
• Setup a client system root.
• Update back the eMS database.
• Create and use templates.
Ways of using Process Simulate

Process Simulate can be run in many ways depending on factors such as your company business
practices and how data is shared with others:
• Teamcenter Database
o Process Simulate on Teamcenter — Run Process Simulate connected to a Teamcenter
database. Teamcenter object customizations setup in the BMIDE and configuration files
are used in Process Simulate. You may run Process Simulate this way if you are an OEM
with Teamcenter.
o Process Simulate Standalone - Teamcenter compatible — Run Process Simulate using

Teamcenter data saved from Process Simulate on Teamcenter. In this use case, you need to
view or modify data that is stored in a Teamcenter database, but you do not have access
to Teamcenter. In the future, all your changes need to be saved back to the Teamcenter
database. You may run Process Simulate this way if you are a supplier that does not have
access to the OEM Teamcenter database.
• eMS Database
o Process Simulate on eMS — Run Process Simulate connected to a eMS database. eMS
object customizations setup in the Customization tool or customization files are used in
Process Simulate. You may run Process Simulate this way if you are an OEM with an
eMServer.
o Process Simulate Standalone - eMS compatible — Run Process Simulate using eMS data
saved from Process Simulate on eMS. In this use case, you need to view or modify data
that is stored in an eMS database, but you do not have access to an eMServer. You may
also need to create new data. In the future, all your changes need to be saved back to the
eMS database. You may run Process Simulate this way if you are a supplier that does not
have access to the OEM eMS database.
Other selected basic topics
• No Database
Process Simulate Standalone — Run Process Simulate using data created directly in
standalone. No database is used at your site to store and manage Process Simulate data. Also,
in the future you do not need to save your changes back to a database. You can run Process
Simulate this way at any company, depending on the requirements of the job.
The focus of this lesson is Process Simulate Standalone - eMS compatible and Process
Simulate Standalone (no database).
Creating a new PSZ (no database)

You can start a completely new study (.PSZ file) based on a default template. You use the default
template when you want to create a new study and you do not intend on updating it from or to an eMS
database in the future. The template used to create a .PSZ file cannot be changed in the future.
A default template named DefaultStudy.pszt is provided in the Tecnomatix install folder under
.\eMPower\templates. The default template can be useful in environments where no eMServer
and where only Process Simulate Standalone is used. It contains the default and robotics
customizations.
You should never overwrite this default template.
Using the default template in Process Simulate Standalone

1. If Process Simulate Standalone is not started, start it and in the Welcome dialog box choose
Create New Study .
2. If Process Simulate Standalone is already started, choose File→Disconnected Study
→New Study .
3. In the New Study dialog box for the Template, select the DefaultStudy.pszt from the
.\eMPower\templates folder.
4. Click Create.
Creating a new PSZ that can update a eMS database in the future
You can start a completely new study based on a template that was generated while connected to the
eMServer (for example, an OEM that provides its template to you). These study templates (.pszt
format) can be created while working in Process Simulate on eMS and used in Process Simulate
Standalone - eMS compatible.
In many cases, users of Process Simulate Standalone - eMS compatible need to collaborate with
others working running Process Simulate on eMS. For example, Process Simulate Standalone -
eMS compatible users could be line builders who create and develop studies independently of an
eMServer connection, and transfer their work to Original Equipment Manufacturers (OEMs) working
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with Process Simulate connected to an eMServer. An OEM may request a line builder to build a new
study for an eMServer-based project. You create a disconnected study as a PSZ file and transfer
it to the OEM who uploads it to his eMServer.
In order to upload properly, you create the study based on an OEM-supplied template,
which contains the OEM’s customization and a list of projects which are stored in the
OEM’s eMServer. An OEM may maintain a number of templates which support the work
of a number of suppliers, and similarly, you may work from a number of templates to
create studies for several OEMs.
Create your own study templates
To create a custom study template:
1. Start Process Simulate (on eMS) .
2. Close the Welcome dialog box without opening a project or study.
3. Choose either File→Disconnected Study →Save or File→Disconnected Study
→Save As .
4. Select where and what to name the pszt file. This is the template file.
5. Select which projects to expose to the Process Simulate Standalone - eMS compatible users.
6. Click Save.
Using the custom template in Process Simulate Standalone
1. If Process Simulate Standalone is not started, start it and in the Welcome dialog box choose
Create New Study .
2. If Process Simulate Standalone is already started, choose File→Disconnected Study
→New Study .
3. In the New Study dialog box for the Template, browse and select the .pszt required to connect
to a database in the future.
4. Select the project to associate the new study (.PSZ) file with.
5. Click Create.
Process Simulate Standalone - eMS compatible

Process Simulate Standalone - eMS compatible allows working in Process Simulate without being
connected to the eMS database. Typically you start with a study that is connected to the eMS
(created with Process Simulate on eMS) and then save the study to a file that can be loaded in
Process Simulate Standalone - eMS compatible. For example if you want to run the simulation on the
shop floor using your laptop (without an internet connection). Changes made in standalone can later
be brought back into the eMS database through Process Simulate on eMS.
Working in standalone using data from an eMS database
1. Start Process Simulate (on eMS) , log in, open a project, and load a study.
2. Save the study from Process Simulate (on eMS) as a .PSZ file with a zip file for the library
objects.
3. Unzip the library objects zip file under the client system root folder.
4. Start Process Simulate Standalone - eMS compatible and set the client system
root folder location in the Options dialog box.
5. Open the .PSZ file in Process Simulate Standalone - eMS compatible.
6. Work on the .PSZ file in Process Simulate Standalone - eMS compatible.
7. Save the .PSZ file in Process Simulate Standalone - eMS compatible.
8. Reloading the .PSZ file to insure that the changes have been saved.
9. Exit Process Simulate Standalone - eMS compatible.
Files used in Process Simulate Standalone - eMS compatible

• Process Simulate Standalone - eMS compatible does not use a connection to an eMS
database. Instead, it can only work with .PSZ files and a sub-set of files from the system root.
• The .PSZ file can be opened by Process Simulate on eMS (connected to an eMServer) and
used to update the original study in the eMS database.
Creating a PSZ File
After loading a study in Process Simulate (on eMS), the File→Disconnected Study →Save
As and File→Disconnected Study →Save commands have several options which

can be set as part of the Save as type:
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• Save only the study

In this case, the .PSZ is created to represent the study. It contains references to library objects
(.COJT part and resource prototypes) from under the system root. The library objects in the
study are not saved.
• Save the study and its library objects to a local system root
In this case, the .PSZ is created to represent the study and a .ZIP file containing all the referenced
library components. This .ZIP file should be unzipped into the local system root before opening
the .PSZ file with Process Simulate Standalone - eMS compatible. Failure to do so results
in library objects not being found.
• Save the study and all the library objects

In this case, you create a single file which includes all data in the disconnected study (pszx
format that contains the psz file and all library components).
File→Disconnected Study →Save As and File→Disconnected Study
→Save is NOT the same as File→Save Scenario from Process Designer
Client system root

Process Simulate Standalone - eMS compatible can have its own local system root (on your
laptop). The default Client system room is the eMS system root on a central server. To point
Client system room to another folder:
1. From the ribbon, choose File→Options ,
2. Click the Disconnected tab.
3. Browse, select the new Client system root, and click OK.
4. Now open the .PSZ file you want.
Importing CAD files in Process Simulate

In Process Simulate, you can convert components and insert assemblies received from the OEM or
that you created externally to Process Simulate. The command to import CAD data has a slightly
different name in Process Simulate on eMS and Process Simulate standalone - eMS compatible:
• In Process Simulate on eMS, choose: File→Import/Export →Import CAD Files .
• In Process Simulate Standalone - eMS compatible, choose: File→Import/Export →
Convert and Insert CAD Files .
The following conversions are available:
• JT→COJT
• NX→COJT (requires a license)
• CATIA→COJT (requires a license)
• ProE→COJT (requires a license)
• STEP→COJT
• IGES→COJT
• DXF→COJT
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The Save XML option, activated by default in Process Simulate Standalone, saves the
converted CAD data in the system root.
Imported data is inserted into the opened study as well as in the system root.
You convert the CAD data once and then use the Insert Component from File command from
the Modeling tab of the ribbon to insert the .xml file of the converted assembly from the system root –
then it can be used with each study.
As you modify the studies offline, the OEM may still be updating studies on the eMServer, with
new parts and part structures, for example. In order to get these changes, the OEM chooses
File→Disconnected Study →Save As , and selects to save the data as a Study and
All Components type with the .pszx extension.
The .pszx format combines the .psz file and library components in one file, which the OEM can
send by E-mail (or by another convenient method) to you. After storing the .pszx file, you choose
File→Import/Export→Import pszx to Current Study and select the file received from the OEM.
The Import pszx to current study command is available only in Process Simulate
Standalone. The command also checks compatibility of study data — only compatible
project data can be imported.
You can configure which data types to import. After choosing OK, the command copies the library
components to the line builder's system root, prompting the user to affirm overwriting the existing
.cojt files.
If you deselect the Do not show this message again check box, the system asks them to
confirm overwriting each .cojt file individually.
In the offline environment, you continue to modify the study, by adding new resources for example.
You can send the updated file to the OEM in .psz format by E-mail (or by another convenient method).
When the OEM receives the data, he it opens eMServer project, opens the .psz file, and performs
eMServer Selective Update from the Quick access toolbar.
When a number of Process Simulate Standalone users collaborate offline, for example
with several suppliers, they can exchange updates to studies as .pszx files.
Updating back to the eMS database

It is important to update the changes that have been made in Process Simulate Standalone - eMS
compatible back to the eMS database. To do so:
1. Start Process Simulate (on eMS) and log in.
2. From the Welcome dialog box, click Open Project .
3. Open the .PSZ file with the File→Disconnected Study →Open in Standard Mode
command.
4. From the Quick access toolbar choose eMS Selective Update – this action updates the study
originally used to generate the .PSZ file with the changes made offline.
5. From the Navigation Tree, load the corresponding study and verify the eMS database was
updated.
More on receiving updates
In typical use cases involving original equipment manufacturers (OEMs) and suppliers, you may
create and develop your Process Simulate studies standalone and transfer the study back to the
OEMs without the overhead of maintaining a database and server.
Then the OEMs import the supplier's studies into their eMS database. When the OEM performs
File→eMServer Selective Update , the data is uploaded to the current working folder in the
project.
A preferred method for OEMs who receive projects from several suppliers, is to set a separate
working folder to contain the studies from each line builders.
Selected Process Simulate features

Process Simulate Standalone has several abilities, including to:
• Define which types of data are inserted to the study for data conversion. Converting CAD data
(individual components and assemblies as monolithic or assembly) – still requires a dedicated
license.
• Update data by inserting a disconnected study into a loaded study.
• Import weld points into a disconnected study from a .CSV file.
Process Simulate on eMS features not supported in Process Simulate Standalone
However, these features of Process Simulate on eMS are not supported in Process Simulate
Standalone - eMS compatible. These commands are related to accessing the database:
• eMServer viewers including Navigation Tree and Properties .
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• eMServer project commands including New Project , Open Project , and Close
Project .
• eMServer commands including the following eMS Selective Update , Check In , Check
Out , and Cancel Check Out .
• Attach File .
Activities
In the Using Process Simulate Standalone section, do the following activities:
• Working with default templates
• Working with custom templates
• Starting and exiting Process Simulate Standalone
• Updating Process Simulate Standalone from the eMS database
• Updating the eMS database from Process Simulate Standalone
Summary
• How to use Process Simulate Standalone.
Lesson 7: Modeling basics
Purpose
To provide a description of how to model in Process Simulate.
Objectives

• How to do some basic modeling in Process Simulate.
• How to create solids using solid primitives and Boolean operations.
• How to create 2D entities and use them to build 3D solids.
• How to create a gun shank.
• How to model a simple robot.
Lesson
Lesson 7: 7: Modeling
Modeling basics
basics
Do I do this?
You use the modeling environment to create or modify the components in your study. For each
component you model you can add geometry, kinematics, or logic. Once you end modeling of a
component, others can use it in their study.
Modeling basics
Overview of Process Simulate basics

Purpose
In this topic, you get an overview of Process Simulate basics learned earlier in relation to the
functionality you learn about in the preceding topics.
Objectives

• Review common commands used to do modeling and layout work in Process Simulate.
• Get an overview of the basic modeling tools.
Starting out
Earlier you learned many things about Process Simulate that is quickly reviewed in this topic. This
is not meant as a replacement to that course.
You learned about the abilities of Process Simulate to layout the contents of a study; however,
there are two basic modes in Process Simulate:
• Layout mode — learned earlier in this training, it is used to modify the content and layout of
objects (for example product and resources) and processes (for example paths) in a study. In this
case you are inserting instances (references) of an object prototype into a study
• Modeling mode — learned in this part of the training, it is used to modify the content and layout
of entities and kinematics in an object. In this case, you modify the object prototype. Object
prototypes are stored as .JT files in .COJT folders under the system root.
Activities
In the Overview of Process Simulate basics section, do the following activities:
• Switching to the Project_209S study
Lesson
Modeling basics
basics
Process Simulate basic modeling tools

Purpose
In this topic, you get overview of the basic modeling tools.
Objectives
• Get an overview of the basic modeling and kinematics tools.
Modeling and kinematics functionality

Modeling and Kinematics Functionality
• Can move the Working Frame.
• Can create new parts, compound parts, resources, and compound resources.
• Several ways to get existing objects into a study
• Can start modeling, end modeling, saving modeling changes, or throw them away
• Can align or duplicate entities
• Can create new reference frames within an object
• Can create 2D entities
• Can create 3D entities
• Can modify existing 2D and 3D entities (for example Boolean, sweeps, extrudes, revolutions,
scaling, etc.
• Reload original modeling configuration – discards the current modeling changes and reloads the
stored modeling configuration from the .COJT file.
Kinematics Functionality
• Can create or modify kinematic definitions
• Can define objects as various tool types (for example grippers, robot tools, etc.)
• Can move a kinematic object’s joints (for example Robot Jog or Joint Jog )
• Create kinematic poses
• Jump to a kinematic object’s poses
• Jump or move a kinematic object to various locations (inverse kinematics)
• Check robot reachability interactively or automatically
Modeling basics
• Mount or unmount tools to kinematic object
• Add or remove external axis (for example gantries or 7th axis) definitions to a kinematic object
• Examine robot properties.
Pick Level
Choose the Pick Level icons from the Graphic Viewer toolbar. The following options are available”
• Component — The entire object is selected when any part of it is selected.

o Whole object — with all objects only the whole object can be selected.
o Study Data — each object can be selected independently (for example a frame, cross
section, note flag, dimension, etc.).
• Entity — When selecting objects shown in united representation (the default): Only the
entity (that is, part of the whole object) is selected. Here is what can be selected:
The results of the Entity Pick Level are dependent on whether the selected object
is shown in united representation or detailed representation. Described in the next topic
o Whole Object — with non-kinematic objects only the whole object can be selected.
o Kinematic Link — On Kinematic objects, each link can be selected independently (for
example on a human, the arm and hand are separate kinematic links).
o Study Data – each object can be selected independently (for example a frame, cross section,
note flag, dimension, etc.).
o Object Frames — Frames within an object can be selected independently.
• Surface/Face — Only the selected surface (or face) of the object is selected.
• Edge — Only the selected edge of the object is selected.
The Surface/Face and Edge Pick Levels are only available when certain
Process Simulate commands are active, such as Project Arc Seam and the
various measurement commands. These Pick Levels is discussed later in this course,
only if applicable.
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Modeling basics
basics
A short cut key to toggle between the Pick Levels is the F12 key.
Setting pick intent

Use the Pick Intent stack to choose how objects are selected in the Graphic Viewer. This can be
accessed by clicking the down arrow next to the eighth icon in the Graphic Viewer toolbar. The last
icon you select becomes the one on the top of the stack.
The Pick Intent stack contains these commands:
• Snap : The position selected is either:

o The closest mid point of an edge – select on a surface near the middle of the edge.
o An end point of an edge – select on a surface near the corner of the edge.
o The center of a face – select on the middle of an edge bounding the desired surface.
• Self-origin : This is the only Pick Intent that depends on the setting of the Pick Level. If the
Pick Level is set to Component , then the self-origin of the object is always selected, no
matter where the object is selected. If the Pick Level is set to Entity , then the self-origin of
the currently selected entity is selected.
• On Edge : The location selected is the closest point along the closest edge.
• Where Picked : The location selected is the point you selected.
A short cut key to toggle between the Pick Intent options is the F11 key.
More modeling topics

Copying and pasting:
• Typical copy/paste techniques can be used such as Copy Paste , Ctrl+C Ctrl+V, etc.
Modeling basics
• Copying and pasting an instance (and object you are NOT modeling) produces another instance
of the same prototype (the same COJT).
• Copying and pasting a modeled object produces another modeled object (a new prototype).
When ending modeling, a new .COJT is placed under the system root.
Access to entities of an object

• In general you do not have access to the entities of object (except for kinematic links), except
while modeling an object. Displayed geometry becomes one unified object and blanked geometry
cannot be unblanked. Frames are blanked.
• To have access to all the entities of an instance that is not modeled, select it and from the ribbon,
choose Modeling tab→Entity Level group→Load Entity Level
• To have access to selected entities of every instance of a prototype: While modeling an object,
select the entities and from the ribbon, choose Modeling tab→Entity Level group→Set as
Preserved Objects . You can use this technique to display frames after modeling of the
object has ended.
Lesson
Modeling basics
basics
Modeling concepts
Purpose
In this topic, you learn how to do some basic modeling in Process Simulate.
Objectives
• Know of the methodology of modeling in this system.
• Get an idea of the solid modeling tools available.
Modeling overview
The Process Simulate modeling menu allows you to create geometry that can be used in Process
Simulate.
This chapter cover the concepts of Process Simulate modeling. In addition to creating geometry,
Process Simulate modeling provides tools to create kinematics (joint motion) to the geometry so that
Robots, CMMs, heads, guns, moveable fixtures, and so on can have realistic motion.
Example of what can be created in modeling:
• Geometry
o Solids (3D entities)
o Wireframe (typically 2D entities)
o Frames
o Etc.
• Kinematics
• Logic (taught in the intermediate course)

o Conceptual conveyor definitions
o Logic blocks and smart components
Modeling methodology
Modeling methodology
1. Open a study in Process Simulate.
2. Load the study into Process Simulate.
3. Optionally, insert an existing object (resource or part).
4. Set the modeling scope to a loaded object (resource or part) or create a new one.
5. Design the prototype’s geometry
Modeling basics
6. Edit the geometry
7. Define kinematics
8. Add logic block information as desired.
9. If changes are good, then end modeling, else reload the object.
In Process Simulate:
• An icon overlay displays to indicate that an object is currently being modeled.
This has changed from previous versions, when a lock icon was used to indicate that
an object is not under modeling. The lock icon is still used to indicate other types of
restrictions for objects.
• A Modeling window layout is shown in the Layout list. In general the Standard or Modeling
window layouts can be used to display the modeling functionality. Other standard window layouts
do not show all of the kinematic and geometric modeling tools on the Modeling menu.
• The Modeling tab of the ribbon contains all the modeling related commands.
Example modeling functionality:

After users model the 3D geometry of an object, if they wish to undo the changes, the Reload
Component command reloads an object’s initial 3D geometry as it exists in the library (before
beginning the current modeling session). This command does not revert other types of modifications
that may have been made, such as renaming the object, assigning it to operations, adding properties,
etc. Reload Component is available as long as End Modeling has not been used to
terminate the modeling session and save the modified object back to the library.
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Modeling basics
basics
Solid modeling overview
Process Simulate is not a parametric modeling system, however geometry can be modeled
and created here. It is primarily meant as a process design and verification system. It is
not a replacement for high end CAD systems like NX, I-DEAS, or Solid Edge. For more
complex geometry, translators are used to bring in objects from a CAD system (For a
complete list of translators, see the online help).
Solid creation:
• Primitives — Process Simulate works with five basic solid primitives. Out of these primitives, a
designer can create many required shapes:
o Box
o Cylinder
o Cone
o Sphere
o Torus
• Other solid creation tools — The Sweep function creates a new solid by sweeping from a start
shape, along the contour of a user-defined curve, and ending with an end shape. The starting
and ending shapes can both be either circles, rectangles, or curves. You can set the dimensions
of the starting and ending shapes. When using a curve for the starting shape, the function
automatically closes the curve with the shortest possible straight line. The function retains the
original object - you can delete this if you wish. Process Simulate supports several operations to
use 2D data to make solids:
o Sweep by Circle
o Sweep by Curves
o Sweep by Rectangle
o Extrude — You can expand a planar object (curve or surface) into a 3D object. The
points of the planar object must be in the same plane. The function supports the following
planar objects: Polylines, curves, and surfaces. When extruding a curve, the function
automatically closes the curve with the shortest possible straight line. The function retains
the original object - you can delete this if you wish. You can select multiple objects if you
wish, as long as they all lay in the same plane. The function is only enabled when an object
on or parallel to the global plane is selected.
o Revolute (revolve) — You can revolve a line (2D object) around a selected axis and
create a 3D object.
Modeling basics
Solid modification:
There are only a few ways that a solid can be modified:
• Scale — You can change the size of a 3D object in all dimensions. Modify the X, Y, and Z
values in one of the following ways:
o Drag one of the yellow lines. (The cursor is enhanced with a Z-axis when dragging one
of the yellow lines in the Graphic Viewer.)
o Specify the required value in the X, Y, or Z boxes using the up and down arrows.
o Manually enter the value in the X, Y, or Z boxes.
The modifications are dynamically reflected in the Graphic Viewer.
• Scale object between points — You can modify the dimensions of a selected object using a
bounding box. The selected object is displayed in the Graphic Viewer in a bounding box with
a yellow line extending diagonally from the bottom corner of the bounding box to the opposing
upper corner of the bounding box.
• Boolean Operations — These are key operations for the solid modeler. supports the following
operations:
o Unite - Creates a solid out of all the volume occupied by two or more solids.
o Subtract - Creates a solid by using the volume of one solid to remove volume from
another solid.
o Intersect - Creates a solid out of the common volume of two solids.
Other notes
Prototypes:
You always model an object prototype. An object instance in a study is a reference to a

prototype (a pointer to the prototype).
When an object prototype is saved, the Self-origin is placed at the World Frame (The
World Frame is the default location of the Working Frame). The location of each entity in
the prototype is relative to its Self-origin.
Concurrent usage of modeled prototypes:
Lesson
Modeling basics
basics
In order to allow modeling of .JTs loaded by other Tecnomatix applications: choose
File→Options , click the Disconnected tab, and check Use local copy of the
System Root files. Then click Settings to open the Local Files Cache Settings dialog box.
3D data files are loaded from the Local Files Cache instead of the System Root. The End
Modeling operation updates the System Root. On the next session the Local Files
Cache is updated by the new file version from the System Root.
Modeling basics
Solid creating with primitives

Purpose
In this topic, you learn how to create solids using solid primitives and Boolean operations.
Objectives
• Use the solid modeling tools to create an object.
Solid Creation Basics

In this topic, you use solid primitives and Boolean operations to make a simple object.
This command is located in the Components group of the Modeling tab.
• Choose New Resource
These commands are located in the ribbon under Modeling tab→Geometry group→Solids :
• Choose Box Creation →Create a box — creates a solid box by specifying Length, Width,
Height, and entity Self Origin.
• Choose Cylinder Creation →Create a cylinder — creates a solid cylinder by specifying

Radius, Height, and entity Self Origin.
• Choose Cone Creation →Create a cone — creates a solid cone by specifying Lower
Radius (bottom of cone), Upper Radius (top of cone), Height, and entity Self Origin.
• Choose Torus Creation →Create a torus — creates a solid torus (donut made by
sweeping a circle around an axis) by specifying Major radius (distance from the center of the
donut to the center of the swept circle), Minor radius (radius of the swept circle), and entity
Self Origin.
• Choose Unite — takes the given Unite entities and generates one new solid that
encompasses the same volume.
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• Choose Subtract — removes the volume of the Subtract entities (the cutting entity) from
the Entity (the entity to be cut).
These commands are located in the Scope group of the Modeling tab.
• Choose End Modeling
• Choose Set Modeling Scope — makes a “local” copy of the .COJT in the study, opens the
object for modeling, and sets it as the parent of every new entity you create.
If modeling more than one object simultaneously, use this command to switch which
is the parent of newly created entities.
If copying a component in a study, a new instance is created. However, if you copy a

modeled component, a new prototype is created.
Activities
In the Solid Creating with Primitives section, do the following activity:
• Modeling a Table
Review questions
Question1
Question2
Modeling basics
Modeling tab→End Modeling File→Open Modeling tab→Set Modeling Scope File→Close End
Modeling Open Set Modeling Scope Close
Lesson
Modeling basics
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Using wireframe to create solids (optional)

Purpose
In this topic, you learn how to create 2D entities and use them to build 3D solids.
Objectives
• Model an object using wireframe.
• Revolve or extrude 2D entities to make a solid
Wireframe basics
These commands are located in the ribbon under Modeling tab→Geometry group→Curves :
• Choose Create Polyline — creates a single entity that is made up of a series of connected
straight lines.
• Choose Create Curve — creates a single curved entity through the selected control points.
• Choose Create Circle — creates a circle by specifying a Center Point and a Radius.
• Choose Fillet — creates a curve with the specified Radius at the intersection of two lines
or curves.
• Choose Split Curve on Intersection — splits a curve where it intersects another curve
or surface.
• Choose Merge Curves — combines two or more curves into one curve
These commands are located in the ribbon under Modeling tab→Geometry group→Solids :
• Choose Revolute (revolve) — sweeps a curve around an axis to create a solid.
• Choose Extrude — sweeps a curve along an axis to create a solid.
Activities
In the Using wireframe to create solids (optional) section, do the following activities:
Modeling basics
• (Optional) Revolving 2D entities to make a solid
• (Optional) Extruding 2D entities to make a solid
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Modeling gun shanks (optional)

Purpose
In this topic, you learn how to create a gun shank.
Objectives

• Sweep 2D entities to make a solid.
• Use other modeling tools to make a more complex object.
Tools used
You use the following 3D modeling commands that you have not used yet. These commands can be
found in the ribbon, under Modeling tab→Geometry group→Solids .
• Sweep Circle — sweeps a circle around an axis
The start and end radius of the circle can be different.
• Cylinder Creation →Create a cylinder (optional) — creates a solid cylinder by

specifying Radius, Height, and entity Self Origin.
• Cone Creation →Create a cone (optional activity step) — creates a solid cone by
specifying Lower Radius (bottom of cone), Upper Radius (top of cone), Height, and entity
Self Origin.
You use the following 2D modeling command that you have not used yet. These commands can be
found in the ribbon, under Modeling tab→Geometry group→Curves .
• Create Arc — creates a curved arc through three points.
Modeling basics
You also use the following modeling commands that you have not used yet. These commands can be
found in the ribbon, under Modeling tab→Layout group.
• Duplicate Objects — depending on the Pick Level, copies entities or components across
an X, Y, and Z grid.
• Mirror Objects — depending on the Pick Level, mirrors entities or components across a
specified plane.
Activities
In the Modeling gun shanks (optional) section, do the following activity:
• (Optional) Sweeping 2D entities to make a solid
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Modeling basics
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Modeling a more complex object (optional)

Purpose
In this topic, you learn how to model a simple robot.
Objectives
• Use the Working Frame to build.
• Use several ways of creating and placing objects in modeling.
Tools used
You use the following functionality from the Modeling tab of the ribbon that you have not used yet:
• Set Working Frame — Temporarily changes the position and orientation of the Working
Frame from the World Origin (origin of the study) to a specified one. This affects many of the
Process Simulatecommands including modeling and placement commands.
• Create Curves →Unite — Takes the given Unite entities and generates one new solid
that encompasses the same volume.
you now begin modeling some more complex objects. However, you have another agenda here
besides learning how to model better. You use this activity to explain and use the working fame and
the placement editor while building a detailed object.
Using the working frame to build

The Working Frame is a special frame in Process Simulate. It can be placed anywhere on the
screen. Many of the menus in Process Simulate place objects on the Working Frame (where ever it
is in the cell) by default. This can be a very powerful tool.
• The Frame option is used to place the Working Frame where ever you want it
• The World option places the working frame back on the World Origin (the default location for
the Working Frame)
Modeling basics
Ways of creating and placing objects in modeling

Method 1:
Create an entity at the Working Frame then move it with Placement tools.
Method 2:
Move the Working Frame then create the entity at the new location of the Working Frame.
Method 3:
Use the optional Frame prompt, in most entity creation dialog boxes, to locate the Working Frame
when you create an entity.
you practice all three methods in the next activity.
Activities
In the Modeling a more complex object (optional) section, do the following activity:
• (Optional) Modeling a simple robot for kinematics
Lesson
Modeling basics
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Summary
• How to do some basic modeling in Process Simulate.
• How to create solids using solid primitives and Boolean operations.
• How to create 2D entities and use them to build 3D solids.
• How to create a gun shank.
• How to model a simple robot.
Lesson 8: Kinematics basics
Purpose
To provide an introduction to Process Simulate kinematics.
Objectives

• How to create some different types of object kinematics.
• How to add lead and follow factor to object kinematics.
• How to add cranks to a kinematic tree.
• How to create a kinematic tree with branching.
• How to define an object, as a gun.
• How to assign attributes
• How to add kinematics to an object and move it around.
• Get some background on inverse kinematics.
• How to create and use inverse kinematics devices.
Lesson
Lesson 8: 8: Kinematics
Kinematics basics
basics
Kinematics background
Purpose
In this topic, you learn how to create some different types of component kinematics.
Objectives

• Know several ways to get guns and grippers into the system.
• Gain a basic background in kinematics.
• Know the methodology to define a kinematic device.
Kinematics background basics
According to wikipedia.org: Kinematics (from Greek, kinein, to move) is the branch of

classical mechanics that describes the motion of objects without consideration of the
causes leading to the motion.
Now let’s learn how to start with a geometric component and add kinematics to component
prototypes. In this topic you use the following kinematics functionality:
• Joint Jog — Located on the Robot tab of the ribbon. This command is for components that
have kinematics defined, it can be used to move each independent joint by itself.
• Pose Editor — Located on the Modeling tab of the ribbon. This command is for
components that have kinematics defined, it can be used create, edit, and jump to existing poses.
A pose is a named set of joint values used during some simulations (for example
like opening and closing a door).
Kinematics basics
• Kinematics Editor — Located on the Modeling tab of the ribbon. When modeling a
component, it can be used to create, edit, or delete the definition of the kinematics.
o Create Link — creates a kinematic link.
o Create Joint — creates a kinematic joint.
Ways to get geometry into Process Simulate

• Model them in Process Simulate.
• Model them in another CAD system and translate them into Process Simulate.
No matter where the geometry is created, the kinematics are added in Process Simulate.
Basic kinematics
The following is a list of definitions that are important to remember when working with kinematics:
You must be in Process Simulate modeling mode to define kinematics.
Here are some basic definitions:

• Link – (also known as a rigid body) a group of entities within a component that remain fixed,
relative to one another. In this way it is the basic non-moving segment of a kinematic chain.
Default names begin with these letters: LNK (for example LNK1, LNK2, LNK3)
• Joint – the basic moving segment of a kinematic chain. A joint consists of 2 links and an axis. It
defines the relative motion between these two links relative to the axis. Default names begin with
the letter J (for example J1, J2, J3). There are 2 types of joints.
o Revolute joint - rotates around axis
According to wikipedia.org: Rotational or angular kinematics is the description of

the rotation of an object
■ The positive direction of rotation around an axis is defined using the right-hand rule. The
right-hand rule is this: Make a fist and point your thumb straight up. Place your fist at the
first point and align your fist so that your thumb points straight toward the second point.
Now your fingers show the direction of rotation around the axis.
o Prismatic joint - linear movement along axis
According to wikipedia.org: Linear or translational kinematics is the description of

the motion in space of a point along a line.
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• A kinematic tree has an order established by the relationship of the joints and links. The parent
link precedes a child link in the sequence order. When the parent link moves, the child link
follows. The parent takes the child with it.
o In a typical kinematic tree, the number of links is equal to 1 more than the number of joints.
For example: if there are 6 joints, there is 7 links.
o The kinematic chain is the simplest example of a kinematic tree. It is an open loop, string
linked mechanism. All the links, except the first, have one parent. Also all the links, except
the last, have one child.
o There is no limit to the length of a kinematic chain. Here is an example of a kinematic chain
(a simple kinematic tree)
Kinematic Tree:
The limit of six degrees of freedom only applies when defining a robot. This is
because robots require the creation of ONE inverse solution.
Attributes of a kinematic joint

1. The joint angle
2. The axis
3. The joint type
4. The distance between the two links of the joint
5. The length of the link (distance between two joints)
6. The angle between two links (parent to child)
The last four attributes cannot be changed; they are fixed.
Kinematics basics
Methodology to define a kinematic device

1. Envision the kinematic chain and create a kinematic tree on paper.
• What are the links, what type of joints, and so on).
Whenever modeling kinematics, first draw a kinematic tree. Each box represents a
link. A joint is represented by drawing an arrow from the parent link to the child link.
o The first link is always the fixed link.
o A link cannot contain any of the geometry of any other link.
2. Create the links.

• Verify that desired entities have been selected as part of the desired link.
3. Define each axis and joint (parent link, child link, axis and joint type).
• An axis is defined by its two end points. The positive direction is from the first point to the
second. (right-hand rule).
• Joints are defined between one object/assembly to a second object/assembly. The father is
the stationary object.
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4. Define a range for each joint.
5. Create other joints in the same way.
6. Test the mechanism’s joints using Joint Jog .
7. Save and close the component prototype.
Creating and editing in the kinematic editor
Use the Kinematics Editor located on the Modeling tab of the ribbon, you can:
If the selected component is being modeled, you can create or modify its kinematic
information. However if it is not being modeled, you can only view its kinematic information.
• Create links, delete links, and change the geometry in a link later. Links are shown in the
Kinematic Editor as boxes whose coloring matches the geometry they contain.
• Create joints, delete joints, and change the axis, range, speed, and acceleration in the joint later.
Links are shown in the Kinematic Editor as an arrow drawn from the parent link to the child link.
o Prismatic (linear) joints are shown as a blue arrow.
o Revolute (rotational) joints are shown as a black arrow.
o Locked joints are shown as a blue or black line with a circular head.
Kinematics basics
• Create dependencies between joints using functions or follow factors.

Following joints are shown as a blue or black large dotted arrow.
Joints with functions are shown as a blue or black small dotted arrow.
• Define kinematic devices and robots.
• Etc.
Activities
In the Kinematics background section, do the following activities:
• (Optional instructor demo) Simple kinematics
• Simple kinematics (Part 1)
• Simple kinematics (Part 2)
Review questions
Question
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Kinematics basics
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fly a kite create geometry define links and joints
Kinematics basics
Kinematics basics summary

Purpose
In this topic, you apply the basic kinematic theory learned in the last topic. The kinematics of a door,
containing two joints, is defined and then used in a simulation.
Objectives

• Add joints to a simple object.
Activities
In the Kinematics Basics Summary section, do the following activities:
• Add Joints to a Simple object
Review questions
Question
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Kinematics basics
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change the type of an existing joint from rotational to linear change the links referenced in a joint
after it is created create links and joints change the geometry in a link after it is created change
the axis of an existing joint
Kinematics basics
Joint dependency basics

Purpose
In this topic, you learn how to make the motion of one joint dependent on another.
Objectives
• Gain an understanding the basics of techniques available to define a joint dependency.
• Create a kinematic functions to define a joint dependency.
Introduction to joint dependency

There are three methods in this system to define joint dependencies, however all three can be
accessed by choosing Kinematics Editor , selecting the dependent joint, and choosing Joint
Dependency . Here are the three methods:
• In the Joint Dependency dialog box, choose Joint Function. It is used to define the dependency
of the selected joint to other joints using various logical and mathematical functions. Using this
technique, dependent joints are hidden from the Joint Jog dialog box and is the most common
method. You use it in this lesson in order to hide the dependent joints.
• In the Joint Dependency dialog box, choose Coupling. This technique can only be used with
compound equipment (a component containing references to several other sub components). It
is used to define the dependency of a joint from one sub component to another. The joint value of
the dependent joint is found by multiplying the factor times the leading joint. This is discussed in a
later lesson in this course.
• In the Joint Dependency dialog box, choose Following. It is used to define the leading joint and
follow factor for the selected joint. The joint value of the dependent joint is found by multiplying
the follow factor times the leading joint. This is similar to coupling except that both joints are
in on component. Using this technique, dependent joints continue to be shown in the Joint
Jog dialog box.
By default all joints move independently. Checking any of the above described options
make the joints motion dependent on another joint.
Description of joint dependencies

Dependent joints can be found in many places such as grippers, weld guns, and robots. For example
in this robot there is a four bar linkage (three joints depend on the motion of a fourth joint). Consider
joints J1 and J2. At first, both joints start out at 0 degrees. Because J2 is dependent on J1 (using the
Following option or the Joint Function option), moving J1 to 30 degrees, simultaneously moves
J2 to —30 degrees.
However if J2 was not dependent on J1, moving J1 to 30 would not effect the value of J2 (leaving
it at 0 degrees).
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Kinematic functions
Mathematically, think of the independent variable as being x and the dependent variable as y. The
only way to change the value of y is to change x. For example:
y = x * 2; If x = 40 then y = 80
This is not the exact function used in the previous example; since you do not want to
introduce trigonometry to explain this kinematic concept.
Similarly in this system, if:

• Joint J1 is independent
• Joint J2 is dependent on joint J1
Kinematics basics
• The value of J2 is defined as J2 * 2
• So if J1 = 40 then J2 = 80
• This is why J1 is available for jogging but J2 is not available.
Whenever calculating the follow factor for a joint pair and one joint is prismatic and the
other is rotational, the units for the rotational joint are radians NOT degrees.
Activities
In the Joint dependency basics section, do the following activities:
• Leading joints and follow factors (robot tool)
Review questions
Question
Lesson
Kinematics basics
basics
FALSE TRUE
Kinematics basics
Introduction to kinematic cranks

Purpose
In this topic, you learn how to add cranks to a kinematic tree.
Objectives

• Draw a kinematic tree of the desired kinematics
• Know the four standard joints of a crank.
• Create and use a crank such as a slider.
Crank basics
In this topic you use the following kinematics functionality that you have not used yet:
More on the Kinematic Editor:
• Kinematics Editor
o Create Crank — used to define kinematic structures consisting of at least one

independent joint and multiple dependent joints that are joined in a kinematic loop.
There is often a need to create joints whose motion is described as a function of other joints. Very
often, these functions are complex. One very common device is a bar actuated by a piston or
solenoid. The bar pivots about one end when the other end is moved by the piston. The piston
must also be free to pivot.
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First draw the kinematic tree

The first step in designing any kinematic device is to draw the kinematic tree. Typically you represent
each link as a box. You then draw arrows from the parent link to the child link to show their kinematic
relationship. Each of the arrows are labeled to show which joint they represent.
For example, if you wanted to have two jogable joints, you would need to have three links (one
more link than joints).
Kinematics basics
In some situations such as a crank, you have four joints with only one jogable joint (independent).
The other three joints of the mechanism are dependent on the independent joint. So as you move the
one independent joint, the dependent joints move simultaneously.
Links and joints cranks
The Kinematics Editor enables you to define a crank, which is a kinematic structure consisting of
at least one independent joint and multiple dependent joints that are joined in a kinematic loop.
Cranks are created using a wizard that takes you step-by-step through the process, including
selecting the type of crank to be defined, the coordinates of each crank joint and the entities that
make up the links of the crank.
The definition of the crank consists of four links and four joints named fixed, input, coupler, and
output. They occur in the order mentioned (FICO).
The resulting kinematic structure from the crank creation wizard contains 4 links, (1 dummy link,) 3
dependent joints, and 1 independent joint.
The crank creation wizard can only be run once for any set of four links. Changes can be
made manually after that.
Cranks include the following links:
1. Fixed — The fixed link is not moved by the joints of the crank being defined. (It may, however,
be moved by a joint defined in a different kinematic structure, including another crank.) The
fixed_input joint (which can move) is between the fixed link and input link.
2. Input — The input link is the parent link to the input_j1 independent joint. This joint is between
the input link and coupler link.
3. Coupler — The coupler link is moved by a dependent joint. The coup_output joint is between
the coupler link and output link.
4. Output — The output Link moved by a dependent joint that completes the kinematic structure.
The output joint is between the output link and fixed link (dummy link).
5. The Kinematics Editor also adds a dummy link (one without geometry) to complete the loop of
the kinematic structure (it is a surrogate for the fixed link).
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The point representing the axes for the rotational joints must lay on the same plane. Any prismatic
joint must be perpendicular to the rotational joints. To assist in doing this, you can select the Optional
custom plane box and select a surface (or frame). The plane is displayed in the Graphic Viewer.
All the joint coordinates are projected on to this plane and the updated values are used to
create the crank. However, the joint values displayed in the wizard remain unchanged.
Thus, if you choose a different plane, you are not be required to redefine these values.
If you select a dependent joint and open the Joint Dependency editor, you can view
the calculations entered by the system automatically to operate the joint. More on this later
Crank types
The following crank types can be defined:
• Four-bar linkage — Crank consisting of four links and four rotational joints (RRRR), only one of
which is independent (known as a "double crank" in Process Simulate).
• Slider — Crank consisting of three rotational joints and one prismatic joint, for example, a
piston. There are three configurations of slider cranks, differing in the relative positions of their
input (driving) joint and fixed link:
o RPRR — The input joint of FICO is prismatic.
o PRRR — The fixed joint of FICO is prismatic.
o RRRP — The output joint of FICO is prismatic.
• Three Points — A mechanism in which an RPRR slider drives a 4-bar linkage crank ( known as
three points because there are three points on the fixed link).
Kinematics basics
Four bar cranks

Four-bar linkage — Crank consisting of four links and four rotational joints (RRRR), only one of
which is independent (known as a "double crank" in Process Simulate).
Before starting to create this type of crank, you should define four points (or frames) on the
same plane to be used to define the axes for the four rotational joints.
Slider crank
Slider — Crank consisting of three rotational joints and one prismatic joint, for example, a piston.
• RPRR — The input joint of FICO is prismatic.
• PRRR — The fixed joint of FICO is prismatic.
• RRRP — The output joint of FICO is prismatic.
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Before starting to create this type of crank, you should define three points (or frames) on
the same plane to be used to define the axes for the three rotational joints.
There are two types of slider cranks:

• Slider
• Offset Slider
You learn more on the Offset Slider later in this course.
Kinematics basics
Using three point cranks

Three Points — A mechanism in which an RPRR slider drives a 4-bar linkage crank ( known as three
points because there are three points on the fixed link).
Activities
In the Introduction to kinematic cranks section, do the following activities:
• Optional instructor demo: Kinematic looping
• Kinematic Looping
Review questions
Question
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Kinematics basics
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TRUE FALSE
Kinematics basics
Kinematic branching
Purpose
In this topic, you learn how to create a kinematic tree with branching.
Objectives

• Create a kinematic tree with more than one branch.
Branching basics
It is possible to have a more complex kinematic tree than a simple chain. A kinematic link can have
more than one child. This is how you create a branching kinematic tree. Here is a simple example of
an open-loop, branching mechanism.
Kinematic tree:
A kinematic tree has only one base and one TCP link. Usually, this is not a robot. If the
mechanism has a TOOLFRAME, and has an inverse solution, only one branch is affected
by the Move to Location command.
Robot tool example of kinematic branching

Let’s recall some of the simple kinematic trees you created so far. In general they had one base link,
which was connected to link1 by a joint. Link1 was then connect to link2 and link2 was connect
to link3, etc. This kinematic chain was linear.
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However in more complex kinematic examples, you may have kinematic branching like in the
following activity. This gun has 5 joints and 5 links that are kinematically related (for example only
one independent joint).
More on the Kinematic Editor:
• Reverse Joint — Keeps the parent-child link and changes the direction of the joint.
Activities
In the Kinematic branching section, do the following activities:
• Robot tool kinematic definition (part 1)
• Robot tool kinematics (part 2)
Kinematics basics
Defining speed and acceleration

Purpose
In this topic, you learn how to define joint speed and acceleration.
Objectives
• Define speed and acceleration values for a joint and see the effect on a simulation.
Speed and acceleration basics

An important part of any kinematic definition is the maximum speed and acceleration permitted for
each joint. It improves the fluidity of the simulation as well as makes cycle calculations time more
accurate.
Definitions
• Speed - The maximum speed of a joint in the current linear or angular unit per second.
o If the joint is a new joint for which no value is specified, the default is 100 mm/sec for
prismatic joints or 90 degrees/second for rotational joints.
• Acceleration - The maximum acceleration of a joint in the current linear or angular unit per
second per second.
o If the joint is a new joint for which no value is specified, the default is 200 mm/second squared
for prismatic joints or 180 degrees/second squared for rotational joints.
Methods for setting up the time of device operations

• Automatic Method: The system uses the Speed and Acceleration setup in the kinematics
definition to automatically calculate the time it take to move from one pose to another. This works
because the max speed for the joint cannot be exceeded, so the operation is stretched.
• Manual Method: Assign an unreasonably large value for the Speed and Acceleration in the
kinematics definition. Then manually specify the time for the device operation. This works
because the max speed for the joint is never exceeded, so the operation is not stretched.
Copying prototypes vs. instances of objects

Each object in the product and resource tree has a prototype referenced by an instance. The 3D data
(.JT file) is associated to the prototype. Each time you add an object into a study you get another
instance of it (which share the same 3D data).
If you copy an object you are modeling, you get a new prototype (new 3D data file). If you copy an
object that you are not modeling, you get a new instance (another reference to the same 3D data).
Activities
In the Defining speed and acceleration section, do the following activity:
• Speed and acceleration
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Defining an object as a tool

Purpose
In this topic, you learn how to define an object so that it is recognized as something that can be
mounted on a robot and used in a simulation.
Objectives
• Define objects using several different tool types (for different robotic applications).
• Recall how to define a gun for use with the geometric gun search tool.
• Recall now to define poses for a kinematic object.
Tool definition basics

In this topic you use the following kinematics functionality:
• From the ribbon, choose Modeling tab→Layout group→Create Frame →Frame by
6 values
• From the ribbon, choose Modeling tab→Kinematic Device group→Tool Definition
Tool definition
The Tool Definition command is located in the Modeling tab of the ribbon. You use it to define
an object as a tool. In this sense, a tool means an object that can be mounted to a robot to enable it
to perform a task. The tool definition contains critical information about the position of the TCPF on
the robot on the tool and more. Some menus that are affected by this setting include:
• Allows using the Mount Tool command to position and attach the tool to the robot's wrist
(TOOLFRAME) and place the TCPF of the robot (for the default controller) on the predefined
frame of the tool.
Kinematics basics
• Allows adding the tool into the gun box of the Operation Properties dialog box of an robotic
simulative operation (for example weld operation, pick and place operation, or continuous feature
operation)
• List of external axes in the Robot Properties dialog box for certain tool types.
• Ability to automatically move to a pose for certain simulative operation types and tool types.
• Ability to use the Geometric Gun Search tool. You learn more on this in the next topic.
• etc.
Options for tool definition types:
• Servo Gun — defines the resource as a servo spot-weld gun. In this case, the Mount Tool
command also defines the joint of the gun as an external axis of the robot to facilitate setting the
gun's joint value at each location.
• Pneumatic Servo Gun — are not defined as robot external axes when they are mounted, but
instead are controlled by OLP commands.
• Gripper — defines the resource as a gripper. It should contain poses for setting the joint values
at the part pick up and drop off locations (the poses can have any name). The Gripping Entities
and Offset distance defined here determine what objects is gripped at the part pick up locations
and released at the part drop off locations: Any part within the Offset distance to the Gripping
Entities at these locations is effected.
• Paint Gun — defines the resource as a paint or dispensing gun. For a paint gun you need to
define the paint gun tip frame (nozzle) and TCPF. The dummy kinematics are only used for
calculation of paint thickness and visualization of trigger states during simulation.
• Gun (for example all other tool types) — defines the resource as a tool you want to mount to
the end of the robot, that is not covered by one of the other types listed above (for example
pneumatic spot-welding, pedestal spot-welding, drilling/riveting, arc-welding, roller hemming,
laser cutting, grinding, deburring, material removal, polishing, waterjet, etc.).
For a pneumatic spot-weld gun, or a pedestal spot-welder: it should contain OPEN,

SEMIOPEN, and CLOSE poses that is automatically used when spot-welds are
simulated. In this case, these pose names are case sensitive.
In general, all tool types must have kinematics defined and at least one pose. However
for some objects (for example such as an arc-weld torch or a paint gun), kinematics are
not needed by the user. In these cases, it is not necessary to define kinematics, since
dummy kinematics and poses are automatically added to the object (if none exists) by the
Tool Definition command.
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How do I define a gun for searching?
A object must be defined as a gun in order to participate in a Geometric Gun Search .
Geometric Gun Search is a Process Simulate cmmando that is discussed later in this course.
You use it to select the best weld gun from a library of weld guns based on various attributes and
whether the gun can spot-weld along the path in your study without collision.
The gun defining is done while the gun is open in Process Simulate modeling. The following is
required to define an object as a gun:
• The object must be a device
• The device must have a TCP (Tool Center Point) frame
• At least the CLOSE state must be defined, but it is recommended to define all the states (OPEN,
CLOSE, SEMIOPEN).
These pose names are case sensitive.
• It must be defined using Tool Definition .
If these minimum demands are fulfilled, the object can be defined as a gun.
If there is a need for other states of the gun (OPEN, SEMIOPEN), they should be defined as well.
To avoid a collision alert between the gun tips and the car part during the Geometric Gun Search,
you can define entities which do not participate in the collision detection, using the no collision list
command in gun define toolbox. The selected entities do not participate in the collision detection of
the Geometric Gun Search. The no collision list does not affect regular Process Simulate collision
detection once you bring the gun into the study.
Pose definition basics

In this topic you use the following kinematics functionality from the ribbon:
• Home
• Pose Editor
• Joint Jog
In order to define a pose on the prototype, it must contain kinematics. Any kinematic object can have
poses stored with it. For example, spot-weld guns need to have the following three poses created for
them (case sensitive): CLOSE, OPEN, and SEMIOPEN.
Kinematics basics
Activities
In the Defining an object as a tool section, do the following activities:
Perform two of these activities:Spot, Drill/Rivet, Material Handling, Arc, Paint, or Debur.
Your instructor may demonstrate others as time permits.
• Spot — Defining an object as a pneumatic spot-weld gun
• Spot — Defining an object as a servo spot-weld gun
• Drill/Rivet — Defining an object as a drill/rivet gun
• Material Handling — Defining an object as a gripper
• Arc — Defining an object as an arc-weld torch
• Paint — Defining an object as a paint gun
• Debur — Defining an object as a deburring tool
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Kinematics basics
Adding kinematics to a simple robot

Purpose
In this topic, you learn how to add kinematics to an object and move it around.
Objectives

• Add kinematics to a simple robot.
• Use direct kinematics to move the robot.
Simple robot kinematics basics

In this topic, you add kinematics to a simple robot. In this activity you assume that the geometry was
already created (either in Process Simulate or somewhere else).
Activities
In the Adding kinematics to a simple robot section, do the following activities:
• Adding kinematics to a robot model
• Using direct kinematics to move the robot
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Kinematics basics
basics
Inverse kinematics device creation and usage

Purpose
In this topic, you learn how to create and use inverse kinematics devices.
Objectives
• Understand the concept of inverse kinematics.
• Convert a direct kinematics (device) to an inverse kinematics (robot) by adding a toolframe.
• Use Inverse kinematics to move the robot.
Inverse kinematics definition

In this topic you use the following kinematics functionality:
• From the Kinematics Editor :
o Create Toolframe — The presence of a TOOLFRAME on a device triggers Process

Simulate to define it for inverse kinematics, if possible. The system adds these frames into
your kinematic device: TOOLFRAME, TCPF, BASEFRAME, and REFFRAME.
Normally, an industrial robot would have 6 rotational joints, yielding 1 or 2 possible

inverse solutions for a reachable location. However, if you have a kinematic device
with more than 6 joints, you can have an infinite number of inverse solutions for a
reachable location.
o Set Baseframe — used to specify a BASEFRAME for the component.
o Set Current Joint Values as Zero — If there is a link in the Kinematics Editor, this
function sets the current joint values as the zero position by a compilation; Process Simulate
prompts you before executing the command. If there is no link, the function is disabled.
• Robot Jog — described in detail in the next topic
• Mount Tool — places the tool at the end of the robot wrist (on the TOOLFRAME), places
the robot TCPF on the predefined position stored in the tool, and attaches the tool to the robot
TOOLFRAME.
If the tool is a servo gun, it is also added as an external axis of the robot. If the tool is a
pneumatic gun, it is automatically actuated at weld spots.
Kinematics basics
This command only works for tools that have been defined using the Tool Definition
command.
Robot jog basics
Robot Jog dialog box expander areas:
The five expander areas in this dialog box that can be Expanded to expose functionality or
Collapsed to hide it.
• Location — You can view the robot at a specific location or add locations before or after it.
• Manipulators — Move and manipulate the robot using the Manipulator Frame in the Graphic
Viewer or the controls in this area. Also, you can limit the robot to a single configuration by
checking Lock and Selecting a configuration from the Configuration list of values.
o The current position of the robot determines which configurations appear in the
Configuration list of values.
o The current robot configuration is displayed and updated continually when Lock
remains cleared.
• External Joints — You can use this area to adjust the values of the robot’s external joints (for
example servo gun joints or 7th axis) without having to access the Joint Jog dialog box. Using
Robot Jog to adjust external joint values enables you to apply lock constraints that cannot be
applied when using the Joint Jog dialog box.
• All Joints — Similar to the Joint Jog dialog box.
• Coordinate Reference — You can use this area to measure the selected location's position
relative to various frames.
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Robot Jog dialog modes:

There are several basic modes for the Robot Jog dialog box:
• Robot Jog (the default behavior) — the robot base is fixed to the ground or an external axis (for
example 7th axis), and TCPF can be moved anywhere kinematically possible for this robot
(Inverse Kinematics). It is also possible to jog the robot on its external axes. .
• Only Robot Jog with Locked TCPF selected — the TCPF is fixed at a location, and the
robot base can be moved anywhere along its external axes (for example 7th axis) of the robot.
• Robot Jog with Locked TCPF and Enable Robot Placement are selected — TCPF
is fixed at a location, robot base can be moved anywhere kinematically possible for this robot
(detached from external axes, if defined).
• Robot Jog with Locked TCPF and Enable Robot and Attachment Chain Placement are
selected — TCPF is fixed at a location, robot base can be moved anywhere kinematically
possible for this robot (attached external axes, if defined).
Kinematics basics
• Robot Jog with Locked Configuration — the TCPF can be moved anywhere kinematically
possible without changing the robot configuration when this is selected on the Manipulation
area of the Robot Jog dialog box.
Inverse kinematics description

This topic describes how to create inverse kinematics devices. In general it is easy. Just add a
TOOLFRAME to the end of the primary branch (for example the end effector) of the kinematic tree.
This also adds a TCPF frame, which is used in inverse kinematics. However, not all kinematic
trees can have inverse kinematics.
The TCPF is the Tool center point frame. It refers to the frame of reference of robots and
robotic resources that is moved to target locations.
Here are some basic rules:

• Use One End Effector — Make a kinematic tree with only one primary branch. The other
branches should contain dependent joints (for example loops).
• No Redundant Joints — Do not use redundant joints in the primary branch.
• Look at the Primary Kinematic Branch Configuration — Follow the kinematic tree from the
fixed link to the end effector. Write down the joint types in order. For example RPP refers to a
kinematic tree where the primary kinematic branch contains a revolute first joint, a prismatic
second joint, and a prismatic third joint. Compare this information to the table below:
Example Primary Kinematic Branch Configurations with Inverse Kinematics:

Primary Kinematic Branch Configuration
Number of Joints
(from the regular inverse kinematic solver)
3 PPP
3 PRP
3 PRR
3 RRR
4 PRPR
4 PRRR
4 RPPR
4 RRPR
5 PPPRR
5 PRPRP
5 RPPRR
5 RRPRR
5 RRRRR
6 PPPRRR
6 RRPRRR
6 RRRRRR
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Using the Special Inverse Solver:
A kinematic structure with three to six joints with a TCPF uses the regular inverse solver. However
if more than six joints with a TCPF are needed (for example a lift assist), it uses the special inverse
solver. This message is shown when defining devices with more than six joints:
The special inverse solver can only be used with the default controller and is not supported
by compound equipment. In these cases if more than six joints are needed, they should
be defined into multiple devices and linked together using either kinematic coupling or
by defining external axes.
Inverse kinematics usage:
• Robot Jog — drag the TCPF of the robot while leave the base fixed, thereby moving all the
joints of the robot at once (Inverse Kinematics)
• Robot Jog with Locked TCPF — drag the base of the robot while leaving the TCPF of
the robot fixed, thereby moving all the joints of the robot at once (Inverse Kinematics)
In this simple topic, you only be moving the robot without a tool mounted to the end
of the robot arm. In this case, the TCPF is at the TOOLFRAME of the robot. When
the Mount Tool command is used to place a valid tool at the end of the robot,
the TCPF of the robot jumps to the TCP frame of the mounted tool. This affects the
locations that are marked and used later in this activity.
Activities
In the Inverse kinematics device creation and usage section, do the following activities:
• Adding a tool frame
• Using inverse kinematics to move the robot
• (Optional extra credit) more inverse kinematics
Kinematics basics
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Kinematics basics
Summary
• How to create some different types of object kinematics.
• How to add lead and follow factor to object kinematics.
• How to add cranks to a kinematic tree.
• How to create a kinematic tree with branching.
• How to define an object, as a gun.
• How to assign attributes
• How to add kinematics to an object and move it around.
• Got some background on inverse kinematics.
• How to create and use inverse kinematics devices.
Lesson 9: Other selected modeling and kinematics topics
Purpose
To provide information on other selected modeling and kinematics topics.
Objectives

• How to define a kinematic rail (or 7th axis).
• How to use cranks to enhance more complex kinematic device development.
• How to do more with kinematic functions.
• How to do a more complex example of kinematic functions.
• How to do another example with kinematic functions.
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modeling and kinematics
and kinematics topics
topics
Rails, gantries, and positioners (external axis) definition

Purpose
In this topic, you learn how to define a kinematic rail (also known as a 7th axis), which is a type
of external axis.
Objectives

• Know the basics about defining external axis components in this system.
External axis definition

Rail, Gantry, and Positioner Definition:
Use what you have learned to:
• Model the desired geometry for a rail, gantry, or positioner
• Add the desired direct kinematics (no inverse is required)
In Process Simulate: Rails, Gantries, and Positioners are types of external joints. For example:
• Rail – It is a separate .COJT that consists of a single linear joint (and is sometimes called a 7th
axis). A robot is Attached to the child link of j1 (in the study, not in modeling).
• Gantry – It is a separate .COJT that consists of three linear joints. A robot is Attached to the
child link of j3 (in the study, not in modeling).
• Positioner – It is a separate .COJT that consists of 2 rotational joints. The part is Attached
to the child link of j2 (in the study, not in modeling).
• Other kinematic devices can be used as externals as well, these three are provided as typical
examples.
Activities
In the Rails, gantries, and positioners (external axis) definition section, do the following activity:
• Sample rail creation overview
Other selected modeling and kinematics topics
More kinematic branching and cranks

Purpose
In this topic, you learn how to use cranks to enhance more complex kinematic device development.
Objectives

• Know more about typical kinematic loops (cranks) including a several example models.
Complete kinematic basics

It is possible to have a more complex kinematic tree than a simple chain. A kinematic link can have
more than one child. This is how you create a branching kinematic tree. Here is a simple example of
an open-Crank, branching mechanism.
Kinematic Tree
A kinematic tree has only one base and one TCP link. Usually, this is not a robot. If the
mechanism has a TOOLFRAME, and has an inverse solution, only one branch is affected
by the Move Loc command.
Working with the main branch

The main chain starts at the base and ends in the TCP link. It is recommended to build the main
chain first and ensure that it works properly. This may require making sure it has an inverse solution,
if needed.
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The four links are called fixed, input, coupler, and output. They occur in the order mentioned (FICO).
In a single crank, the fixed and output links belong to the main branch, while the input and coupler
links are not accessible. The input or the coupler is the "step" joint.
When two cranks are connected, the output of the one crank is the input of the other crank, and
does not belong to the main branch.
Example of a parallel pantograph (or four bar linkage)

A Fanuc 420 has an example of a parallel pantograph. This is a RRRR crank, and the bars define a
parallelogram. The second link is the fixed bar, the third link is the output bar. The vertical pantograph
arm is the coupler bar, and the horizontal pantograph arm is the input bar.
This is the same as the four−bar linkage crank.
Example of a non-parallel pantograph (or four bar linkage)

A Kuka k662 has an example of this. This case is similar to the ABB irb 60 case. The pantograph
in the ABB is a parallelogram, while in the Kuka it is not. This difference is that in non-parallel
pantographs, the motion of the coupler cannot be calculated using a follow factor, because it is not
linear. It is the result of the structure of the robot.
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Example of a prismatic screw (or slider linkage)

A Cincinnati 646 has an example of a prismatic screw (notice the sliders on the back of the robot).
Our lever attached to a piston is another example of a prismatic screw. Each is an RPRR Crank,
and the bars define a triangle. The prismatic joint is the input joint. The prismatic joint intersects two
rotational joints (no offset allowed).
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RRRP slider
PRRR slider
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PRRR offset slider
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RPRR offset slider
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RRRP offset slider
Activities
In the More kinematic branching and cranks section, do the following activities:
• (Instructor Demo) Other slider cranks including offset slider
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Variable joint limits

Purpose
In this lesson, you learn how to define joints whose limits depend on another joints limits. this
is known as variable limits.
Objectives

• Use variable joint limits.
• Define variable joint limits.
Help topics
Additional information for this lesson can be found in:

• Process Simulate→Kinematics Menu→Kinematic Editor→Defining Kinematics→Creating Joints
Introduction to variable joint limits

When the limits of a joint are not constant but vary, depending on the pose of other joints, the joint
is said to have variable joint limits.
In order to maintain the joint limits of a dependent joint, you use the variable joint limits functionality. It
is used to modify a dependent joint’s range−−based on another joint−−to avoid crashing into itself, an
outside fence, or to simulate real robot environments.
One simple example of a variable limit is a very inflexible person with only two joints: One joint allows
him to bend at the waist and the other to bend at the shoulder:
• If he stands up straight, he can move his arm 180 degrees: 0 degrees is the arm straight up in
the air and 180 degrees is hands on his quadriceps.
• However, if he bends at the waist 90 degrees, his arm motion is greatly diminished to
approximately 60 degrees: 0 degrees is the arm straight up in the air and 60 degrees is hands on
his quadriceps.
Here is the table of extreme points for this example:
Waist joint Shoulder joint

0 0
0 180
90 0
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Waist joint Shoulder joint

90 60
Variable joint limits graph
You use a joint-dependence graph to configure a mechanism’s working range. The working range
of a mechanism is found by do the following:
1. Put the mechanism axes into extreme positions.
2. Create a table of the extreme points between two joints. (The dependent and independent
joints). For example when j2 is -60 degrees, then j3 cannot be any larger than 215 degrees or
smaller than -19 degrees.
3. Create the joint-dependence graph using the table of extreme points. (Only one direction has to
be defined, the other is created automatically).
Defining variable joint limits
In a typical robot, j3’s limits are dependent on j2’s value and j2’s limits are dependent on j3’s value).
So, changing j2's value changes j3's limits and changing j3's value changes j2's limits.
If j2 and j3 were not dependent, the range graph would be a rectangle and have only four points in the
chart. The reason to have a variable limit is to avoid hitting something. So the shape of the range
graph is anything but rectangle. For example, it could be a parallelogram. You could also have
hexagon that looks like a rectangle without two opposite corners. With a hexagon, there would be
six points in the chart.
The shape of range graph can be any shape that defines a convex polygon. This is because the
dependency must be invertible. The extreme points that cause a problem are ignored.
When creating the range graph (which shows the working range), you need to look at the Cartesian
space. A curve in Cartesian space becomes a line on the range graph. And a straight line in
Cartesian space can become a curve on the range graph.
Activities
In the Variable joint limits section, do the following activities:
• Understanding variable joint limits
• Defining the variable limits
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More on kinematic functions

Purpose
In this topic, you learn how to do more with kinematic functions.
Objectives

• Know more about basic and advanced options available when defining joint functions.
Function basics
From the Kinematic Editor dialog box, clicking Joint Kinematics Functions opens the Joint
Kinematics Function dialog box. It enables defining a joint as a dependent joint. These commands
define functions which receive the values of the independent joint or joints, and which return the
value of the dependent (function) joint.
A dependent joint is a joint whose movement is totally dependent on the motion of one or more other
joints and which therefore does not constitute an independent, accessible degree of freedom. It is not
listed in the Joint jog dialog box together with the data for the active mechanism.
If a Joint Jog dialog box moves an independent joint, any dependent joints move according to their
functional dependence.
Process Simulate function definitions

A function−joint function consists of an expression.
When expression includes a reference to an independent joint, that reference can assume any
of four different forms:
• t# and d# Designate a rotational or prismatic joint, respectively, numbered # in the order of the
joints as determined when the mechanism is defined by the mechanism define command. This
order is determined by the system and is subject to change if the mechanism is subsequently
redefined. The maximum allowable number of joints is 64.
• T( name ) and D( name ) Designate a rotational or prismatic joint, respectively, specified by its
name determined when the joint was defined or as subsequently renamed by the user.
The format of an expression itself has one or more of the forms listed below. In all of the forms, the
spaces as shown are optional; thus (mnp) and ( mnp ) are equally valid.
• ( string ) One of seven forms enclosed in parentheses ( ):
• Sine or cosine abbreviation: Uppercase S or C for rotational joints, or lowercase s or c for

prismatic joints, followed by one or more digits from 0 to 9, to express the sine or cosine of the
specified joint in radians. This expression abbreviates references to joints in the format d# or t#; it
does not abbreviate expressions using D(name) or T(name). Examples: (S9) means (sin(t9))
for rotational joint 9; (s9) means (sin(d9)) for prismatic joint (C1) similarly means (cos(t1)) and
(c1) means (cos(d1)). An expression like (sin(T(j2))) cannot be abbreviated.
• ( number ) A real number. A minus sign is prefixed if the value is negative. If the value is a
decimal fraction, a decimal point is appended and followed by one or more digits; if the fraction
is less than 1 the leading zero may be omitted. If the value is a whole number, the .0 portion
may be omitted. Examples: (−0.21), (−.21), (200.03), (762).
• sin (expression ) or cos (expression ) or tan (expr ) The respective trigonometric value of the
expression in radians. Examples: (sin(t3)), (cos(T(j3))), (tan(D(j1)/a3)).
• asin ( expr ) The arc sine of the expression, returning values in the range −p/2 to p/ Example:
(asin(nx)).
• acos ( expression ) The arc cosine of the expression, returning values in the range 0 to p.
Example: (acos(nx0y−ny0x)).
• atan ( expression) The arc tangent of the expression, returning values in the range −p/2 to
p/ Example: (atan(31.7)).
• atan2 ( expression1 , expression2 ) The arc tangent of expression1 divided by expression2,

returning values in the range −p to p. Example: (atan2(31.7,1.7)).
• anorm( expression1 , expression2 ) Normalize angle: Expression1 is the angle to be normalized.

expression2 is the value to be normalized to (in radians). Example: anorm(0.5, 1)
• sqrt ( expression ) The square root of the expression. Example: (sqrt(4)).
• ln ( expression ) The natural logarithm of the expression. Example: (ln(4)).
• exp ( expression ) The expression constituted as an exponent. Example: (exp(2)).
• pow ( expression1 , expression2 ) Expression1 raised to the power expressed by the exponent
consisting of expression2. Example: (pow(10, 2)) returns 100.
• abs ( expression ) The absolute value of the expression. Example: (abs(−3)) returns 3.
• floor ( expression ) The largest integer not greater than the expression. Example: (floor(27.9))
returns 27.
• ceil ( expression ) The smallest integer not less than the expression. Example: (ceil(27.9))
returns 28.
• int ( expression ) The integer portion of the expression; the fractional portion is truncated.
Example: (int(27.9)) returns 27.
• sgn ( expression ) The sign of the expression, returning 0 if the expression is positive, 1 if the
expression is negative. Example: (sgn(−3)) returns 1.
• ! ( expression ) Not the expression, where the expression is Boolean.
• rad ( expression ) The conversion of the expression to radians.
• deg ( expression ) The conversion of the expression to degrees.
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• ( expression1 * expression2 ) The product of expression1 and expression2; the * is optional.
• Pi – Pronounced pie, it has the value of approximately 3.14
• 1/x – Inverse of x.
• ( expression1 + expression2 ) The sum of expression 1 and expression2; expression2 may

itself be a sum of two or more expressions. Example: (2+(3+(3))) returns 8. The parentheses
are optional.
• ( expression1 / expression2 ) The quotient of expr1 divided by expression2; expression2 may be

a sum of two or more expressions. Example: (6/(1+2)) returns 2. The parentheses are required.
• ( expression1 % expression2 ) The remainder of expression1 divided by expression2;

expression2 may be a sum of two or more expressions. Example: (9%7) returns 2.
• ( expression1 == expression2 ) Returns 1 if the indicated expressions are equal, 0 if the

comparison is false.
• ( expression1 != expression2 ) Returns 1 if the indicated expressions are not equal, 0 if the
• ( expression1 >= expression2 ) Returns 1 if expression1 is greater than or equal to expression2,

0 if the comparison is false.
• ( expression1 <= expression2 ) Returns 1 if expression1 is less than or equal to expression2, 0

if the comparison is false.
• (( expression1 > expression2 ) Returns 1 if expression1 is greater than expression2, 0 if the

• ( expression1 < expression2 ) Returns 1 if expression1 is less than expression2, 0 if the

• ( expression1 && expression2 ) Boolean and: evaluates Boolean expressions expr1 and expr2 in
the order given and returns 1 if they are both true, 0 otherwise. If expr1 is false, this function
returns 0 and exits without evaluating expr2.
• ( expression1 || expression2 ) Boolean or: evaluates Boolean expressions expr1 and expr2 in
the order and returns 0 if they are both false, 1 otherwise. If expr1 is true, this function returns
1 and exits without evaluating expression2.
Implementation notes
The Process Simulate function-joint implementation is heavily dependent on nested parentheses.
When formulating a formula, ensure that the parentheses are properly placed and balanced.
The command line and editor commands verify user-supplied functions and issue error messages if
the syntax is incorrect.
Activities
In the More on kinematic functions section, do the following activities:
• (Optional Instructor Demo) Implementing joint logic with functions
• Optional Instructor Demo) Kinematics following a surface
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Train joint function example

Purpose
In this topic, you learn how to do a more complex example of kinematic functions.
Objectives
• Know more about advanced options available when defining joint functions.
Train joint basics

You can create many different complex devices in Process Simulate. The following explains the
theory and creation of one such device. It is called the train joint due to its similarity with an old time
steam drive train. It is a common joint that converts rotary motion into linear motion.
There are several versions:
• One in which the wheel drives the prismatic link via bar linkage.
• Another in which the wheel drives the prismatic joint directly.
You do the bar linkage joint first.

The model consists of four entities:
• A bracket to hold the axle, the wheel, and two connector bars.
One bar is connected to the wheel and has a rotational joint at each end. The other bar is connected
to the first bar and has linear motion.
There are three (3) joints created. The first joint (axle) is the point of rotation of the wheel. The
second joint (cpin) is the attach point of the bar to the wheel. And the third joint (barpin) is the attach
point of one bar to the other. The resulting device drives bar2 prismatically when the wheel turns. you
need to solve for the values of cpin and barpin. They both need to be a function of axle.
At any given time you know certain values. You know the joint value of axle and the length of the
bars. And at any given time, the three joints form a triangle. Using the known values and the law of
sines you can solve for the unknown joint values.
Defining the train joint

First define some variables:
• axle - joint value of axle joint
• RL1 - the distance from the pivot point of the wheel and the pivot point of the connector bar.
• BA1 - first angle of triangle
• BA2 - second angle of triangle
• BA3 - third angle of triangle
• BL1 - length of connecting bar 1 (distance between pivot points)
• BL2 - length of connecting bar 2 (distance between pivot points)
From the law of sines:

• sin(BA1) / BL1 = sin(BA2) / RL1
• (RL1 / BL1 ) * sin(BA1) = sin(BA2)
Since RL1 and BL1 are both constants you can replace them with C. And you want to find BA2
so you take the asin of both sides. Giving us:
• BA2 = asin( C * sin(BA1) )
You can now have 2 of the three interior angles of the triangle defined. And given that the sum of the
angles must be 180 you can solve for the third.
• BA1 + BA2 + BA3 = 180
• BA3 = 180 - BA1 - BA2
Substituting the solution for BA2 back in:

• BA3 = 180 - BA1 - asin( C * sin(BA1) )
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You can now have functions for BA2 and BA3 based on BA. But Process Simulate requires that you
solve for the joint values and your current functions solve for angles. The joint value is 0 for the HOME
or starting position. The joint value at any other time is just the change in joint angle from the starting
angle. So joint value can be found by subtracting the starting joint angle from the current joint angle.
Let us establish some new prefixes.
• OA actual angle at start or HOME position (OA1, OA2, OA3)
• JA joint value (JA1, JA2, JA3)
Process Simulate gives you joint value JA1. So BA1 becomes:

• BA1 = OA1 + JA1
The joint value for BA2 is calculated by subtracting the original angle of BA2 from the current angle of
BA2.
• JA2 = BA2 - OA2
Substituting your angle calculation for BA2:

• JA2 = asin( C * sin(BA1) ) - OA2
Substituting joint value calculation for BA1

• JA2 = asin( C * sin( OA1 + JA1 )) - OA2
For Process Simulate the constants C, OA1 and OA2 must be calculated.
• C = RL1 / BL1
In your example RL1 = 478.13 and BL1 = 1500.0

• C = 478.13 / 1500.0 = 0.3187558
• OA1 = 0 radians
• OA2 =0 radians
• JA1 = 0 radians
The actual Process Simulate function becomes:

• ( asin ( ( 0.3187558 ) * sin( ( T(axle) + (0.0) ) ) ) (0.0) )
Depending on the direction of the axis of j1, you may need to multiply this quantity
by -1.0
The additional parentheses are required for the function parser.
Lastly you need to generate the joint values for JA3. Again you know that the joint value is the
current joint angle minus the original joint angle.
• JA3 = BA3 - OA3
Substituting in the formulas for the angle calculations:

• JA3 = 180 * BA1 * asin( C * sin(BA1) ) - OA3
Substituting joint value calculation for BA1:

• JA3 = 180.0 * ( OA1 + JA1 ) * asin( C * sin( OA1 + JA1 )) − OA3
Converting to radians and substituting for constants the actual function to put in Process Simulate is:
• ( (3.1415927) ( ( 0.0 ) + T(axle) ) asin( ( (0.3187558) * sin( ( (0.0) + T(axle) ) )
) ) - (3.1415927) )
Process Simulate allows for both positive and negative joint values. For revolute joints the
sign is determined by the right-hand rule. In your example, JA3 must rotate in the opposite
direction from JA. This means that the axis for J1 and J2 should be in the same direction
but the axis for J3 should be in the opposite direction. If all three axis are created in the
same direction, then the function becomes:
• ( (3.1415927) ( ( 0.0 ) + T(axle) ) + asin( ( (0.3187558) * sin( ( (0.0) + T(axle) ) )

) ) + (3.1415927) )
Activities
In the The train joint - function example section, do the following activity:
• (Instructor Demo) Examine the train joint
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Cam joint function example

Purpose
In this topic, you learn about another example using kinematic functions.
Objectives
• Know more about advanced options available when defining joint functions.
Cam joint basics

Another popular joint is the piston or cam type joint. This joint too converts revolute motion to
prismatic motion. But there are only two joints and no bar linkages.
The motion you need to define is such that as the wheel rotates a bar moves back and forth. As the
angle of rotation goes from 0 to 180, the bar moves in one direction. While the angle of rotation goes
from 180 to 360, the bar travels in the opposite direction.
If joint angle of axle is between 0 and 180 then prismatic joint value is between 0 and maximum
stroke. And the prismatic value increases as the axle joint angle increases.
If joint angle of axle is between 180 and 360 then the prismatic joint value is between maximum stroke
and 0. The prismatic value starts at max stroke and decreases as the axle joint angle increases.
So your basic function becomes:
if ( axle > =180 ) then
prismatic = max ( axle * factor )
else
prismatic = axle * factor
Defining the cam joint

For ease of understanding you first define some terms and then the function
Normalize angle:
• ANG angle to be normalized
• NF1 value to be normalized to in radians for check 2 * PI
• NF2 value to be normalized to in radians for joint value calculation PI
• INT integer portion of a number. fractional portion is truncated.
• ANORM(ANG, NF) = ( ANG ( ( INT( ANG / NF ) ) * NF ) )
ANORM: Normalize an angle to the specified value.
Follow factor:
• PMT maximum prismatic joint travel in mm.
• RPC number of radians in cycle ( PI )
• FF = ( PMT / RPC )
Sine and Cosine:

• Sine of an angle is negative if the angle is between 180 and 360.
o sin(angle) < 0 if 180 < angle < 360
• Sine of an angle is positive if the angle is between 0 and 180.

o sin(angle) > 0 if 0 < angle < 180
• How do you check for angle = 0 and angle = 180?

o cos(angle) =
o −1 if angle = 180
o 1 if angle = 0, 360
Taking your original joint value function:

if( axle >= 180 ) then
prismatic = max ( axle * factor )
else
prismatic = axle * factor
Substituting your definitions the joint value function becomes:

If ( ( cos(axle) = −1) || (sin(axle) < 0) ) then
prismatic = PMT ( FF * (ANORM(axle, NF2) )
else
( prismatic = FF * ANORM(axle, NF2) )
Our original function uses one joint value calculation between 0 and 180 and another calculation
between 180 and 360. Since Process Simulate does not have an if−then−else structure you must
simulate one. Booleans are provided. They are evaluated and return 0 for FALSE and 1 for TRUE.
So, to get the affect of if−then−else, you use two checks and a summation. you multiply the joint
value calculation by the result of the check. If the check is false, then the result of the joint value
calculation is multiplied by 0. You create the checks so that only one is true at a time. Then if you add
the two functions together you get one joint value times 0 plus one joint value times The effect is that
when one check is true you calculate the joint value using its associated function.
Our new function definition becomes:
(( ( cos(axle) = −1) || (sin(axle) < 0) ) * (PMT ( (FF) * (ANORM(axle, NF2)) ) ) ) )
+
(( ( cos(axle) = 1) || (sin(axle) > 0) ) * ( (FF) * (ANORM(axle, NF2)) )
So you can now plug in the constants and formulas for the actual Process Simulate function.
• PMT = 42 inches = 1066.8 mm
• RPC = 180 = PI
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• NF1 = 360 = PI * 2.0 = 6.2831853
• NF2 = 180 = PI = 3.1415927
• FF = 42.0 in / PI = 1066.8 / 3.1415927 = 339.57299
• ANG = T(axle) joint value of axle joint
The final format ready for input to Process Simulate:

(
( (
cos(T(axle)) == (−1.0) ) || ( sin(T(axle)) < (0.0)
) *
(
(1066.8) −
(
(339.57299) *
(T(axle) (( int(( T(axle) / (3.1415927) ) )) * (3.1415927) ))
)
)
)
+
(
(
cos(T(axle)) == (1.0) ) || ( sin(T(axle)) > (0.0)
) *
(
(339.57299) *
( T(axle) (( int(( T(axle) / (3.1415927) ) )) * (3.1415927) ) )
)
)
)
Since Process Simulate produces both positive and negative joint values, you might want
to take the absolute value of the result to keep the motion consistent regardless of the
direction axle is rotated.
Since the sine and cosine functions are not continuous you may want to use the following function
instead:
339.5729923 *
( (3.1415926) (abs(((rad(((deg( (T(axle)) ) )
%
(360) ))) (3.1415926) ))))
Activities
In the The cam joint - function example section, do the following activity:
• (Instructor Demo) Examine the cam joint
Compound equipment (optional)

Purpose
In this topic, you learn how to setup compound equipment.
Objectives

• Create and use compound equipment.
• Reconcile navigation tree instances (in compound equipment).
• Create and use kinematic coupling.
Compound equipment overview

Functionality
• Support assemblies including kinematics and PLC information
• Supporting monolithic JT which includes kinematics
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Why is this important to you?

• Support assemblies structures
• Support compound kinematics and PLC information
• Enable getting updates from the CAD without losing the kinematics information (JT can be
modified independently)
Equipment basics
Process Simulate supports the use of hierarchies of objects called equipment. Changing the 3D
representation, name or positions of the children of such nodes always requires modeling.
Users can construct a compound device from a number of equipment objects. Compound devices
are similar to regular devices - they are composed of links, joints and frames. While both regular
and compound devices can be constructed using most kinematics dialogs, the main differences
between them include:
• The joints of compound devices move sub assemblies but not entities.
• Compound devices can be nested, while regular devices cannot.
• The joints of compound devices can be connected to each other using 'coupling'.
• Attachments between nested devices can be created. In contrast to regular attachments, these
attachments are saved with the prototype.
The attachment parent must be either a link geometry of a PLMXML device or a link
object of a JT device.
The joints, links and frames of compound devices are always associated with a single node - the
root node of the device.
This node is not necessarily the root node of the equipment.
To create a compound device, start modeling this node and use the regular Kinematics Editor to
create the links and joints. The Link Properties dialog box allows you to select the link geometries.
For a compound device you can select only sub assemblies but not entities
You can create nested devices by building kinematics for both a root and a child node of equipment
and you can connect joints of nested devices using the Joint Function dialog box. Nested devices are
useful, for example, to build fixtures consisting of several identical clamps.
Kinematics data of compound devices is stored separately from the geometric data. Thus it is
possible to update the geometry from CAD without losing the kinematics. It is also possible to use JT
kinematics as leaf nodes in Equipment. Poses that are defined for a nested compound device contain
both the joints of the root device and all joints of the sub devices.
Also, the Logic Block command supports connecting subcomponents within a compound instance.
Kinematic coupling
To define coupling
1. Choose the Equipment prototype being modeled.
2. From the ribbon, choose Modeling tab→Kinematic Device group→Kinematics Editor .
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3. In the Kinematics Editor, select a joint of a sub-device to become dependent and click Joint
Kinematics Functions .
4. In the Joint Kinematics Function dialog box, coupling is enabled if you are editing compound
kinematics.
Choose this option if you wish to define dependency between the selected joint and a
joint of a sub device in the device hierarchy.
5. For Leading Joint, select the joint upon which to base the dependency.
6. For Factor, enter a dependency factor.
For example, if the leading joint of the sub-device is rotated by 3 degrees and you
entered a factor of 5, the joint is rotated by 15 degrees.
7. Click Apply.
The joint function is applied to the dependent joint.
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Global and local attachments

There are several types of attachments:
• Local attachment — tools and resources are attached in a study. This connection is lost
when you put the tools and resources into a new study.
• Global attachment — the attachment is saved in the database instead of the study. Global
attachments can be reused in any study based on the same resources.
• Local over global — In addition, even after creating a global attachment, you can a create
local attachment to investigate scenarios without canceling the global attachment.
• Mount — An attachment created by the Mount Tool command.
In the Object Tree, you can use Customize Columns to add the Attach To column to the viewer.
This causes the Attach To and T columns to be displayed. The T column indicates the type of
attachment: mount, local attachment, global attachment, or local over global.
Setting up dual arm and cooperative robots

Dual arm and cooperative robots are defined using compound equipment (Equipment prototype ).
Learn more about this later in the training in the Dual arm and coordinated motion applications lesson.
Activities
In the Compound equipment (Optional) section, do the following activity:
• Setting up compound equipment (Instructor demo)
More topics (not covered in class)
Purpose
In this topic, you briefly learn about some other kinematics related functionality not directly covered in
this course.
Objectives
• Know a little bit more about creating and using MotionParameters.e files in order to get more
accurate robot simulations.
Advanced kinematic definitions (MotionParameters.e file)

Functionality
• In Process Simulate the motionparameters.e file is used during simulation. It must benamed
motionparameters.e
In Robcad, the motionparameters.e file was known as the .e file.
The motionparameters.e file, pronounced “motion parameters dot e” file, is an ASCII

text file stored under the robot model’s .COJT folder containing measured robot motion
parameters such as speed, accel/decel, zones, configurations, and delay/settle times.
Simulation packages contain only limited knowledge about the robot’s technical
capabilities such as reach, speed, limits etc. Other information such as payloads,
momentum, acceleration, and similar parameters where limited. The .e file was the
initial solution for this problem (for example it was the pre-RRS technique). Tecnomatix
engineers performed measurements on the robots themselves in order to determine
specific parameters (for example a very long process requiring intimate knowledge
of the robot).
The syntax for this file can be found in the Motion Planning Definition File Reference
Guide included on the Process Simulate DVD.
• Allows the use and editing of former Robcad .e files when renamed to motionparameters.e
Upgrade to Version creates the motionparameters.e file (which is a duplication of the

original .e file) in the .cojt folder. Comments in the original .e file are not copied to the
new motionparameters.e file unless they are wrapped with begin text/end text tags.
• Uses Microsoft Windows legal file naming format
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Process Simulate can read motionparameters.e files located under .cojt folders.
There are cases where users open a device for modeling from the object folder (but not
directly from a .jt file) with integrated .e file data. If there is no motionparameters.e
file under the folder, the system creates it with the .e content when saving the modeled
device in the study/library.
• More accurate behavior of devices
• Reuse legacy Robcad data
Getting into the details within a motionparameters.e file is a very advanced topic and is
behind the scope of this course. However, some additional information can be found by
reviewing the online help for the motionparameters.e file found on the install DVD.
Summary
• How to define a kinematic rail (or 7th axis).
• How to use cranks to enhance more complex kinematic device development.
• How to do more with kinematic functions.
• How to do a more complex example of kinematic functions.
• How to do another example with kinematic functions.
Lesson 10: General robotics
Purpose
To provide an introduction to the robotics section of this training course.
Objectives
After you complete this topic, you should be familiar with:

• The basic concepts of Process Simulate is discussed.
• An overview of robotics
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Robotics overview
Purpose
In this topic, you get an overview of key robotics terms and robotic applications. Many of which
are used in this course. You review some diagrams to guide you through the process to create a
robotic simulation in Process Simulate. The sequence is different depending on what type of robotic
path you want to make
Objectives
• Know where to go in order to learn to create the type of robotic simulation you want.
• Review some basic industry information about robotics.
• Review some basic industrial robotic applications (uses for industrial robots).
Robotics introduction
According to Wikipedia.org: The box of robotics may be more practically defined as the
study, design and use of robot systems for manufacturing (a top-level definition relying
on the prior definition of robot). Typical applications of robots include welding, painting,
assembly, pick and place, packaging and palletizing, product inspection, and testing, all
accomplished with high endurance, speed, and precision.
This training course assumes that the attendees are somewhat familiar with industrial robotics,
their uses, and related terms such as:
• Teach pendant
• Payload
• Working envelope
• Kinematics
• Singularity
• Seventh Axis
• Degrees of freedom
• Tool center point
• etc.
Robotics applications
The goal of this class is too make several collision free robotic simulative operations for different
robotic applications.
General robotics
According to Wikipedia.org: The field of robotics may be more practically defined as the
study, design and use of robot systems for manufacturing (a top-level definition relying on
the prior definition of robot). Typical applications of robots include various manufacturing
tasks accomplished with high endurance, speed, and precision.
There are many types of robotics applications. In this training, you choose the type of robotic path
development that you want to learn about:
Discrete robotic applications

• Spot-welding applications — For example:
o Spot Welding with the weld gun mounted on the robot (using pneumatic or servo weld guns)
o Ped. spot welding (Part grasped by a gripper mounted to the robot)
• Drilling and riveting applications — For example:

o Drilling
o Riveting
Material handling
• Material handling applications — For example:
o Assembly
o Packing/Palletizing
o Part Transfer
o Etc.
Continuous robotic applications

• Arc-welding applications
• Painting applications
• Other Continuous Applications — For example:

o Gluing/Dispensing
o Grinding/Deburring/Material Removal/Polishing
o Laser cutting
o Laser welding
o Roller Hemming
o Sealing
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o Waterjet
o Etc.
High-level robotics flow charts

There are separate sections in this course for creating each type of robotic path:
• Robotic spot welding
• Drilling and riveting
• Robotic material handing
• Continuous feature operations

o Robotic arc welding
o Robotic painting
o Other continuous applications besides arc and paint (for example glue, debur, waterjet, etc.)
In this lesson you review some diagrams to guide you through the process to create a robotic
simulation in Process Simulate. The sequence is different depending on what type of robotic path
you want to make.
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Simulation Monitor
The Simulation Monitor displays the information to help you debug robotic programs and the
simulation.
To open this viewer: From the ribbon choose View tab→Screen Layout group→Viewers
→Simulation Monitor.
Settings — Use the Settings dialog box to select:
• Auto-opening of tabs — the Simulation Monitor automatically opens a new tab for each robot
that returns messages. If this option is cleared, all the messages are stored on the main tab.
• Auto-scrolling of tabs — the Simulation Monitor automatically scrolls to the last message
- the message display is updated continually. This setting freezes the message display as the
simulation proceeds, enabling users to examine messages of interest. Clearing the option again
resumes message updates.
+ — Use it to display a tab for a robot or resource if auto-enabling of tabs is off. The icon is only
enabled when a relevant selection is made.
The message list that is generated continues to display even after you reset the simulation to
the start, or close and reopen the Simulation Monitor. The list is deleted upon pressing the Play
Simulation Forward button.
You use the Simulation Monitor to view messages per robot as the simulation progresses, as well as
messages related to the simulation. The messages display in runtime if the Simulation Connected
is selected. When it is not selected, the messages are displayed only when users pause the
simulation, and at the end of the simulation.
Severity level icons enable filtering the messages:
• Show Errors
• Show Warnings
• Show Informations
• Show Trace
In the Simulation Monitor you can copy of messages and their details by selecting message table and
then pasting the selected text into a spreadsheet.
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The Simulation Monitor replaces the Error Viewer found in older versions of Process
Simulate. Therefore, when the simulation ends, the Error Viewer does not pop-up
automatically. If users did not press the Simulation Connected in order to see
the simulation information, they have to open the Simulation Monitor from the Viewers
list.
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Creating a study (again)

Purpose
In this topic, you learn create an empty study to open Process Simulate.
For other activities in class, you use pre-existing studies.
Objectives

• Recall now to create a new study.
Do I do this?
Most tasks you perform in Process Simulate, begin by making a study.
In the open study, you may decide to layout the components.
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Activities
In the Creating a study (again) section, do the following activity:
• Creating a new study (again)
Activity: Creating a new study (again)

The objective of this activity is to create another study.
Demo video
Copy and paste this video link into a new web browser to watch the demo video:
file:///.\sysroot\training_videos\new_sa_study.mp4
Activity data
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Project used in this activity: .\Projects\Project_209S\Line 1 StudyFolder\model kinematics

Study created in this activity: Study2.psz
Launch the activity.
Create a new study in a project folder
1. Choose File→Disconnected Study →New Study .

Continue to use the DefaultStudy.pszt for the Template.
2. From the New Study dialog box, for Study type, select RobcadStudy.
3. Click Create and OK.
4. From the ribbon, choose Modeling tab→Components group→Create Compound Resource

.
5. In the Resources folder of the Object Tree, rename CompoundResource1 to Assembler

Study.
6. In the Operation Tree, right-click and choose New Compound Operation .
7. In the New Compound Operation dialog box for the Name, enter Assembler Study.
8. For Scope, select Operation Root and click OK.
Save the study
1. From the Quick access toolbar choose Save .
2. In the Save As dialog box, browse into the your Line 1 folder.
3. For the File name, enter Study2.psz and click Save.
4. Click OK.
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Review questions
Question1
Question2
Question3
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The working folder is not important and does not need to be set. It is good practice for multiple people
to share the same working folder that are working together. Your working folder is a temporary place
where objects are put if the system does not know where to put them. A working folder is used with
Process Simulate (connected), but not Process Simulate Disconnected (Standalone) It is highly
recommended that you set a working folder in all projects that you work in. Shortcut Collection
CompoundObject RobcadStudy A folder containing simulation results and analysis output. A portion
of the complete project containing those products, operations, and resources, which have to be
analyzed, simulated and optimized.
General robotics
Manufacturing feature representation

Purpose
In this topic, you learn some background information regarding manufacturing feature representation.
Objectives
• Distinguish the manufacturing feature types.
• View manufacturing features.
• Know sources for manufacturing features.
• Know how to setup the basic manufacturing feature orientation.
• Use auto save.
Manufacturing feature types

Most manufacturing features represent a theoretical position (without orientation) or series of
positions of the robot TCP on the part and describe how a robot moves along a part. Each
manufacturing feature can also contain several attributes.
There are several types of manufacturing features. Not all of them are discussed in this training:
• Weld point — Used to represent discrete manufacturing processes such as spot-welding,

drilling, or riveting. It does not have any associated geometry, but is represented as a red cube
by default.
• Continuous Mfg — Used to represent continuous manufacturing processes (anytime a robot

moves continuously along an edge or face of a part) such as arc-welding, gluing/dispensing,
laser cutting, laser welding, painting, material removal/grinding/deburring/polishing, etc. It has
geometry (for example a curve or line) associated to it. Here are some other default types of
continuous manufacturing features:
o ArcContinuousMfg
o GlueContinuousMfg
o LaserCutContinuousMfg
o LaserWeldContinuousMfg
o PaintContinuousMfg
o RollerHemmingContinuousMfg
o SealContinuousMfg
o WaterJetContinuousMfg
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Another manufacturing feature type, PLP , is not discussed in this training. It is used to
represent the point where the part is being constrained (for example clamped) in a fixture.
Viewing manufacturing features

Where to look for manufacturing features:
• Operation Tree — Manufacturing features are shown here as a child of the simulative operation
they are related to (until they are projected to create the location operations)
• Graphic Viewer — Manufacturing features are shown here until they are projected to create
locations (then they are blanked by default)
• Mfg Viewer — Manufacturing features are always shown here.
Mfg Viewer:
This viewer contains a filterable table of manufacturing features. It contains various columns of
attributes that can be added and other functionalities including:
• Find by Caption — Find a manufacturing feature based on its caption
• Unassign — Unassign a manufacturing feature from a part
• Customize — Enables you to select the manufacturing feature attributes that are displayed
in the MFG Viewer.
By default, only the out of the box and custom attributes and object types are shown in
the Customize dialog box.
• Filter by Type — Filters the display of the MFG Viewer based on the manufacturing
feature type.
Emphasizing Continuous MFG Display

You can change the color and width of the curves representing continuous manufacturing features.
This can be done for specific manufacturing features or all.
• From the ribbon choose Process tab→Continuous group→Emphasize Continuous Mfg

— used to change the width and color of specific manufacturing features for easy viewing in
the Graphic Viewer.
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• To change it for all, choose File→Options , click the Appearance tab, and select
Emphasized Graphic Appearance→Emphasized Mfgs.
Sources for discrete manufacturing features
Discrete manufacturing features, such as weld points or rivets, are always tied to one or
more parts. In order to “see” a Manufacturing feature in Process Simulate it must be
created and associated to a part or operation that is either associated to the study directly
or indirectly (indirectly means it's associated to a part that is associated to an operation
associated to the study).
For weld points and rivets:

• Imported from a spreadsheet (CSV)
o This is the most typical technique. See the next section for details
• Created directly in Process Simulate

These commands, located on the ribbon Process tab→Discrete group, only create WeldPoint
objects. You cannot choose to create custom object types:
o Create Weld Point by Coordinates — create a weld point at a location selected by one
of the standard frame specification methods.
o Create Weld Points — create multiple welds on the part where ever you select.
o Create WP on Robot’s TCPF — create a weld point at the current TCPF position of
the selected robot, or TCP of the selected gun, servo gun, or pneumatic servo gun. The
command is enabled when any of these is selected.
By default, manufacturing features show in the Graphic Viewer as a red square and are also
displayed in the Mfg Feature viewer.
Importing weld points or rivets
Defining custom attributes for weld points or rivets
In Process Simulate standalone, you cannot create custom object types or attributes. However,
you can create studies based on a template from Process Simulate on eMS that already contains
customized object types and attributes.
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Rivets and weld points are represented in the eMS database as WeldPoints or an
object type derived from WeldPoints . Your administrator can use the eM-Planner
Customization tool to add custom attributes to the object type you use to represent rivets
and weld points.
For example, you could add attributes such as Diameter, Length, and Sealant.
Define additional tabs for the Properties dialog box to view custom attributes in a more
friendly way.
For more information see the TR41213 Process Designer and Process Simulate Data
Management, Variants, and Importing course.
Custom attributes on Mfgs can be mapped to the locations that result from projecting
the Mfgs.
Importing weld points or rivets
Although rivets and weld points could be created directly in Process Simulate one-by-one, they are
typically imported from an system where the Product Design group has authored them.
When running Process Simulate Standalone - eMS compatible, you can use the Import Mfgs
command to add Mfgs from external CAD programs to your study. If the imported Mfg already exists
in the study, it is updated from the CSV file. When you run Update eMServer after completing
your offline session, the new and updated Mfgs are uploaded to the eMServer database.
Prior to launching Import Mfgs , you must prepare a file in CSV format containing the Mfgs
to be imported.
The Name of the Mfg and its location fields X, Y, and Z are mandatory. If the file does not contain
exactly these fields, the import does not work.
You can also add the following optional columns:
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• A Leading Part and any number of Connected Part fields. These are the parts with which the
Mfg is associated (when the leading part is moved, the Mfg moves together with the part, but
when connected parts are moved, the Mfg remains at its current location).
If a leading part is defined for the Mfg but it does not exist in the study, the system
ignores the leading part and connected parts.
• Attributes (other than relation attributes) — add an Attribute_<Attr_Name> column to the CSV
file. For example, Attribute_Diameter, Attribute_Length, and Attribute_Sealant
• Class — this is a sub class of weld points. If there is no value, then a PmWeldPoint is created.
Attributes of the sub class are supported.
• Rotation fields Rx, Ry, Rz in radians.
If the CSV file contains multiple Mfgs with the same name, none of them are imported.
If the study contains multiple Mfgs with the same name, the first Mfg in the study is updated
and the others are ignored.
If you have specified a leading part in the CSV file that occurs more than once in the study,
the first occurrence in the study is set and the others are ignored.
The system imports new Mfgs under the set "Current Operation". If no operation is set as
current, the system imports Mfgs under the Operations root.
1. From the ribbon, choose Process tab→Planning→Import Mfgs .

The Import Mfgs dialog box is displayed.
2. Find your CSV file or use the Browse button to navigate to it and click Open.
3. Set Use Working Frame if you wish to import the Mfgs with coordinates relative to the working
frame or clear it to import the Mfgs with absolute coordinates.
4. Click Import.
The system imports new Mfgs under the set "Current Operation". If no operation is set as current,
the system imports Mfgs under the Operations root.
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5. Click View Log File if you wish to view detailed information on the import results.
6. Save your PSZ file if you are satisfied with the results of the import.
The imported Mfgs are now displayed in the Operation Tree and Mfg Viewer.
Sources for continuous manufacturing features
Continuous manufacturing features are always tied to one or more parts. In order to “see”
a Manufacturing feature in Process Simulate it must be created and associated to a part
that is either associated to the study directly or indirectly (indirectly means it's associated to
a part that is associated to an operation associated to the study).
For Continuous Manufacturing Features:

• Imported from a spreadsheet (CSV).
o From the ribbon, choose Process tab→Planning group→Import Mfgs .
• Associate curves or line objects (.COJT) created in Process Simulate using the ribbon, choose
Process tab→Continuous group→Create Continuous Mfg from Curve .
By default manufacturing features show in the Graphic Viewer as a and are also displayed in the
Mfg Feature viewer.
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Using auto save
From the General tab in the Options dialog box (File→Options ), users can configure the
frequency in minutes of the prompt's display.
Check Every to enable auto save and set the frequency (in minutes) of the pop-up reminder which
prompts you to save your work. When prompted, click Yes to save your work locally.
Initiating a regular save operation resets the auto save timer.
Lesson
General robotics
robotics
Review questions
Question1
Question2
General robotics
FALSE TRUE FALSE TRUE
Lesson
General robotics
robotics
Summary
Subjects learned in this Topic:
• The basic concepts of Process Simulate is discussed.
• An overview of robotics
Lesson 11: Spot welding applications
Purpose
To provide an introduction to Process Simulate.
Objectives

• The basic terms and processes of spot welding
• Basic Process Simulate Robotics path development process.
• Some background information regarding manufacturing feature representation.
• How to project welds to create weld locations.
• How to make some changes to the weld path associated to the weld operation.
• The Multi Section tool
• How to use the Weld Distribution Center (WDC)
• The process methodology used in this topic
• Overview of how to define poses for kinematic devices.
• How to set up the study.
• How to maneuver the part in and out of the fixture.
• How to create a rough mounted workpiece (external TCP or pedestal welding ) path.
• How to orient the locations on a gripped part.
• How to use the Geometric Gun Search tool.
• How to use servo guns.
Lesson
Lesson 11:11:Spot Spot welding
welding applications
applications
Spot welding primer (optional topic)

Purpose
In this topic, you learn the basic terms and processes of spot welding.
Objectives
• Know the basics of spot welding.
• Know the basics of designing a spot-welding manufacturing line.
• Know the basics of design targets.
Spot welding basics

The automotive industry utilizes spot-welding as the most common method of joining metal sheets.
This method uses high pressure and current to melt two sheets at their point of contact, such that
when the melted areas harden they are fused together. The process historically used for spot-welding
on a mass-production basis was hard automation, in which many points are welded together at
one time. This method is rapid, but suffers from the disadvantage of being extremely inflexible:
model changes require extensive and expensive rebuilding of manufacturing machinery, thereby
encouraging manufacturers to continue producing obsolete models to the detriment of their ability to
compete.
The introduction of robotic spot welding, to which this document applies, has brought a new
level of flexibility to manufacturing. This process spot-welds points one at a time, using either a
general-purpose or a specially built robot which carries a welding gun constructed from a variety of
mechanical, electrical and hydraulic components.
The points to be spot-welded usually have diameters of 6−8 mm, are spaced 10−400 mm apart, and
should be located a few millimeters or more away from the edges of the metal sheets. Spot-welding
guns usually have three poses: fully open, half open, and closed. One arm usually is movable and
the other arm is either fixed or has a very limited range of movement.
With some manufacturers, the engineer who designs the spot-welding lines also constructs his own
spot-welding guns from basic components: cylinders, valves, transformers, etc. Other manufacturers
purchase the gun as a single unit, and the engineer needs only to select the geometry of the shanks.
Still other manufacturers stock the guns complete with their shanks, requiring the engineer to select
only the gun itself.
Welding controllers control the welding guns. They typically supply five to sixteen different sets of
welding currents and current times, and are activated by output signals from the welding robots.
Designing a spot-welding line

The engineering department responsible for designing the robotic lines, receives drawings of the
individual segments from the design department. The engineering department then determines the
number and location of the welding points, and also designs the clamps and arranges them on
the fixture.
This process is designated weld study; it produces welding points marked on the drawing.
Spot welding applications
The next stage, frequently performed by the same department, is designing the robotic lines; this
operation includes:
• Assigning welding points to each robot
• Assigning a welding gun and shanks to each robot
• Assigning the order of welding the points and the order of the robots
• Placing the robots and the workpieces relative to each other
All of these steps, together with writing the programs for the robots, are intended to be performed
on the Process Simulate workstation.
Design targets
The entire design process may require several hours average time per welding point.
Despite the time required, the design is prone to errors and still leaves much work for the
implementation stage, resulting in a further waste of time and money. The final design then falls short
of optimum. To minimize these problems, the design work has several clearly defined goals:
• Determining the correct welding-gun geometry, particularly the shanks, so as to enable reaching
all welding points without collision, while minimizing cycle time and welding-gun weight.
• Assuring reachability to all welding and intermediate (via) points, without collision and with an
optimal (minimal) cycle time.
• Assuring maximum usage of stock equipment: robots, guns, shanks, tips, etc.
• Detecting design errors at the design stage.
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Process methodology
Purpose
In this topic, you get an overview of the basic Process Simulate robotics path development process.
Objectives
• Know now to relate the basic principles in industry to those used in this system.
• Develop a robotic path by moving from the least number of constraints to the most number
of constraints.
• Remember to think about strategic planning concepts when developing a robotic path.
Basic principles
Robot Program:
• When using a teach pendant, the robot is moved to a position and the joint angles are recorded.
• Robot Program consists of ...
• A SEQUENCE of poses consisting of JOINT ANGLES with associated INSTRUCTIONS
Process Simulate Robotics Program:
• Process Simulate Robotics uses Inverse kinematics to determine the joint values needed to
reach a given target location.
• Process Simulate Program consists of ...
• A PATH which consists of TARGET LOCATIONS (Position and Orientation) with associated
ATTRIBUTES
• With this definition of a program, the process in Process Simulate is independent of the robot
and the tool. Later, the Process Simulate program can be downloaded to robot program, so that
it can control the robot. This gives the flexibility in Process Simulate to select a different robot
at any time before you download.
Do I do this?
In Process Simulate, you start with the simplest situation: a part and spot welding manufacturing
features. Then you slowly add one more piece to the study—such as weld guns, robots, fixtures,
etc.—until the path is perfected. Here is the process to follow:
Here the are detailed steps:

1. Create the study.
• Define the guns (geometry and kinematics), if they are not already
• Create and load a study with Process Simulate.
• Layout (position) the contents of the study
2. Create or import spot manufacturing features between multiple parts.
3. Create the weld operations.

• Assign weld manufacturing features to weld operations which are related to specific robots.
4. Project weld operations to create spot-weld robotic paths.

• Project weld points to create target locations on the workpiece.
5. Refine the robotic paths using the robot tool.

• Check orientation of the target locations using a first approximation gun.
• Create first approximation sequence of locations using a robotic simulative operation (weld
path).
• Cut sections and search for valid guns to perform the welding.
• Perform a first run along the path.
6. Refine the robotic paths using the robot and robot tool.
• Add robot and test reachability of robot.
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• Check for collisions and adjust path.
• Optimize path cycle time.
• Repeat this process for other robots in the
Strategic planning
Begin the design process with strategic planning, by viewing the spot-welding line as a whole. Use
Process Simulate to load the complete study with an approximate, preliminary placement of its
objects. Then observe the study to answer these questions:
• How should each robot be positioned relative to the workpiece?
• What type of welding gun should be used?
• Which weld points on the workpiece does each robot handle?
Projecting spot manufacturing features

Purpose
In this topic, you learn how to project welds to create weld locations.
Objectives

• Know how to setup weld location projection constraints.
• Project spot manufacturing features to create weld locations.
Overview
A location in Process Simulate is unique type of frame that contains the position and orientation of the
tool center point frame (TCPF) at a point. Locations are generated with their origins placed according
to where the projection of the related curve intersects a surface or solid it is projected onto. The
locations guide the TCPF of the robot approach vector and a vector perpendicular to the workpiece.
Locations also contain process information specific to robotic operations such as: Gun state, location
type, speed, etc. for each location.
Do I do this?
After creating manufacturing features, you create weld operations, and then you project the weld
operations to create the robotic path.
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Sources for basic manufacturing feature orientation

• Obtain the location orientation from Process Simulate
The Mfg feature contains the position (X,Y,Z) of the resulting location.
o From the ribbon, choose Process tab→Discrete group→Project Weld Points
• Obtain the location orientation from CAD (NX or CATIA) or a Mfg import file
The Mfg feature contains the position (X,Y,Z) and orientation (Rx,Ry,Rz) of the resulting location.
o From the ribbon, choose Process tab→Discrete group→Obtain Weld Orientation
Using either of these two commands with weld points produces a location operation for each
Manufacturing feature. The location operation contains the position and orientation of the robot TCP
at the manufacturing feature. The orientation of the location operation can be further refined using
various tools in Process Simulate which is described later in this training.
Weld location constraints

Spot-weld and rivet locations must be on the surface and one axis must be perpendicular to the
surface.
The location’s orientation is very important. Projecting orients the locations in the path so that one
axis is normal to the surface and two axes are tangent to the surface.
Location defaults, including those related to projection, can be modified by choosing
File→Options and clicking the Weld tab or by clicking Options from the Project
Weld Points dialog box.
Weld Location Orientation:

• Approach Vector — Indicates the direction of approach of the weld gun. This axis is set
by default to X.
• Perpendicular — One axis has to be perpendicular to the surface being welded in order to create
a high quality and efficient weld. This axis is set by default to Z.
Weld Point Projection:

• Permitted gap between parts — Enables you to specify the minimal distance between parts
included in the same group. Weld points cannot be projected or flipped on to a part located
beyond the permitted gap. The default value is 0.2 mm.
• Consider weld point orientation — If selected, the system applies gun orientation to new weld
point projections, including translation and rotation.
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• Projection Direction — Enables you to determine the direction in which the weld locations are
projected:
o Away from the part projects the weld points away from the part (this is the default setting
and is used for alignment)
o Toward the part projects the weld points toward the inside of the part.
Spot Weld Permitted Deviation Angle:

This refers to the amount that the surface tangent axes (normally X-axis and Y-axis) are allowed to
deviate from tangent (thereby deviating the Z-axis from perpendicular.
• Perpendicular — By default 3 degrees.
Projecting weld locations
From the ribbon, choose Process tab→Discrete group→Project Weld Points produces
welding locations, while maintaining the weld location constraints mentioned above. The resulting
weld locations are on the surface and one axis, by default Z, is perpendicular to the surface.
• Choose the desired spot manufacturing features or a simulative operation containing spot
manufacturing features.
• Select the Align projection with outer surface check box to align the weld location with a
more accessible surface.
• Select the Project on approximation only check box, if exact geometry is not available.
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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 (for example, 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.
• Force projection over holes — When this option is set, the system ignores the faces’ borders
and relates to them as untrimmed surfaces. When projecting on an approximate surface, this
option is only supported on planar surfaces. It is recommended to select faces using the Face
Selection dialog to better control projection over holes.
If faces are selected, the faces are also slightly extended in order to allow projection
close to the face edge.
This is a very basic step in the robotic path creation process. There is no guarantee that
the path is reachable or collision free at this point.
Activities
In the Projecting spot manufacturing features section, do the following activity:
• Viewing spot manufacturing features in Process Simulate
• Projecting spot-weld manufacturing features
Review questions
Question
Make the path reachable by the robot Make a collision free path. Create a simulative operation (path)
of locations. Orient the locations in the path so that 1 axis is normal to the surface and two axes
are tangent to the surface.
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applications
Editing a weld path

Purpose
In this topic, you learn how to make some changes to the weld path associated to the weld operation.
Objectives

• Modify a weld location’s orientation.
• Delete and unassign weld locations.
Do I do this?
After projecting the weld operations, you can refine the spot paths using only the robot tool.
Modifying the weld location orientation

When projecting weld locations, a preliminary orientation of the weld location is created, so the next
step in the process is to check the orientation of the locations. You start by taking any weld gun to
further refine the weld location orientation (for example approach vector and perpendicular vector). At
this stage it is not necessary for the gun to be attached to a robot.
Weld location orientation refinement tools covered in this topic:
• Manipulate Location – This is one of the most basic commands. Allows manipulating a
via, weld, or seam location with a Manipulator Frame and the assigned robot tool, or assigned
part, placed at the location. You must have a location selected first. (Frequently used location
modification tool)
When using this tool with spot-welds it is high recommended to check Limit locations
manipulation according to options and Rotate to maximum allowed limitation.
This limits the manipulation according to the settings on the Weld tab of the Options
dialog box.
• Align Locations — This is one of the most basic commands. It enables you to align
the orientation of several weld locations to another reference weld location while keeping the
Perpendicular axes normal to the surface. Alignment is useful in order to determine an uniform
welding approach direction for all the locations.
Weld location orientation refinement tools covered in later topics:
• Flip Locations on Surface
• Pie Chart
• Automatic Approach Angle
• Etc.
Deleting and unassigning weld locations

Weld Location Deletion:
Users can delete a weld location from a study without removing its corresponding weld point from the
study, simply by deleting the location.
Weld Location Unassignment:
The Weld Location Unassignment area of the Weld tab of the Options dialog box enables you to
configure the location for unassigned weld locations. This setting enables you to find unassigned
weld locations quickly and makes your work more efficient. The following options are available:
• Operation Root — Unassigned weld locations are stored under the operation root. This is the
default option.
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• Direct Parent of Weld Operation — Unassigned weld locations are moved up one level from
their original location.
• Ancestor Process of Weld Operation — Unassigned weld locations are stored under the
station process to which the weld operation belongs.
These settings apply to manual unassignment, such as unassigning locations from

operations by removing them from the Properties dialog box of the operation, and for
unassignments through the Weld Distribution Center dialog box.
Activities
In the Editing a weld path section, do the following activity:
• Adjusting a weld path
Review questions
Question
Lesson
applications
Download Copy Delete Align Locations Location Manipulator
Multi sections and gun cloud

Purpose
In this topic, you learn about the Multi Section and Gun Cloud commands. Multi Section
can be used to create a group of 2D cross sections or 3D volumes at each weld location.
Objectives

• Create and use multi sections.
• Create and use a gun cloud.
Do I do this?
Steps for creating multi sections

• Create and place a cutting box on weld location(s).
• Create multi-sections of the workpiece to evaluate the suitability of a gun.
• Edit multi-sections (adjust section clipping).
• Choose gun to be placed on sections and evaluate gun design (measure required throat depth
and throat height to weld all sections in the multi section).
• Adjust locations in Multi Section dialog box as desired.
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• Based on gun overlay, modify the shank (export cross section and gun overlay to CAD system)
OR select another gun that is appropriate for this particular process using:
o From the ribbon, choose Process tab→Planning group→Geometric Gun Search .
• Close the Multi Section dialog box and store the section as an object (JT file).
Gun cloud
You can use the Gun Cloud command to create a gun cloud that simultaneously displays a
weld gun at every weld location in a weld operation. You can also create a gun cloud for operations
with multiple guns.
You can export the study with a gun cloud (on all weld locations of a selected weld operation) to use
the exported JT for the fixture planning.
To create a gun cloud:
1. From the ribbon, choose Process tab→Discrete group→Gun Cloud .
2. Select a weld operation that contains weld guns. The selection populates the Weld operation
field in the dialog.
3. Click OK. The application displays a weld gun at every weld location.
The gun displays at each location according to its designated orientation for that
location.
4. Click Export if you wish to export the study as a JT file to aid in further planning.
Activities
In the Multi sections section, do the following activity:
• Gun shank validation
Review questions
Question
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applications
Cut on a via location a group of 2D cross sections or 3D volumes output to a .JT file only cut
on weld locations
Weld distribution center (WDC)

Purpose
In this topic, you learn how to use the Weld Distribution Center (WDC).
Objectives

• Use the primary Weld Distribution Center (WDC) functions.
• Setup the Weld Distribution Center (WDC).
Overview
There are several ways to assign welds to weld operations:

• Make the assignment in an external system and import into Process Designer (via CC or XML)
• Use the Weld Distribution Center located on Process tab of the ribbon of Process
Simulate.
Do I do this?
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Weld Distribution Center overview
The Weld Distribution Center (WDC) is a tool for high level distribution of weld points in the
station. The WDC is an environment that provides information about the weld points and the ability of
the robot and guns in the station to weld them.
WDC provides a Robot, Gun capability matrix allowing users to determine which robot and gun in the
station are capable of welding any weld point.
To use the WDC, select the relevant weld points, weld operations, robots or station and view their
status. For each weld point, the WDC displays:
• Overall weld ability (the first column) — whether robots can reach the weld point without any
collision
o — at least one robot has full reachability for this location without collision.
o — at least one robot can gain full reachability for this location without collision if it
is rotated.
o — the weld point cannot be accessed due to robot reachability limitations or because of
collisions with loaded robots.
• Weld Point- the name of the weld point
• WP attributes – the attributes columns can be controlled by the user according to the existing
customization (for example Weld Point subType, or force.
• Reachability status – There are several values:
o — the robot has full reachability to the weld point.
o — the robot has partial reachability to the weld point. The robot reaches the weld point,
but must rotate its TCPF to match the TCPF of the weld point.
o — the robot has full reachability to the weld point if it exceeds its working limits.
o — the robot has partial reachability to the weld point if it exceeds its working limits. The
robot reaches the weld point, but must rotate its TCPF to match the TCPF of the weld point.
o — the robot has full reachability to the weld point if it exceeds its physical limits.
o — the robot has partial reachability to the weld point if it exceeds its physical limits. The
robot reaches the weld point, but must rotate its TCPF to match the TCPF of the weld point.
o — the robot cannot reach the weld point.
• Accessibility (Collision status) – check for collisions in the robot reach position. There
are several values:
o — the robot has access to the weld point without collision.
o — the robot has partial access to the weld point. The robot can access the weld point if
the latter is rotated. In this case, the robot approaches the weld point from a different angle.
o — the robot has access to the weld point if it exceeds its working limits.
o — the robot has partial access to the weld point if it exceeds its working limits. The robot
reaches the weld point, but must rotate its TCPF to match the TCPF of the weld point.
o — the robot has access to the weld point if it exceeds its physical limits.
o — the robot has partial access to the weld point if it exceeds its physical limits. The robot
reaches the weld point, but must rotate its TCPF to match the TCPF of the weld point.
o — the robot does not have access to the weld point due to collision.
• Attribute (compare) — The matching Attribute indicates whether the weld point and gun
attributes match (customer defined in the WdcAttributesMatching.xml file).
• Assign (x) — The column header indicates the number of weld points assigned to each
operation, where x is the number of weld points.
A main feature of the WDC is the ability to distribute weld points to an operation in the station while
balancing the number of weld points for robot / operation in the context of the cycle time.
Users distribute weld points by selecting the check box in the matrix that represents the connection
between the weld point and the operation. The system then implements distribution "online" and
updates other viewers such as the Operation Tree and Relation Viewer.
During weld point distribution the application provides immediate feedback regarding:
• WP balance – number of weld points in each operation
• Operation cycle time (actual time) – total cycle time of the operation. The cycle time is
composed of the weld point time values:
o Actual time = Number of WP x (Weld Point Welding time + Weld Point Motion time + Weld
Point Holding Time)
o Cases of actual time exceeding operation planned time are marked in red
o When no time values are defined in the system for each weld point, users can set a default
time for all the weld points using the Settings option
WDC primary functionality

These options are found on the Weld Distribution Center toolbar:
• Automatic Approach Angle — Solves the partial reachability and accessibility problems
of the selected weld points by rotating the weld points. This enables the robot to approach
from a different angle.
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• Add objects to the WDC — Adds an object selected in any viewer to the Weld Distribution
Center. Valid object types are robots, operations, weld locations, and weld points. This button is
activated when you select a valid object in a viewer:
o Adding a robot automatically adds all of the robot’s operations and the weld points assigned
to the robot.
o Adding an operation automatically adds the robot and the weld points assigned to the
operation.
o Adding a weld point automatically adds any operations and robots assigned to the weld point.
• Remove objects from the WDC — Removes the selected object from the Weld Distribution
Center.
• Check for collision and reachability — Refreshes the calculation of robot collisions and
reachability. The calculation updates the display of collision and reachability information in the
Weld Distribution Center.
• Automatically distribute WP — Operates on all the unassigned, selected weld points

displayed in the Weld Distribution Center and assigns a robot that meets the following
requirements:
o Reaches the weld location.
o Does not collide with other components at the station. By default, devices (including robots
and guns) are not included in this requirement. You can include devices in the calculation
using the Settings dialog box.
• Open Pie chart — Opens the Pie Chart for a selected weld point or robot.
• Settings — Opens the Settings dialog box, enabling you to configure various settings.
• Configure Attributes List — Opens a dialog box to configure attributes to display in the
Weld Distribution Center.
• Jump robot to WP
• Filter by WP type or assigned — Filters the display of weld points in the Weld Distribution
Center according to the criteria configured in the Filter button’s menu. Configure the filter criteria
by clicking at the right of the Filter button to display the menu.
• Export WDC to Excel — Exports the current Weld Distribution Center display to an Excel file.
Icons are not included in the Excel worksheet.
• Flip Weld Points — Flips the physical orientation of the selected weld points and recalculates
their reachability and accessibility.
WDC main dialog box:
A error is shown in the dialog box if the gun is not mounted to the robot.
WDC settings
The Settings dialog box, enables you to configure the following:
• Default weld time.
• Inclusion of specified devices for robot collision calculations.
• Inclusion of specified welding gun poses for robot collision calculations.
WDC Settings dialog box:
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Activities
In the Weld Distribution Center (WDC) section, do the following activity:
• Using Weld Distribution Center (with Automatic Approach Angle)
Review questions
Question
Lesson
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FALSE TRUE
Process methodology, revisited

Purpose
In this topic, you learn the process methodology used in this course for creating and fine tuning
spot weld paths.
Objectives

• Review the robotic principles covered earlier in this course.
• Review the process methodology used in this course for creating and fine tuning spot weld paths.
Robotic principles
Robot Program:
• When using a teach pendant, the robot is moved to a position and the joint angles are recorded.
• Robot Program consists of a SEQUENCE of poses consisting of JOINT ANGLES with associated
INSTRUCTIONS
Process Simulate Program:

• Process Simulate uses Inverse kinematics to determine the joint values needed to reach a
given target location.
• Process Simulate Program consists of a PATH that consists of TARGET LOCATIONS (Position
and Orientation) with associated ATTRIBUTES
With this definition of a program, the process in Process Simulate is independent of the robot and
the tool. Later, the Process Simulate program can be downloaded to robot program, so that it can
control the robot. This gives the flexibility in Process Simulate to select a different robot at any
time before you download.
The process: From least constraints to most constraints

In Process Simulate, you start with the simplest situation: a part and manufacturing features. Then
you slowly add one more piece to the study–such as weld guns, robots, fixtures, etc.–until the path is
perfected. Here is the process to follow:
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Here the are detailed steps:

1. Create the study.
• Define the guns (geometry and kinematics), if they are not already
• Create and load a study with Process Simulate.
• Layout (position) the contents of the study
2. Create or import spot manufacturing features between multiple parts.
3. Create the weld operations.

• Assign weld manufacturing features to weld operations which are related to specific robots.
4. Project weld operations to create spot weld robotic paths.

• Project weld points to create target locations on the workpiece.
5. Refine the robotic paths using the robot tool.

• Check orientation of the target locations using a first approximation gun.
• Create first approximation sequence of locations using a robotic simulative operation (weld
path).
• Cut sections and search for valid guns to perform the welding.
• Perform a first run along the path.
6. Refine the robotic paths using the robot and robot tool.
• Add robot and test reachability of robot.
• Check for collisions and adjust path.
• Optimize path cycle time.
• Repeat this process for other robots in the
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Overview of gripper creation (optional)

Purpose
In this topic, you review what you did earlier to define poses for a kinematic device and define it as
a gripper.
This topic is covered earlier in this course.
Objectives

• Add poses to a kinematic object.
• Define a kinematic object as a gripper.
Discussion of steps to add poses to an object

• Open the object for modeling
• (kinematics should be already defined)
• Joint jog the mechanism into the desired position or approximately into position
• Edit the poses for the current mechanism
• Create a new pose
• Use the current joint values or enter new ones
• Accept the values entered for this pose
• Define the rest of the poses for this mechanism
• Save the object
What Poses Need to be Defined?

For grippers, the OPEN and CLOSE poses must be defined (Pose names are case-sensitive).
Define an object as a gripper (discussion only)

This topic, excerpted from your earlier discussion, describes the procedure for defining an object as
a gripper:
1. Model it.
2. From the ribbon, choose Modeling tab→Kinematics group→Tool Definition .
3. Follow the same process you learned to define an object as a gun except:
• In the Tool Definition dialog box, click Gripper (instead of Gun) to constitute the device as
a gripper.
4. The Offset is the distance from the TCP Frame where other objects attach to the gripping entities
at the pick location of a pick and place operation.
5. Save and end modeling the object.
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Study setup
Purpose
In this topic, you learn how to set up the study.
Objectives

• Set up a mounted workpiece (for example pedestal welding) study
• Mount a gripper tool to a robot.
Do I do this?
Setting up the study

The assumption with this use case is that you cover a study that contains the parts, a robot, a welding
device, and a gripping device.
• Get and place the robot
• Get the gripper
• Mount it on the robot
• Get the workpiece
• Place it on the gripper
• Attach it to the gripper
The gripper should be mounted to the robot. The part and any spacers should then be
attached to the gripper.
Mount tool
The Mount Tool command located on the Robot tab of the ribbon:
• Relocates the tool from a frame on the tool (for example self origin) to a frame on the robot (for
example the TOOLFRAME)
• It attaches the gun to the TOOLFRAME of the robot
• It moves the TCPF of the robot to predefined position and orientation on the mounted tool.
When RRS and OLP is performed, it is possible to set the TCPF to several positions as
defined in the Teach Pendant (non-default teach pendant) or Robot Properties. More
on this topic in the TR45315 Process Simulate Standalone Robotics Advanced course.
Activities
In the Scenario Setup section, do the following activity:
• Putting the gripper on the robot (for pedestal welding)
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Review questions
Question
A newspaper A chair The parts A robot A gripping device A welding device
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Material handling (pick and place) operations

Purpose
In this topic, you learn how to maneuver the part in and out of the fixture.
you create pick and place operations which contain special via locations for picking up and dropping
off the part.
Objectives
• Prepare create and use pick and place operations.
Pick and place basics

To create a new Pick and Place Operation:
1. Select a parent operation in the Operation Tree.
2. From the ribbon, choose Operation tab→Create Operation group→New Operation →New
Pick and Place Operation .
3. Choose the Pick and Place poses
4. Choose the pick and place TCP positions.
Any of the techniques described before for editing paths of via locations can be used
with this path type as well. A material handling path can also be created using a (which
only contains via locations), if you don't want to use the special pick and place behavior.
An extension to what is learned here is provided in the course. In that course you learn
how to create a program that contains several paths. Then you create logic and sensors
to setup the simulation in a way that is more true to life.
Activities
In the Material handling (pick and place) operations section, do the following activity:
• Get/put the part in the fixture
Creating a rough mounted workpiece (pedestal welding) path

Purpose
In this topic, you learn how to create a rough mounted workpiece (also known as external TCP
or pedestal welding) path.
Objectives
• Know a little bit more about how to do pedestal welding in this system.
• Know the differences in this system between mounting the welding device to the robot or the
robot gripping the part and moving it to a pedestal mounted welding device.
• Set up a mounted workpiece path.
• Check whether a robot gripping a part can reach the welding device.
• Jump a robot to a location.
Introduction to pedestal welding

Pedestal Welding: In this use case, the workpiece is attached to a gripper mounted on the robot. The
welding is performed on a weld gun mounted to a pedestal. It is also known as ped. welding.
Different representations for compound weld operations (Changed through Operation Properties
):
• Pedestal Welding (External TCP)
• Gun on Robot Welding
External TCP Support:

• Simulation support
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• From the ribbon choose Operation tab→New Operation→New Weld Operation
• From the ribbon choose Operation tab→Operation Properties
• From the ribbon choose Process tab→Multi Sections
• From the ribbon choose Process tab→Pie Chart
• From the ribbon choose Robot tab→Reach Test
• From the ribbon choose Robot tab→Robot Smart Place
• Etc.
External TCP usage differences

In order to define a weld operation as a pedestal weld, the External TCP check box should be
checked (this is the main difference between pedestal and gun on robot welding in Process Simulate).
It can be checked when the weld operation is created or it can be set by right-clicking the weld
operation, Selecting Operation Properties , clicking the Process tab, then clicking External TCP.
With External TCP weld operations, the weld gun is NOT mounted to the robot, but it is specified in
the Gun prompt on the Operation Properties Process tab. Typically a gripper is mounted to the robot,
which is used to pick up the parts and move them to the pedestal weld gun.
Setting up a mounted workpiece path

• Use the from the last topic
• Create spot manufacturing features (welds) on the workpiece
• Project target locations on the workpiece at the work points
• Create a path through all the locations
• Get the external (ped) welder and orient it
• Associate the locations with the TCP frame of the external welder by checking the External TCP
check box on the Operations Properties dialog box
Robotic reach test
Reach Test — located on the Robot tab of the ribbon, you can use it to test whether a robot
can reach all selected locations, and to optimize the study layout.
Typically, you should select either the robot or the part (with the locations associated to it
with the Placement Manipulator before opening Reach Test .
You can jump to a location by double-clicking a location in the Reach Test dialog box.
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The selected locations are displayed in the Locations box, and a symbol is displayed in the R (reach)
box indicating whether the robot can reach the location. The symbols are as follows:
• The robot can reach the location. The location is colored blue in the Graphic Viewer.
• The robot has partial reachability to the location. The robot reaches the location, but must
rotate its TCPF to match the TCPF of the location.
• The robot has reachability to the location outside its working limits (but within its physical
limits).
• The robot has partial reachability to the location outside its working limits (but within its
physical limits). The robot reaches the location, but must rotate its TCPF to match the TCPF
of the location.
• The robot has full reachability to the location outside its physical limits.
• The robot has partial reachability to the location outside its physical limits. The robot reaches
the location, but must rotate its TCPF to match the TCPF of the location.
• The robot cannot reach the location at all. The location is colored red in the Graphic Viewer.
Toggling the display of working limits in dialog boxes:
When this check box is selected, joint limit color indications are shown in these windows and dialog
boxes:
• Graphic Viewer
• Weld Distribution Center
• Reach Test
• Robot Viewer
• Joint Jog
• Pie Chart
• Smart Place
To activate it: choose File→Options , click the Motion tab, and select Indicate joint working
limits. Joint working limits can be set as a percentage of the total joint range, or a specific value.
Toggling the use of Location Information in static dialog boxes:
When this check box is selected, simulation information is automatically read from the location or
parent operation while using these static dialog boxes:
Simulation information includes the robot name, the gun, and TCPF on the location or
operation.
• Pie Chart
• Smart Place
• Reach Test
• Optimizing Weld Distribution
Therefore, some simulation information boxes in these dialog boxes are inactive and you are not
able to edit them.
However when this check box is deselected, you can enter simulation information in the simulation
information boxes to get a different result.
To activate it, choose File→Options , click the Motion tab, and select the Use location
information in static applications check box.
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Jumping to a location basics

There are several ways to get a robot to a location you only discuss one method for now. The
others is discussed later in this course:
• Kinematics→Jump to Location
Activities
In the Creating a rough mounted workpiece (pedestal welding) path section, do the following activity:
• Creating a rough mounted workpiece (pedestal welding) path
Review questions
Question
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Type of simulative operation created Robot color Robot size Clicking External TCP in the Operation
Properties dialog box.
Orienting workpiece locations
Purpose
In this topic, you learn how to orient the locations on a gripped part.
Objectives
• Orient the locations using several techniques.
• Use the pie chart tool to analyze the ability of a robot to reach a location.
Do I do this?
Steps to orienting the locations

• Adjust the orientation of one of the locations, as a reference location using the next two steps
• Define a location to check.
• Then modify the location orientation until it is reachable.
• Align the rest of the locations to match the reference location
• Define and check the path so that all locations are reachable
• Spot simulate the path
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Using the pie chart

Pie Chart — located on the Process tab of the ribbon, it enables you to determine the approach
vector for a weld gun to a selected weld location. It provides an easy method for determining how a
robot with a weld gun should approach a weld location in order to perform welding — the system
calculates the approach for the robot and its mounted gun. If a robot has not been assigned, the
Pie Chart option enables you to determine the gun collision status. You can also use Pie Chart to
create a collision set.
For example: In the picture below you would move the Rotate Location Around slider until the X-axis of
the location (the long one) is in the blue area of the pie chart. The location itself do not change in color.
If you had selected Indicate joint working limits from File→Options, this dialog box shows
additional information:
Activities
In the Orienting workpiece locations section, do the following activities:
• Orient the locations
Review questions
Question
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The location itself changes to a blue color The robot is orange or yellow The X-axis of the location
is in the blue area of the pie chart.
Introduction to weld gun search

Purpose
In this topic, you learn how to use the Geometric Gun Search tool.
Objectives

• Use the basic geometric gun search capabilities.
Geometric gun search basics

It is a step-by-step wizard that guides the user to find the optimum gun for welding.
• Load the desired data in Process Simulate.
• Open the Geometric Gun Search dialog box.
• Choose the weld path.
• Choose the desired guns to be checked.
• Check if the selected guns collide.
Parts or tooling can be selected for checking the guns against. Gun poses that is
used at each location can be selected.
• Define the misc. options such as flip gun, angle of rotation, gun poses, number of steps, etc.
• Display result table. It displays a comparison between the tested guns and all the spots in the
selected path.
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Activities
In the Introduction to weld gun search section, do the following activities:
• Weld gun search
Servo guns
Purpose
In this topic, you learn how to use servo guns.
Objectives
• Use a servo gun.
• Know definition related to servo guns.
• Recall now to define an object as a servo gun.
Overview
In Process Simulate a pneumatic gun's weld poses must be defined before it is used (for example
CLOSED, OPEN, SEMIOPEN). Whereas a servo gun's weld poses are defined as an attribute on
the target locations.
After a servo gun is mounted to a robot, it is defined as an external axis of the robot and
the joint values for the gun can be stored on the locations. Another type of external axis
you discuss later is a 7th axis.
A servo gun is an electrical spot-welding gun controlled by a servomotor and an encoder.

A servo gun usually has two arms: the first, the dynamic or active arm, also designated
main joint, is controlled by an electric motor; the second, the static or passive arm,
also designated balance joint, is actuated either pneumatically, or mechanically with a
spring-return device.
Servo guns differ from traditional pneumatic guns in that whereas the pneumatic guns have
three poses, open, semi open and closed, servo guns are continuous and can move their
joint to any desired value within its limits. Thus the robot can open and close the servo gun
during motion, thereby reducing cycle time.
Using servo guns has an affect on the Gun Define, Joint Jog, Default Controller, Sequence Editor,
and the resulting simulation.
Servo gun usage

When welding is complete, the servo gun opens in either of two different ways:
• The passive arm retracts to its open position, and the active arm moves to a new value.
• The passive arm retracts to its open position, and the active arm moves to its position before the
welding operation, but using a different arrival-zone value; thus the robot starts moving to a new
location while the gun is still moving. Kuka robots use this method.
For motion to welding locations, the robot:
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1. Moves to the compound welding location.
2. Moves the servo gun to its CLOSE pose.
3. Simultaneously moves the passive servo-gun joint to its OPEN pose, and moves the active
servo-gun joint to its DEPART attribute value if any.
Servo gun definitions

• Active arm — the active arm is defined as a regular external axis of the robot. Any function, by
which the controller controls an external axis, can therefore control also the servo gun.
• Passive arm — movement of the passive arm is limited; it is used for balance against the active
arm.
• Gun poses — The servo-gun model must have a CLOSE state (pose). The commands in the
Process Simulate Gun Search dialog box require the CLOSE state, and may also use optional
OPEN and SEMIOPEN poses.
• Mounting Tool — Mount places the servo gun on the robot and attaches it to the robot, and also
constitutes the active arm as an external axis of the robot.
• Creating and updating locations — The locations for servo-gun simulations must have external
axis values in order to move the active arm together with the robot. To Set External Axis
command is used to add servo gun's active arm joint value to the location.
Define an object as a servo gun (discussion only)

a gripper:
Before defining a servo gun, ensure that:
• the gun is currently being modeled.
• The Modeling and Kinematics commands have been issued as required to define that object as
a kinematic device.
• At least the CLOSE pose is defined for the device.
• A tool center-point frame (TCPF) is defined for the object.
1. Follow the same process learned to define an object as a gun except:

• In the Tool Definition dialog box, click Servo Gun (instead of Gun) to constitute the device
as a servo gun.
2. Save and end modeling the object (the same as pneumatic guns).
Activities
In the Servo guns section, do the following activities:
• (Optional instructor demo) Simulating robots with servo guns
• Working with servo guns
Review questions
Question
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It cannot be used in a simulation The gun’s joint values are stored on the locations Its joints are
shown on the Joint Jog dialog box of the robot It is defined as an external axis of the robot
Summary
• The basic terms and processes of spot-welding
• Basic Process Simulate Robotics path development process.
• How to project welds to create weld locations.
• How to make some changes to the weld path associated to the weld operation.
• The Multi Section tool
• How to use the Weld Distribution Center (WDC)
• The process methodology used in this topic
• How to set up the study.
• How to maneuver the part in and out of the fixture.
• How to create a rough mounted workpiece (external TCP or pedestal welding ) path.
• How to orient the locations on a gripped part.
• How to use the Geometric Gun Search tool.
• How to use servo guns.
Lesson 12: Drilling and riveting applications
Purpose
In this lesson, you learn about drilling and riving applications.
Objectives

• Creating rivet manufacturing features.
• Creating drilling and riveting operations.
• Waypoints and the Waypoint Viewer.
Lesson
Lesson 12:12:Drilling
Drilling and riveting
and riveting applications
applications
Overview of drilling and riveting applications

Purpose
In this lesson, you get an overview of drilling and riveting applications.
Objectives

• Know more about common drilling and riveting applications.
Drilling and riveting (fastening) overview

A machine first drills a hole, seals it, and then rivets are inserted to join materials together such as the
fuselage of an aircraft. Drilling and riveting can be performed using a robot with a tool or a dedicated
machine. When done with a dedicated machine, the drilling and riveting are done at the same time. If
it is done with a robot, it is usually done in two cycles: one for drilling and then one for riveting.
Drilling and riveting applications
This manufacturing process could be represented as a Weld point .
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Do I do this?
Creating drill/rivet manufacturing features

Purpose
In this lesson, you learn how to create the drill and rivet manufacturing features.
Objectives

• Import drill/rivet manufacturing features from a file.
Do I do this?
In this lesson you import manufacturing features using the techniques described earlier in the generic
robotics part of the training. You also use the rivet custom manufacturing feature type and attributes
created as a training example.
Activities
In the Creating drill/rivet manufacturing features section, do the following activities:
• Creating the drill/rivet manufacturing features
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Create drilling and riveting operations

Purpose
In this lesson, you learn how to create drilling and riveting operations.
Objectives

• Sources for basic manufacturing feature orientation.
• Weld location constraints.
• Projecting weld locations.
Do I use this?
Projecting weld operations to create drilling/riveting robotic paths is described in this lesson:
Tools used to refine a rivet path are described in the final portion of the course.

• Obtain the location orientation from Process Simulate
The Mfg feature contains the position (X,Y,Z) of the resulting location.
o From the ribbon, choose Process tab→Discrete group→Project Weld Points
• Obtain the location orientation from CAD (NX or CATIA) or a Mfg import file
The Mfg feature contains the position (X,Y,Z) and orientation (Rx,Ry,Rz) of the resulting location.
o From the ribbon, choose Process tab→Discrete group→Obtain Weld Orientation
Using either of these two commands with weld points produces a location operation for each
Manufacturing feature. The location operation contains the position and orientation of the robot TCP
at the manufacturing feature. The orientation of the location operation can be further refined using
various tools in Process Simulate which is described later in this training.
Weld location constraints

Spot-weld and rivet locations must be on the surface and one axis must be perpendicular to the
surface.
The location’s orientation is very important. Projecting orients the locations in the path so that one
axis is normal to the surface and two axes are tangent to the surface.
Location defaults, including those related to projection, can be modified by choosing
File→Options and clicking the Weld tab or by clicking Options from the Project
Weld Points dialog box.
Weld Location Orientation:

• Approach Vector — Indicates the direction of approach of the weld gun. This axis is set
by default to X.
• Perpendicular — One axis has to be perpendicular to the surface being welded in order to create
a high quality and efficient weld. This axis is set by default to Z.
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Weld Point Projection:

• Permitted gap between parts — Enables you to specify the minimal distance between parts
included in the same group. Weld points cannot be projected or flipped on to a part located
beyond the permitted gap. The default value is 0.2 mm.
• Consider weld point orientation — If selected, the system applies gun orientation to new weld
point projections, including translation and rotation.
• Projection Direction — Enables you to determine the direction in which the weld locations are
projected:
o Away from the part projects the weld points away from the part (this is the default setting
and is used for alignment)
o Toward the part projects the weld points toward the inside of the part.
Spot Weld Permitted Deviation Angle:

This refers to the amount that the surface tangent axes (normally X-axis and Y-axis) are allowed to
deviate from tangent (thereby deviating the Z-axis from perpendicular.
• Perpendicular — By default 3 degrees.
Projecting weld locations
From the ribbon, choose Process tab→Discrete group→Project Weld Points produces
welding locations, while maintaining the weld location constraints mentioned above. The resulting
weld locations are on the surface and one axis, by default Z, is perpendicular to the surface.
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• Choose the desired spot manufacturing features or a simulative operation containing spot
manufacturing features.
• Select the Align projection with outer surface check box to align the weld location with a
more accessible surface.
• Select the Project on approximation only check box, if exact geometry is not available.
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 (for example, 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.
• Force projection over holes — When this option is set, the system ignores the faces’ borders
and relates to them as untrimmed surfaces. When projecting on an approximate surface, this
option is only supported on planar surfaces. It is recommended to select faces using the Face
Selection dialog to better control projection over holes.
If faces are selected, the faces are also slightly extended in order to allow projection
close to the face edge.
This is a very basic step in the robotic path creation process. There is no guarantee that
the path is reachable or collision free at this point.
Activities
In the Create drilling and riveting operations section, do the following activities:
• Creating riveting operations
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Waypoints and the Waypoint Viewer

Purpose
In this lesson, you learn how to create and simulate waypoint structures shown in the Waypoint
Viewer.
Objectives

• Navigating waypoints in the Waypoint Viewer.
• Setting up waypoints.
• Working with waypoints.
Do I use this?
Navigating waypoints in the Waypoint Viewer

Instead of creating via locations for riveting and drilling, you create waypoints in the Waypoint Viewer.
This viewer provides one high-level reusable structure.
A waypoint is a defined location through which the TCPF of a robot must pass before and after
performing an operation (drilling and riveting operations are supported). You can use waypoints to
assist in planning collision-free paths for robots. Using the Waypoint Viewer saves configuring
identical via locations for multiple operations. Savings in time and effort increase the more your
waypoint structure expands. The Waypoint Viewer provides a graphical, intuitive view of the waypoint
structure for the selected robot. When your waypoint structure is complete, you can save it in the
study, reuse it for additional operations, and/or download it to the robot. However, they are not
shown in the Operation Tree or Sequence Editor.
Waypoints are only supported for NcCode and default controllers.
You use the Waypoint Viewer to configure waypoints for the selected robot, connect operations
(assigned to the selected robot) to the waypoints, and download the waypoints. To configure
waypoints and operations in the Waypoint Viewer:
• A waypoint structure is associated to a robot and can only contain weld operations for that robot.
• Connect a waypoint to several operations: The robot must pass though the waypoint whenever it
performs any of the connected operations.
• Connect a chain of waypoints to an operation: The robot must pass through all the waypoints in
the chain whenever it performs the connected operation.
• If you run a sequence that includes two operations that share a waypoint, the robot does not
need to pass through the waypoint in between the operations.
• You can only download waypoints using the Waypoint Viewer Download command. The main
program, containing the robotic paths, is still downloaded using the regular Download to Robot
command.
• If you link a compound operation to a specific waypoint, all the child operations of the compound
operation are linked to the selected waypoint (lower level operations are ignored). However,
if you link one of the child operations (for example, OperationY) to a different waypoint (for
example, WaypointX), OperationY is linked to WaypointX and all the other operations remain
linked to the first specified waypoint.
Waypoints are not supported when running line simulations.
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Simulating with waypoints
In this example, the current operation is Weld_Op1. When you run the simulation, the robot TCPF
passes through Waypoint1, Waypoint, Waypoint2, and all the locations of Weld_Op1. After this,
the robot returns to Waypoint2, Waypoint, and Waypoint1.
Running the Weld_Op1 operation has no impact on Weld_Op2. If you want Weld_Op2 to
run after Weld_Op1, you need to link them in the Sequence Editor.
In this example, Weld_Op2 is linked to Weld_Op1 in the Sequence Editor. The current operation
is a compound operation that is the parent of both operations. When you run the simulation, the
robot TCPF passes through Waypoint1, Waypoint, Waypoint2, all the locations of Weld_Op1,
and then returns to Waypoint2, Waypoint, and Waypoint1. After this, the robot proceeds to
Waypoint3, Waypoint4, all the locations of Weld_Op2, and then returns to Waypoint4, Waypoint3,
and Waypoint1.
In this example, Weld_Op3 is linked to Weld_Op4 in the Sequence Editor. The current operation is a
compound operation that is the parent of both operations. When you run the simulation, the robot
TCPF passes through Waypoint1, Waypoint3, all the locations of Weld_Op3, all the locations of
Weld_Op4 It then returns to Waypoint3 and Waypoint1.
Setting up waypoints
1. From the ribbon choose View tab→Viewers →Waypoint Viewer to display the Waypoint
Viewer.
2. Click the dropdown box in the Waypoint Viewer toolbar and select a robot.
If a waypoint structure has already been saved for the selected robot, it is loaded into the
Waypoint Viewer.
3. Click Create Waypoint to create a new waypoint. The new waypoint is created on the
current robot TCPF and displayed in the Waypoint Viewer. The Robot Jog dialog box opens to
enable you to manipulate the robot TCPF (and the waypoint).
New waypoints are displayed with a shaded background and a symbol to indicate that
they are currently unconnected.
4. Select a weld operation or a compound operation (with nested weld operations) in the Operation
Tree and click Add Operation to add it to the Waypoint Viewer.
• New operations are displayed with a shaded background and a symbol to indicate
that they are currently unconnected to any waypoint.
• Operations nested under the compound operation that are not weld operations
are ignored.
• When adding a compound operation, all weld operations nested under the
compound are connected to the selected waypoint, unless a specific weld
operation appears in the Waypoint Viewer and is connected to a different waypoint.
5. Click Link Waypoints to enter a mode to link waypoints to other waypoints or to weld
operations.
6. Click a waypoint, drag your mouse to a waypoint or operation, and release the mouse.
The direction in which you drag the mouse sets the direction of the link. You cannot
create a link from an operation to a waypoint; only links from waypoints to operations
or other waypoints are legal.
7. Repeat this process until you have created all the required links.
8. Click Link Waypoints again to exit this mode.
9. When you are satisfied with your waypoint structure, simulate it in the Sequence Editor, Path
Editor, or click Download from the Waypoint Viewer toolbar.
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Clicking Download from the Waypoint Viewer only downloads the waypoint
structure file. To download the main program, containing all the weld operations, click
Download from the Program Inventory dialog box.
Working with waypoints

Nominal Sequence — This is the intended sequence as shown in the Sequence Editor with the
waypoints.
1. Add the paths to a compound operation
2. Sequence the paths in the Sequence Editor.
Non-nominal sequence — This is the sequence that may have to run, for example, if a panel is
missing and you have to skip some of the weld operations for now.
1. Create a program.
2. Add the desired paths to the program using the Path Editor.
Activities
In the Waypoints and the Waypoint Viewer section, do the following activities:
• Waypoints and the Waypoint Viewer
Summary
• Creating rivet manufacturing features.
• Creating drilling and riveting operations.
• Waypoints and the Waypoint Viewer.
Lesson 13: Material handling applications
Purpose
To provide an introduction to Process Simulate for material handling applications (for example
Assembly, Packing/Palletizing, Part Transfer).
Objectives

• How to set up the study
• How to do palletizing
Lesson
Lesson 13:13:Material
Material handling
handling applications
applications
Do I use this?
Material handling applications
Overview of gripper creation (optional)

Purpose
In this topic, you review what you did earlier to define poses for a kinematic device and define it as
a gripper.
This topic is covered earlier in this course.
Objectives

• Add poses to a kinematic object.
• Define a kinematic object as a gripper.
Discussion of steps to add poses to an object

• Open the object for modeling
• (kinematics should be already defined)
• Joint jog the mechanism into the desired position or approximately into position
• Edit the poses for the current mechanism
• Create a new pose
• Use the current joint values or enter new ones
• Accept the values entered for this pose
• Define the rest of the poses for this mechanism
• Save the object
What Poses Need to be Defined?

For grippers, the OPEN and CLOSE poses must be defined (Pose names are case-sensitive).
Define an object as a gripper (discussion only)

a gripper:
1. Model it.
2. From the ribbon, choose Modeling tab→Kinematics group→Tool Definition .
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Material handling
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3. Follow the same process you learned to define an object as a gun except:
• In the Tool Definition dialog box, click Gripper (instead of Gun) to constitute the device as
a gripper.
4. The Offset is the distance from the TCP Frame where other objects attach to the gripping entities
at the pick location of a pick and place operation.
5. Save and end modeling the object.
Material handling study setup
Purpose
In this topic, you learn how to set up the study.
Objectives
• Set up a material handling study.
Do I do this?
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Material handling
applications
Setting up the material handling study

• Get and place the robot
• Get the gripper
• Mount it on the robot
• Get and place conveyors, rails, and containers
• Get and place the workpieces
Activities
In the Material handling study setup section, do the following activities:
• (Instructor demo) Material handling example
• Pick and place (Material handling) setup
Material handling (pick and place) operations

Purpose
In this topic, you learn how to create pick and place operations to do material handling. In this topic,
you perform palletizing activities as an example.
You create pick and place operations which contain special via locations for picking up and dropping
off the part.
Objectives

• Know the basics of pick and place (material handling).
Do I do this?
You create pick and place operations, add approach and retract locations on the part, and define
a sequence of operations.
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Material handling
applications
Pick and place basics

To create a new Pick and Place Operation:
1. Select the parent operation.
2. Choose New Operation →New Pick and Place Operation .
3. Choose the Pick and Place poses
4. Choose the pick and place TCP positions.
Any of the techniques described before for editing paths of via locations can be used
with this path type as well. A material handling path can also be created using New
Generic Robotic Operation (which only contains via locations), if you don't want
to use the special pick and place behavior.
An extension to what is learned here is provided in the TR45315 Process Simulate

Standalone Robotics Advanced course. In that course you describe how to create a
program that contains these pick and place paths. Then you create logic and sensors to
setup the simulation in a way that is more true to life.
Activities
In the Material handling (pick and place) operations section, do the following activities:
• Create the basic (PNP) process
• Stacking boxes
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Material handling
applications
Summary
• How to set up the
• How to do palletizing
Lesson 14: Arc-weld continuous feature applications
Purpose
To provide an introduction to creating arc-weld robotic paths in Process Simulate.
Objectives

• Creating arc welding paths using arc welding specific tools.
Lesson
Lesson 14:14:Arc-weld
Arc-weld continuous
continuous feature
feature applications
applications
Overview of arc-weld robotic applications

Purpose
In this topic, you learn about arc-weld robotic applications.
Objectives
• Gain a basic understanding of arc weld principles.
Arc weld basics

One application is to create robotic gas metal arc welding (GMAW a.k.a. Metal Inert Gas a.k.a.
MIG) sessions.
Arc Welding Basics (1):
1. Direction of travel
2. Contact tube/tip and Shield gas nozzle
3. Electrode
4. Shielding gas
• Protects against dross and porosity (Quality problems)
5. Molten weld metal
6. Solidified weld metal
7. Workpiece
Arc welding basics (2)

• An electric arc is established between the workpiece and a consumable electrode
Arc-weld continuous feature applications
• The arc continuously melts the electrode as it is automatically fed into the weld puddle
o Feed is speed dependent on wire diameter, welding current , stick-out, and torch travel speed
• The weld metal is shielded from the atmosphere by a flowing gas mixture
• Just need to guide the torch position and orientation along the weld seam
Arc welding basics (3)
• Stick-out distance
o A.k.a. wire electrode extension
o Distance from contact tip to end of electrode
• Tip-to-Work distance
o Distance from contact tip to workpiece
o Tip-to-work distance = stick-out + arc length
o Tip-to-work distance should be kept consistent to avoid overheating and wasting shield gas
• Torch orientation
o Should bisect the angle between the workpieces
o Travel angle should be approximately vertical (shield gas has an effect; for example CO2
tends to push instead of drag)
Seam creation basics

Seams
• Seam — arc weld path of weld locations with associated via locations. Created weld locations
follow the curve of the continuous manufacturing feature with a linear motion type (except arcs
which use circular motion type)
• Continuous Feature Operation — can contain one or many seams
Welding is performed at the TCP of the torch
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Arc-weld continuous
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• Distance to TCP – Stick-Out distance
• Torch Offset – additional distance (for example to modify penetration, arc length, prevent burn
through on varying thickness workpieces, etc.)
The TCP is usually placed at the stick-out distance. The arc length, which is
approximately the typical OLP calibrated tolerance (1 mm), can be considered using
a torch offset, by using “auto seam tracking” (controller specific) or touch sensing
(also known as a search).
Bisector angle
• Measured from bisector to side wall
• Default is 0 degrees (on the bisector)
• for example bisector angle of 0 degrees for a fillet weld
• for example bisector angle of 5 degrees for a beveled butt joint
Bisector – bisects the angle between the workpieces
Travel angle
• Measured along welding direction
• Also known as the lead angle
• Default is 90 degrees, but is not typical
• Drag
o for example travel angle of 80 degrees
o Less than 65 degrees causes excess spatter
o Backhand welding
o For deeper penetration (and wider bead width) or root pass on multi-layer welds
• Push
o for example travel angle of 100 degrees
o Forehand welding
o Do 95% of the time. Normal (standard) and multi-layer welds (excluding the root pass)
have a slight push
o Better for thin parts and less penetration
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Arc-weld continuous
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Seam orientation
• Most welding is done with the base wall flat on the ground (Horizontal or flat seams). This
produces the best welds.
• In rare cases welding is done with the part at 10 degree angle down hill for maximum speed. This
is known as a gravity weld.
• For welding vertical seams:

o Vertical up (welding from bottom to top)
o Vertical down (welding from top to bottom)
Do I do this?
Lesson
Arc-weld continuous
continuous feature
applications
Arc-weld continuous manufacturing features and operations

Purpose
In this topic, you learn how to use continuous manufacturing features. These objects are used to
make continuous feature operations which are used to represent arc welding, gluing/dispensing, laser
cutting, painting, material removal, grinding, deburring, and polishing processes.
Objectives

• See the relationship between continuous manufacturing features and continuous manufacturing
operations.
Do I do this?
There are several reasons to create manufacturing features, including for arc-welding:
Creating Arc-weld continuous operations
Create an arc-weld manufacturing feature
This manufacturing process could be represented as a Continuous Mfg or an

ArcContinuousMfg .
Continuous Process Generator — Found on the Process tab of the ribbon, this command
creates a continuous feature operation without the need to create a manufacturing feature first. It
is a time saving technique specifically designed for creating manufacturing features between two
parts, such as an arc-weld.
After selecting the faces, the command automatically performs all of the following:
• Previews one or more paths (preview seams) for the manufacturing feature to be created (and
used in the projection calculations).
• Enables you to fine-tune the edges and faces, for example: edit the selection (add/remove
faces), change the face extension, merge curves to a single seam, define seams’ start/end, skip
welds and direction.
• Creates new continuous manufacturing feature for each seam.
• Sets the manufacturing feature type.
• Assigns the Mfg to the part of the first base face.
• Creates a new continuous feature operation or allows you to append seam operations and
assigned manufacturing feature to an existing continuous feature operation.
• Assigns the continuous manufacturing feature to the new or existing continuous feature operation.
• Creates new seam operations for each continuous manufacturing feature and nests them under
the new or existing continuous operation with the correct face definitions. The system defines
which faces from the base and side sets belong to each seam operation.
• If there is a single robot in the loaded data, the command assigns this robot and its mounted
tool to the operation.
You can also use the Continuous Process Generator to fine-tune the edges and faces, for
example: edit the selection (add/remove faces), change the face Extension distance, Merge all
curves to a single seam, define seams’ start/end, and direction. The command also provides support
for Skip welding (or stitch welding) where the seam operation is composed of welds separated
by spaces (similar to a dashed line).
Projecting the manufacturing feature
There are two ways to project the continuous manufacturing feature to create the arc-weld locations.
The training demonstrates both:
• (Optional) Using the Continuous Process Generator during manufacturing feature

creation.
• (Optional) Using Project Arc Seam after manufacturing feature creation.
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Arc-weld continuous
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Using Continuous Process Generator for arc-welding
1. From the ribbon choose Process tab→Continuous group→ Continuous Process

Generator
2. In the Continuous Process Generator dialog box for Process, select Arc.
3. Select the geometry to be welded. The geometry is setup in two groups depending on which side
of the weld it is on (base or side).
4. Setup the resulting operation including the name, associated robot, tool, and parent operation.
5. Setup the resulting manufacturing feature including the type and parent folder for the related
.COJT.
6. (Optional) Setup the resulting location distribution (manufacturing feature projection parameters).
In most cases, it is recommended to do the projection now.
7. Click OK.
Activities
In the Continuous manufacturing features and continuous feature operations section, do the following
activity:
• Using continuous feature operations
Review questions
Question
Lesson
Arc-weld continuous
continuous feature
applications
Arc welding, Gluing/Dispensing, Laser cutting, Painting, or Material

Removal/Grinding/Deburring/Polishing Gluing/Dispensing Laser cutting Painting Material
Removal/Grinding/Deburring/Polishing Material Handling (Pick and Place) Spot Weld
Creating paths from continuous manufacturing features

Purpose
In this topic, you learn how to project continuous manufacturing features to create continuous
manufacturing robotic paths.
Objectives

• Understand and setup continuous location projection constraints.
Overview
A location in Process Simulate is unique type of frame that contains the position and orientation of
the TCP frame at a point. Locations are generated with their origins placed according to where the
projection of the related curve intersects a surface or solid it is projected onto. The locations guide
the tool center point of the robot approach vector and a vector perpendicular to the workpiece.
Locations also contain process information specific to the robotic application such as:
Gun state, Location type, Speed, etc. for each location.
Do I do this?
Continuous location constraints

A continuous manufacturing feature location’s orientation is very important.
• Typically one axis is to be normal to the surface being worked on. This Normal axis set by
default to Z.
• Another axis indicates the direction of Movement Vector of the continuous manufacturing
feature. This axis is set by default to X.
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Arc-weld continuous
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Default approach and perpendicular axis are defined and can be modified using
File→Options and choosing the Continuous tab.
Projecting arc-weld continuous manufacturing features
From the Process tab of the ribbon, choose Project Arc Seam to project an arc manufacturing
feature at the intersection of two parts or at the intersection of two part faces and create an
arc-welding path.
Before executing Project Arc Seam, you specify a continuous robot compound operation. This
command projects the seams that appear in the Operation Tree as children of the specified
continuous robot compound operation.
You do not need to specify anything in the Arc Mfg Features area of the Project Arc Seams dialog
box, since you specified it when using the Continuous Process Generator in the previous
lesson.
Projection Parameters area of the Project Continuous Mfgs dialog box:

• Tolerance Based Spacing — The system places the projected locations according to the
geometry of the target manufacturing feature. Configure the following parameters:
o Maximal segment length — The maximum allowed distance between two locations created
when projecting continuous manufacturing features.
o Maximal tolerance — The maximum allowed distance between a location and the curve
that defines the seam geometry.
o Optimize locations creation for arc and line segments — When set (this is the default),
this option optimizes manufacturing feature projection on condition that all the locations in
the source manufacturing feature conform to the Arc tolerance and Minimal line length you
define. The system creates a projection using two locations for straight lines, three locations
for arcs, and five locations for circles. When this option is off, the system creates a projection
of consecutive locations, requiring a large amount of computer resources. After completing
the projection, the system sets the motion type of each location according to the segment
detection results for the curve. A location's motion type is determined by the way the robot
approaches the location. For circular curves, the system sets the last two points as circular
motion; for linear curves, the last point is set as linear motion. Locations projected by those
points are set with those motion types.
• Equal Distance Spacing — The system places the projected locations according to the following
parameters:
o Start Offset — The offset distance from the beginning of the manufacturing feature to the
first projected location.
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Arc-weld continuous
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o End Offset — The offset distance from the last projected location to the end of the
manufacturing feature.
o Traverse distance — The distance between projected locations.
• Project on approximation only — Only JTs containing XTBRep (exact geometry) support
projecting on exact geometry. If the part exact geometry is not available in the JT file (for
example, 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. .
• Keep position on curve — If the manufacturing feature is not on the same plane as the part on
which you are projecting it, setting this option ensures that the projected locations remain on the
manufacturing feature. Clearing the option causes the system to project the locations on the part.
Arc-weld projection tools
• Indicate Seam Start — located on the Process tab of the ribbon, you use it to create a
continuous manufacturing features from any curve in the current project. You can either use an
existing curve, create a new curve, or import a curve into the project from an external CAD
program. After creating a continuous Mfg, you can Project Continuous Mfgs on to parts.
• Project Arc Seam — located on the Process tab of the ribbon, it takes a manufacturing
feature as input. You can select a base wall part, a side wall part, and various torch alignment
parameters. The path that is produced should require far fewer modifications than an arc weld
path created with Project Continuous Mfg Features (discussed in a later lesson).
Automatically setting the location attributes
From the Operation tab of the ribbon, choose Apply Path Template to automatically set
the location attributes to company standards or robot application specific settings (such as for
arc-welding, spot-welding, painting). In this lesson you use an sample path template that was creating
for the purpose of this training course.
You learn how to create a template file for the Apply Path Template Action in the
Advanced Robotics course. This tool does not work until you setup the XML file for it. A
sample XML is provided with the course training data. The file is named RobotSim.xml
and is located in the Sample Default Path Template folder
Activities
In the Creating paths from continuous manufacturing features section, do the following activity:
• Creating an arc-weld path from a manufacturing feature
Review questions
Question
Lesson
Arc-weld continuous
continuous feature
applications
Make the path reachable by the robot Make a collision free path. Create a simulative operation (path)
of locations. Orient the locations in the path so that 1 axis is normal to the surface and two axes
are tangent to the surface.
Seventh axis and more (external axis usage)

Purpose
In this topic, you learn how to use setup and use external axis (joint). For example, a robot on a rail
(7th axis) or gantry is considered an external axis (joint) or a robot on a multi axis gantry system.
Objectives

• Know the basics about external axes.
• Use external axes.
Do I do this?
You can associate the kinematics of a device to a robot, by defining it as an external axis. This is
typically done for robots on rails and gantries; as well as part positioners. There are special tools that
you can use for paths with external axis robots.
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External axis basics
In Process Simulate: Rails, gantries, and positioners are types of external joints. For example:
• Rail – It is a separate .COJT that consists of a single linear joint (and is sometimes called a
7th axis). A robot is Attached to the child link of j1 (in the study, not in modeling). This
child link is the rail carriage.
• Gantry – It is a separate .COJT that consists of three linear joints. A robot is Attached to the
child link of j3 (in the study, not in modeling).
• Positioner – It is a separate .COJT that consists of 2 rotational joints. The part is Attached
to the child link of j2 (in the study, not in modeling).
• Other kinematic devices can be used as externals as well, these three are provided as typical
examples.
External axes usage
Set External Axes Values sets the values of external axes (such as rails, servo guns and so on)
that were defined in Robot Properties on a selected location. When the robot reaches this location,
the external axes is positioned at the set values.
To set the external axes values:
1. Choose one or more robotic locations or an operation from the Operation Tree or the Graphic
Viewer, and then click Set External Axes Values .
2. In the Set External Axes Values dialog box, select the external axes whose values you want to
save
3. Click OK. The current values of the robot’s external axes are stored at the location. When the
robot reaches this location, the external axes is positioned according to these values.
In the Path Editor, the External Axes column indicates how many external axes have
been defined at the selected location and of those, how many axis values have been
set with this command. Mouse over the pencil in the External Axis column to display
a tool tip with the set values.
Add 7th axis to a robot
1. Use Relocate command located on the Graphic Viewer toolbar to place the robot on
the carriage rail.
2. Use Attach command located on the Tools tab of the ribbon to attach the robot to the
rail carriage.
3. Use External Axes tab of Robot Properties command located on the Robots tab of the
ribbon to add/remove the rail axis to/from the robot’s list of joints.
Servo gun axes are added automatically when they are mounted, however all other
external axes must be added manually from this tab (unless the information was
previously defined as part of the compound equipment definition).
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More external axis commands

These commands related to an external axis, are located on the Robot tab of the ribbon.
• Clicking Clear External Axes Values enables you to clear previously set external values
from the selected location.
• Clicking Set External Values to Location on the Robot Jog dialog box opened from Add
Location Before or Add Location After , you can store the current (approach) external
axes values on the location currently being manipulated.
• After clicking External Axis Creation Mode (to activate this mode), each time that Add
Current Location or Add Location By Pick is clicked a location is created with the
current (approach) external axes values stored on it.
Smooth rail
This tool allows the automatic setting of rail values along a path.
To use it:
1. From the ribbon, choose Robot tab→OLP group→Smooth Rail .
2. In the Smooth Rail dialog box, select a start and an end location inside a robotic operation (path).
The selected first and last locations should already have an external axis value defined.
3. For Method, choose either Interpolate On Travel Distance or Project Locations on Rail Axis.
• Interpolate On Travel Distance - The application interpolates the rail values set on the
start and end locations with the relative Cartesian travel distance from the start location,
along the path
• Project Locations On Rail Axis - The application interpolates the rail values set on the start
and end locations with the relative positions of each locations along the rail.
4. Click OK or click Apply. The command creates/updates the rail values of all locations between
the selected ones.
Activities
In the 7th axis and more (external axis usage) section, do the following activities:
• (Optional Instructor Demo) Working with a 7th axis
• Working with a 7th axis (setting values)
Lesson
Arc-weld continuous
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Creating and editing more arc-weld continuous manufacturing

feature paths
Purpose
In this topic, you work with a like more complex part to learn more about arc-welding path
development.
Objectives

• Understand how to arc-weld a more complex part.
Do I do this?
You create arc continuous features, create continuous feature operations, project the continous
feature operations, and refine the arc-weld paths.
Verifying location orientation

When projecting manufacturing features, a preliminary orientation of the seam locations are created,
so the next step in the process is to check the orientation of the locations. You start by taking any
gun to farther refine the seam location orientation (for example approach vector and perpendicular
vector). At this stage it is not necessary for the gun to be attached to a robot.
Location orientation refinement tools used in this topic:
• →Flip Locations on Surface — flip weld locations on a surface 180 degrees around
their approach axes. The approach axis is defined in the Weld Tab of the Options dialog box.
• →Flip Locations on Solid — flip weld locations 180 degrees on solids and specify the
parts that are included in the flip.
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Arc-weld continuous
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Location orientation refinement tools:
• Torch Alignment — edit seam locations created with Project Arc Seam or
Continuous Process Generator . Using this command to make small changes can save
the need to create new operations.
• Reverse Operation
• And several other commands under the Edit Path group of the Operation tab.
• Placement commands such as Relocate and Placement Manipulator on the Graphic Viewer
toolbar.
• Etc.
Activities
In the Creating paths from continuous manufacturing features section, do the following activity:
• Creating arc manufacturing features for the whitehouse part and project them using Continuous
Process Generator
• Modifying arc weld operations and seams
Lesson
Arc-weld continuous
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Summary
• How to create arc welding paths using arc welding specific tools.
Lesson 15: Paint continuous feature applications
Purpose
To provide an introduction to creating paint paths in Process Simulate.
Objectives

• How to create paint continuous manufacturing features.
• How to project paint continuous manufacturing features to create paint continuous manufacturing
robotic paths.
• How to use paint continuous manufacturing features.
• Making changes to the path associated to the paint continuous manufacturing operation.
Lesson
Lesson 15:15:PaintPaint continuous
continuous feature
applications
Overview of paint continuous robotic applications

Purpose
In this topic, you learn about paint robotic applications.
Any type of robotic application involving the robot following the contour of the part
is considered continuous in Process Simulate. There are many examples such as
arc-welding, painting, grinding, deburring, hemming, gluing, laser cutting, water jet,
sealing, etc.
Objectives
• Gain a basic understanding of robotic painting principles.
Painting basics
The contemporary process of vehicular spray painting is a result of many years of development in
an effort to improve quality while reducing time and costs. The process of painting vehicle bodies
currently uses a painting line which receives the body after the primer coats have been applied. A
representative process comprises five stages:
1. Preparation — dust is removed before applying the final color.
2. Interior-paint booth — the final base color is sprayed onto inner portions of the body where
access is relatively difficult. This stage benefits greatly from the use of one or more robots.
3. Exterior-paint booth — the final base color is sprayed onto exterior of the body where relatively
easy access renders practical use of specialized equipment.
4. Manual touchup — additional final base color is sprayed manually onto portions of the vehicle
not adequately covered in the base booth.
5. Oven drying — the final base color is baked dry and hard.
These stages may be repeated for additional coats of paint such as the application of clear enamel
over the base coat. In addition, completely different spraying processes may be used for spare parts,
spray gluing, and underbody and other sealing; these processes usually differ from the processes
for painting vehicle bodies.
The robotic paint booth

The painting operations which occur in the interior-paint booth best lend themselves to robotic
applications; indeed, robots have been used for many years in vehicular spray-paint booths in order
to improve the quality and consistency of the paint process compared to manual spray-painting
methods. Advantages of using robots include:
• Accuracy and repeatability are easier to achieve
• Robots are not affected by painting hazards that are problematic for humans
Paint continuous feature applications
• Long-arm robots easily cover large vehicles, such as trucks or vans, which are difficult to reach
manually.
• Robots perform difficult and monotonous jobs without tiring or complaining.
A modern paint booth is usually constructed as a clean room, and includes a conveyor, the vehicle
being painted, one or more manipulators to open and close doors and lids, at least one robot, a
controller for the robot, a paint gun with its associated hoses, compressors and other equipment,
and the paint-gun controller.
Painting equipment
Of the items included in a paint booth, three constitute the painting equipment actually involved in
the programmed, automated painting process:
• The robot controller; it usually executes the robot program and initiates signals which activate
the paint controller.
• The paint controller; it controls the opening and closing of the spray gun. It also produces the
spray fan and determines the shape of the fan, the rate and amount of paint being used, and the
size of the droplets comprising the paint spray.
• The spray gun; it is the device which receives the signals from the paint controller in order to
perform the painting process.
Paint-spray composition
Four items of equipment produce the paint as sprayed on the vehicle:
• A fluid pump which pumps the paint to the spray gun.
• An atomizing-air pump which pumps pressurized air through the main spray-gun nozzle to break
up the sprayed paint into tiny droplets the size of which is carefully controlled.
• A horn-air pump which drives pressurized air toward the sides of the paint spray as it exits from
the gun, controlling the shape of the paint fan. If the horn-air pressure is low, the fan is short
and wide; if the pressure is high, the fan is long and narrow.
• A paint gun which includes the main nozzle from which the paint exits together with the atomizing
air, and various secondary nozzles which introduce horn air to control the shape of the paint fan.
The paint thus exits in the shape of a fan from the main nozzle of the paint gun.
Paint-spray control
The atomizing- and horn-air pressures and the various paint-flow parameters are usually controlled
by the robot program, using data recorded in a paint-parameters table residing either in the robot
controller or in the paint controller. Individual data are recorded for each type of paint or color which
the application uses. The robot controller communicates the relevant paint parameters to the paint
controller either by sending the parameters or by sending a paint-parameters code constituting a key
to a particular paint and its associated parameter values.
In addition to controlling the spray-fan values, the robot controller needs also to communicate
instructions to open and close a spray gun, for example, to start and stop painting.
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Activating the air pressures and the gun nozzle occupies time. The delay from the time the paint
controller receives the command until the command takes effect, is measured in milliseconds. When
the delay pertains to a spray gun, it is designated gun delay. The delay for opening a gun may differ
from the delay for closing the gun.
Either the robot controller can compensate for the delay by sending the opening and closing signals
slightly sooner, or the programmer can compensate for the delay by inserting instructions sooner
in the program.
Painting-program goals
A painting program for a production robot needs to achieve five goals:
1. Evenly cover the entire surface with paint within a specified range of thicknesses.
2. Minimize the cycle time required to execute the program.
3. Minimize the amount of material used in order to achieve the required thickness, for example,
minimize overspray and other waste.
4. Rapidly achieve production quality in order to minimize down time and the use of scrap vehicle
bodies.
5. Achieve a maintainable program which minimizes the number of paint brushes, for example,
sets of paint parameters. Since each set of paint parameters is duplicated for each different
paint material, using many sets makes the program difficult to calibrate with tests from actual
production samples.
Producing the program

Producing a painting program for a production robot to achieve the goals listed above, usually entails
the steps listed below:
1. Analyze the target area assigned to a specific robot, and determine the paths through which the
robot should move in order adequately to cover the area
2. Determine the order in which the various paths, including both the painting and non-painting
portions, should be joined
3. Teach the combined paths to the robot and solve any reach and collision problems that may
occur in the process.
4. Assign speed values to the motion program
5. Perform a dry run: run the robot through the program and solve dynamic reach and collision
problems if they occur.
6. Determine the points where a spray gun should open and the points where a gun should close,
and verify that the program can still be executed.
7. Assign paint parameters to each painting portion of the path, according to coverage and thickness
requirements. Paint parameters are tested on the actual production line to determine available
sets of parameters that provide the desired nominal width and thickness at a specified speed.
The list of these sets is then delivered to the programmer.
• The various parameters used in a painting program are not independent. For example,
changing the speed because of motion problems affects the thickness; changing the distance
from the surface to prevent a collision affects the coverage and the thickness.
8. Execute a preliminary wet run.
9. Check coverage and thickness.
10. If improvements are needed, edit the program and reteach the robot. Dry and wet runs can be
repeated until complete satisfaction is achieved.
Painting-program problems
Up to the present, programming painting robots on line is more of an art than a science. It requires
long initial programming efforts and produces cumbersome robot programs that are hard to maintain.
In particular, problems arise due to:
• The complexity of the workpiece.
• Difficulties associated with reachability and collisions.
• Runners occurring at edges and in corners.
As a result, producing a workable program is a trial-and-error process usually requiring several

weeks during which the painting line is shut down.
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Do I do this?
Setting up paint brushes and meshes

Purpose
In this lesson, you learn how to set up paint brushes and meshes.
Objectives

• Understand the basic process to setup paint coverage simulation.
• Define a paint brush.
• Define a paint mesh for a part.
Do I use this?
Overview of paint coverage simulation setup

You can configure continuous operations for painting parts or components. The following is a typical
workflow for performing coverage:
1. Define a paint gun (you can define the Tool Type using the Tool Definition command).
2. Mount a paint gun on the robot.
3. Create a continuous operation.
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4. Define a robot brush (paint gun attached to the robot that applies paint to the manufactured
object) using the Paint Brush Editor command.
5. Create a 3D mesh of points on the target part, using the Create Mesh command.
Paint brushes
The Paint Brush Editor command is used to define the name and geometry of the brushes used
to calculate paint coverage during simulation.
Whenever the brush touches a point on the mesh, paint is applied. It is also possible to apply a
number of paint layers, to configure the size and shape of the paint brush for various tasks, and to
set various display options.
The Z-axis of the paint gun tip frame should point towards the surface normal. This is
essential in order to visualize coverage correctly.
To create and edit paint brushes:
1. After selecting a robot (optionally with a mounted paint gun), choose Process tab→ Paint and
Coverage group→Paint Brush Editor .
The Paint Brush Editor appears.
2. To add a new brush, click Create Brush on the Paint Brush Editor toolbar.
The Create Brush dialog box appears.
a. Enter a Brush Name or number.
b. Select a Solid to represent the paint jet. If necessary, create a new resource with a custom
shape, such as a cone, to use as your solid.
c. Set the Origin Frame on the selected solid. This is the frame on the solid (part of the same
resource) that connects to the paint gun's Tip Frame.
d. Click OK to save the new paint brush.
3. If you need to remove a paint brush, select it and click Delete Brush on the Paint Brush
Editor toolbar.
4. To edit a brush, click Edit Brush . The Edit Brush dialog box appears. This is similar to the
Create Brush dialog box but is populated with the parameters of the selected brush. Edit the
parameters the way you want and click OK.
5. Click Close to exit the Paint Brush Editor.
Meshes
The Create Mesh command is used create a mesh that can be used to show paint coverage
on the part.
You can only create a mesh on parts with XTBRep exact geometry; it is not possible to create a mesh
on parts with approximate geometry. If a part is comprised of multiple entities, some of which have
XTBRep exact geometry and some of which do not, meshes are only created for those entities
with exact geometry. The system notifies you when selecting parts that consist of entities without
XTBRep exact geometry.
It is recommended to blank all the non-relevant entities prior to creating the mesh (consider
using the Load the Entity Level command). This improves performance during both
mesh creation and simulation.
To create a mesh:
1. Select the part you want to paint.
2. From the ribbon choose Process tab→Paint and Coverage group→Create Mesh . The
Create Mesh dialog box appears and the selected part populates the Parts list.
3. The Exact column indicates if the part has at least one entity with XTBRep exact geometry.
4. The Mesh column indicates if a mesh already exists for the part. Creating a mesh again for this
part overwrites the previous mesh.
5. If you wish to create a mesh for more parts, click the Parts list and pick additional parts.
6. In the Tessellation Tolerances area, set the following parameters:

• Distance — The maximum distance allowed between adjacent vertices of the mesh.
• Deviation — The maximum allowed divergence of the approximate geometry from the exact
geometry. For a curve, this is the deviation of the line segment from the geometric curve. For
a surface, this is the deviation of a triangular facet from the exact surface.
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This diagram employs a curve to illustrate the parameters but the same is true for surfaces.
• Angle — The maximum angle allowed between adjacent approximation items (line segments
in the case of a curve, and facets in the case of a surface).
7. Click Preview to view the mesh or click OK to create the mesh and close the Create Mesh
dialog box.
• The mesh does not appear in the Object Tree.
• It may take the system a significant amount of time to create/preview the mesh and
save studies that include meshes. The mesh may expand the study's size significantly.
• You cannot delete the mesh of a part. However, the mesh is removed from the study
when you delete the part. It is overwritten when creating a new mesh for the part.
Activities
In the Setting up paint brushes and meshes section, do the following activities:
• Setting up paint brushes and meshes
Creating and projecting paint manufacturing features

Purpose
In this lesson, you learn how to create and project paint manufacturing features.
Objectives
• Create paint continuous operations using Continuous Process Generator.
• Set continuous location constraints.
Do I do this?
There are several reasons to create manufacturing features, including for robot paths that follow the
contour of the part (continuous feature):
Creating paint continuous operations

Create a paint manufacturing feature
This manufacturing process could be represented as a Continuous Mfg or a

PaintContinuousMfg .
Continuous Process Generator — Found on the Process tab of the ribbon, this command
creates a continuous feature operation without the need to create a manufacturing feature first. It is a
time saving technique specifically designed for creating manufacturing features for painting.
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(Optional) Projecting the manufacturing feature to create locations
There are two ways to project the continuous manufacturing feature to create the paint locations. The
training demonstrates both:
• Common abilities of projecting with either Continuous Process Generator or Project
Continuous Mfg . You can use both to create locations based on a maximal curve tolerance
and optionally select a reference seam to set the torch orientations.
o Tolerance Based Spacing — The system places the projected locations according to the
■ Maximal segment length — The maximum allowed distance between two locations
created when projecting continuous manufacturing features.
■ Maximal tolerance — The maximum allowed distance between a location and the curve
■ Optimize locations creation for arc and line segments — When set (this is the
default), this option optimizes manufacturing feature projection on condition that all the
locations in the source manufacturing feature conform to the Arc tolerance and Minimal
line length you define. The system creates a projection using two locations for straight
lines, three locations for arcs, and five locations for circles. When this option is off,
the system creates a projection of consecutive locations, requiring a large amount of
computer resources. After completing the projection, the system sets the motion type of
each location according to the segment detection results for the curve. A location's motion
type is determined by the way the robot approaches the location. For circular curves, the
system sets the last two points as circular motion; for linear curves, the last point is set as
linear motion. Locations projected by those points are set with those motion types.
• Using the Continuous Process Generator during manufacturing feature creation. You can
also set the location orientation and each stoke automatically goes in opposite directions.
o Tangent ZigZag — all locations are oriented in a similar direction to the direction of the
reference stroke and are tangent to the stroke (the movement vector is aligned with the
stroke direction).
o Tangent — locations are tangent to their stroke and are oriented according their stroke
direction (maintains a unidirectional movement vector).
• (Optional) Using Project Continuous Mfg after manufacturing feature creation. You can
also create equal distant locations.
o Equal Distance Spacing — The system places the projected locations according to the
following parameters:
■ Start Offset — The offset distance from the beginning of the manufacturing feature to
the first projected location.
■ End Offset — The offset distance from the last projected location to the end of the
■ Traverse distance — The distance between projected locations.
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Using Continuous Process Generator for painting
1. From the ribbon choose Process tab→Continuous group→ Continuous Process

Generator
2. In the Continuous Process Generator dialog box for Process, select Coverage pattern.
3. Select the geometry to be painted, start/end points, spacing, and strokes.
4. Setup the resulting operation including the name, associated robot, tool, and parent operation.
5. Setup the resulting manufacturing feature including the type and parent folder for the related
.COJT.
6. (Optional) Setup the resulting location distribution (manufacturing feature projection parameters).
In most cases, it is recommended to do the projection now. However, if you want the projection
to create locations with equal distant spacing, you have to project using Project continuous
Mfg instead.
7. Click OK.

default to Z.
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Creating appropriate brush geometry

Defining a component as a paint gun
Earlier in the training, you defined a component as a Paint Gun using the Tool Definition
command. You can now mount this gun on a robot and assign it as the Tool of an operation. As
part of this process, you created geometry to represent the paint nozzle, a paint gun tip frame,
and a tcp frame.
• paint gun tip frame — This frame is located at the paint gun nozzle and is shown yellow
in this picture.
• tcp frame — The frame that becomes the robot's TCPF after the gun is mounted and is shown
red in this picture. This frame moves to the paint locations on the part surface.
However, you do not see any paint coverage when you simulate this gun. In order to simulate paint
coverage, you must add a geometry to the paint gun to represent the brush (paint fan).
Defining a brush (paint fan) for a paint gun
Many shapes are possible for the brush, however a typical shape is a cone. A cone representing the
brush (paint fan) has its apex at the paint gun tip frame. The length of the cone is the effective
depth, also known as the over spray. This is the distance from the gun nozzle in which parts can
be effectively painted. The effective depth must be greater than the distance from the nozzle to
the tcp frame.
During simulation, the tcp frame of the paint gun is superimposed atop locations on the
surface being painted.
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Use the formula of similar triangles to calculate the radius of the cone to be created to represent
the brush:
distance / effective depth = cone radius at the distance / cone radius at the effective depth
For example, you have a distance of 300 mm, an effective depth of 350 mm, and a cone radius
at the distance of 25 mm.
So, you should create a cone to represent the brush that has a height of 350 mm and a radius of
29.17 mm. This cone geometry can be placed in the paint gun component.
Activities
In the Creating and projecting paint manufacturing features section, do the following activities:
• Creating and projecting paint manufacturing features for the whitehouse part
Modifying paint continuous manufacturing features
Purpose
In this topic, you learn how to use paint continuous manufacturing feature related tools.
Objectives
• Use seam modification tools
• Use paint continuous manufacturing feature modification tools.
• Use paint robot tracking tools.
• Edit the path to set where to turn the painting of the part on and off.
Do I do this?
Using the Location Manipulator
You use Location Manipulator to adjust the positions of via, weld, and seam locations. It is
useful when you wish to adjust a number of locations together, even if they are of different types.
• The Location Manipulator can show a different user interface, depending on what is
selected before it is opened:
o Selecting a single location displays the Location Manipulation dialog box:
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o Selecting multiple locations or a seam displays the Multiple Locations Manipulation dialog
box:
• When multiple locations or a seam are selected, the Status column in the Locations list displays
one of the following statuses for each location:
o — The system has moved the location according to the instruction.
o — The system has not moved the location. It remains in its original position. This can
only occur when Limit locations manipulation according to options is checked.
o — The system has moved the location as far as possible but a system limitation prevents
full implementation of the instruction. This can only occur when Rotate to maximum
allowed limitation is checked.
• This dialog box contains a toolbar with these commands:
o Reset Absolute Location — Resets the absolute locations of the selected locations to
their rotation and translation values as when they were projected.
o Snap to Maximum Allowed — If locations have exceeded their maximum values, this
function sets the exceeded value to its maximum allowed value.
o Flip Locations — You use it to flip locations on a surface 180 degrees around their
approach axes. The approach axis is defined in the Options dialog. Alternatively, you can flip
weld locations on solids and specify the parts that are included in the flip.
o Show Location Limits in Graphic Viewer — Display a cone-shaped icon in the Graphic
Viewer representing the allowed deviation limits for the location.
Using Insert Location Inside Seam
You use Insert Location Inside Seam — located on the Process tab of the ribbon, you use
it to add seam locations to seam operations. It is available when the selection is empty or when a
continuous location is selected. This command is useful for fine-tuning paths and debugging.
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• Add new location — You can add the new location before or after the selected location in the
sequence, or automatically place the new location in the correct position on the path.
• Position — Also the position can be determined by selecting a point on the seam, entering the
distance to the a selected location, or the percentage between the selected location and the next
location (before or after).
Using Split Seam Operation
Split Seam Operation — located on the Process tab of the ribbon, you use this command to
split a robotic seam operation into two separate operations. If, for example, there are reachability or
accessibility issues for an operation’s assigned robot, you can split the problematic operation into two
separate operations and assign each operation to a different robot. You can only split operations
containing three or more locations.
Using the Teach Pendant to start/stop painting
The Teach Pendant command is used to add attributes to locations in a path. These attributes
change the simulation in Process Simulate and can be downloaded to the real robot. Attributes can
be specific to a robot controller language or be default controller commands. Default controller
commands can be simulated, but download commented out.
1. Select a location or operation with a robot associated to it.
2. From the ribbon, choose Robot tab→OLP group→Teach Pendant .
3. Click Add, choose Standard Commands→Paint, and select a paint command such as
#ChangeBrush , #OpenPaintGun , or #ClosePaintGun .
Paint trigger tools
Paint triggers are another technique to turn on and off painting (instead of using OLP commands in
the Teach Pendant). They are graphical and cannot be downloaded.
These commands are located on the Process tab of the ribbon:
• Create Paint Trigger — you use this command to create a trigger which specifies where a
Paint gun begins or ends its painting operation.
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o Type is either: Open Paint Gun, Change Brush, or Close Paint Gun.
• Edit Paint Trigger — you use this command to edit existing paint triggers. For example, you
can select a different parent location for the paint trigger or edit its name.
Additional (paint) robot tracking tools (discussion)

Overview of Robot Tracking Tools:
You must customize the ribbon and add these two commands before you can use them
using Customize Quick Access Toolbar .
• Robot Tracking Mode On/Off — Turns robot tracking mode on or off.
You can define a robot line tracking mechanism to enable simulated robots to track
objects moving on a conveyor. This can be used, for example, when simulating the
painting of parts. For event-based simulations only. Not covered in this course.
• Robot Tracking Viewer — enables you to define robot-frame tracking sets. After enabling
robot tracking mode, Process Simulate reports when the robot is able to reach the frame during a
simulation and when it cannot. Additionally, in the Graphic Viewer, you can see the robot jump to
the frame. For example, if a robot paints a car door while another robot is opening the same door,
you can use the Robot Tracking Viewer to verify that the painting robot is able to reach a selected
frame on the door at all times during the door opening operation. The Robot Tracking Viewer
also automatically displays the object to which the reference frame is attached. Tracking sets are
considered engineering data and Process Simulate saves them for future sessions.
To perform robot frame tracking:
1. Choose Robot Tracking Viewer .
2. In the Robot Tracking Viewer, click New Robot Tracking Set to create a new robot tracking
set.
3. In the New Tracking Set dialog box, click in the Robot box and select the robot to perform tracking.
4. In the New Tracking Set dialog box, click in the Reference Frame box and select a frame for the
robot to track.
Process Simulate automatically fills the Tracked Object box with the name of the
object to which the Reference Frame is currently attached, if it exists.
5. Optionally, click in the Tracked Object box and select an object (to which the Reference Frame
is not attached).
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Process Simulate prompts you to remove the current attachment and attach the
Reference Frame to the object you selected. Click Yes if you wish to proceed. If you
click No, the Reference Frame is not attached to the Tracked Object. In this case,
the robot tracks the Reference Frame but moving the Tracked Object does not cause
the frame to move and the robot remains stationary.
6. Click OK. The new tracking set is displayed in the Robot Tracking Viewer.
If the Reference Frame is not attached to the Tracked Object, the Robot Tracking
Viewer displays the icon and the following tooltip:
7. Optionally create more tracking sets in the Robot Tracking Viewer.
You can configure tracking sets for multiple robots to track multiple frames or the
same frame.
8. Optionally, do either of the following:
• Choose a tracking set and click Edit Robot Tracking Set to edit it. The Edit Tracking
Set dialog box appears.
Edit any of the tracking set parameters and click OK.
• Choose a tracking set and click Delete Robot Tracking Set to delete it. The selected
tracking set is removed from the Robot Tracking Viewer.
9. In the left-hand column of the Robot Tracking Viewer, check the tracking sets you wish to activate
and clear those you wish to turn off.
10. Click Robot Tracking Mode On/Off to toggle the robot tracking mode to On. Click it again to
toggle the robot tracking mode to Off.
When the Tracked Object moves, Process Simulate calculates (using robot inverse
calculation) whether the robot can reach the Reference Frame. If the robot can reach
the Reference Frame, the robot moves its TCPF to the Reference Frame and moves
together with the frame. Process Simulate continues to calculate the robot’s reach and
when the frame moves out of the robot’s reach, the robot stops moving and remains
where it is. Additionally, whenever the robot can reach the frame, the Robot Tracking
Viewer displays Yes in its Reach column, otherwise, it displays No.
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• Typically, the Reference Frame is attached to the Tracked Object. Therefore, it is

sufficient to move the Tracked Object to observe robot frame tracking. If, however, the
frame is not attached to the Tracked Object, moving the Tracked Object does not
cause robot frame tracking — it is necessary to move the Reference Frame.
• Any Process Simulate action that moves the Tracked Object (assuming the Reference
Frame is attached) causes robot frame tracking. For example, running a simulation or
placement commands.
• Robot Tracking Mode On/Off — it can enable/disable the robot frame tracking
when the Robot Tracking Viewer is closed. This is sufficient to view a robot tracking a
frame in the Graphic Viewer. However, if you wish to view visual cues (Yes or No) or
make changes to tracking sets, you must launch the Robot Tracking Viewer.
• Tracking sets are considered engineering data and Process Simulate saves them
for future sessions
Activities
In the Simulating paint coverage and more section, do the following activities:
• Simulating paint coverage
Review questions
Question
Add Location After Manipulate Location Insert Location Inside Seam Split Seam Operation Location
Manipulator
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Simulating paint coverage and more

Purpose
In this lesson, you learn how to simulate and manage paint coverage.
Objectives

• Understand the process to simulate and manage paint coverage simulation.
• Use the Teach Pendant to start/stop painting.
• Perform paint coverage simulation and set paint coverage settings.
Do I use this?
Overview of the paint coverage simulation process

You can configure continuous operations for painting parts or components. The following is a typical
workflow for performing coverage:
1. Add OLP commands to stop/start painting using the Teach Pendant command.
2. Activate Cover During Simulation .
3. Play the simulation of the continuous paint operation.
4. To simulate again, use Paint Coverage Settings to delete the mesh.
Simulation of paint coverage
The Cover During Simulation command turns on and off the calculation of paint coverage
during simulation.
Typically, you run the continuous paint operation without applying paint while building the operation
to optimize performance and to prevent unwanted coverage. When the operation is ready, you can
activate Process tab→Paint and Coverage group→Cover During Simulation to show paint
coverage during simulation.
Coverage on concave surfaces is calculated accurately, but might not be displayed

accurately in the Graphic Viewer.
Paint coverage settings
The Paint Coverage Settings command is used to select paint options, such as which paint
objects to display.
From the ribbon, choose Process tab→Paint and Coverage group→Paint/Coverage Settings .
The Paint & Coverage Settings dialog box appears.
• For simulations with objects that are hidden by other objects and when using a long paint brush
fan (which is desirable for covering uneven surfaces), it is possible that coverage is also applied
to the mesh of the hidden/lower surface, even though it is "hidden" by the top object.
To prevent this, select the Ignore hidden surfaces check box.
• You can configure the following Display options:
o Selecting the Meshes check box highlights the meshes while the Paint/Coverage Settings
dialog box is open.
o Selecting theCoverage check box displays the paint coverage, if already calculated.
Deselect this check box to improve visibility of selected entities.
o Selecting theBrush check box displays a ghost paint brush during simulation.
• The Stroke Map displays the colors used to denote the different accumulated paint layers during
the simulation.
You can select any box and change its color.
• To remove the accumulated coverage, for example if there are too many layers, click Delete
coverage.
Activities
In the Simulating paint coverage and more section, do the following activities:
• Simulating paint coverage
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Summary
• How to create continuous manufacturing features.
• How to project continuous MFG features to create continuous manufacturing robotic paths.
• How to use continuous manufacturing features.
• Making changes to the path associated to the continuous manufacturing operation.
Lesson 16: Other continuous feature applications
Purpose
To provide an introduction to creating other continuous feature paths in Process Simulate.
Objectives

• How to project continuous manufacturing features to create continuous manufacturing robotic

paths.
Lesson
Lesson 16:16:OtherOther continuous
continuous feature
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Overview of other continuous robotic applications

Purpose
In this topic, you learn about various other robotic applications besides arc-welding and painting.
Any type of robotic application involving the robot following the contour of the part
is considered continuous in Process Simulate. There are many examples such as
arc-welding, painting, grinding, deburring, hemming, gluing, laser cutting, water jet, sealing,
riveting and drilling.
Objectives
• Gain a basic understanding of other continuous robotic applications.
More continuous robotic applications
Gluing/Dispensing/Sealing
For example, a bead of glue is applied to the part from a dispenser. There are two common
scenarios: the dispenser is mounted on the robot, or the robot grips the part and moves it along
an external glue dispenser.
This manufacturing process could be represented as a Continuous Mfg , SealContinuousMfg

, or a GlueContinuousMfg .
Grinding/Deburring/Material Removal/Polishing
For grinding/deburring, various tools are used to smooth the edges of metal parts. There are two
common scenarios: the tool is mounted on the robot, or the robot grips the part and moves it along an
external grinding/deburring machines. The first scenario may also include a tool changer allowing the
robot to switch the mounted tool between various grinding and deburring tools.
Other continuous feature applications
This manufacturing process could be represented as a Continuous Mfg .
Waterjet
A way of cutting parts with a mixture of high pressure water and abrasives which is passed through a
small diameter nozzle at very high pressure. The jet travels at a speeds up to 900 m/sec, with
sufficient kinetic energy to cut a wide range of materials including foam, plastic, metal, and stone.
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WaterJetContinuousMfg .
Laser Cutting
(According to www.wikipedia.org) a laser can be used to cut materials, and is typically used for
industrial manufacturing applications. Laser cutting works by directing the output of a high power
laser, by computer, at the material to be cut. The material then either melts, burns, vaporizes away,
or is blown away by a jet of gas, leaving an edge with a high quality surface finish. Industrial laser
cutters are used to cut flat-sheet material as well as structural and piping materials.

LaserCutContinuousMfg .
Laser Welding
(According to www.wikipedia.org) a welding technique used to join multiple pieces of metal through
the use of a laser. The beam provides a concentrated heat source, allowing for narrow, deep welds
and high welding rates.

LaserWeldContinuousMfg .
Roller Hemming
(According to www.wikipedia.org) a technology used to join inner and outer closure panels together
(hoods, doors, tailgates, etc.). The flange of the outer panel is bent over the inner panel in progressive
steps by means of the roller hemming head.

RollerHemmingContinuousMfg .
Do I do this?
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Creating other types of continuous manufacturing features

Purpose
In this topic, you learn how to use additional general continuous manufacturing feature creation tools.
Objectives

• Use general continuous manufacturing feature creation tools.
Do I do this?

For Continuous Manufacturing Features:
• Project Continuous Mfg Features — Found on the Process tab of the ribbon, this
command creates a Continuous Robotic Operation containing a sequence of location operations.
You learn about continuous manufacturing features in more detail in a later topic in
this course.
This command produces one or many location operations for each Manufacturing feature. Each
location operation contains the position and orientation of the robot TCP at the manufacturing feature.
The orientation of the location operation can be further refined using various tools in Process
Simulate which is described later in class.
Steps to create a continuous feature operations

1. Create a new Continuous Mfg object and assign parts for the robotic process to the Continuous
Mfg.
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Method to create a Continuous Mfg object:

• While modeling an object, select a curve to represent the Continuous Mfg,
choose Create Continuous Mfgs from Curves from the Process tab of
the ribbon, and assign parts.
2. Create a new Continuous Feature Operation and assign the Continuous Mfg to it.
Method to create a Continuous Feature Operation:

• Process Simulate Only Method: From the Operation Tree, choose the desired
parent operation. Choose New Operation →New Continuous Feature
Operation from the Operation tab of the ribbon.
3. Choose Project Continuous Mfg Features
4. Check and modify locations to insure robot reachability.
5. Set motion and process parameters.
6. Simulate and analyze the results.

default to Z.
General continuous manufacturing feature creation tools
Create Continuous Mfg from Curve — Located on the Process tab of the ribbon, you use it to
create a continuous manufacturing feature from any curve in the current study. You can either use an
existing curve, create a new curve, or import a curve into the project from an external CAD program.
After creating a continuous manufacturing feature, you can Project Continuous Mfgs on to
parts.
Common modeling commands used to create manufacturing features

These commands are located in the Process Simulate Modeling→Create 2D sub-menu:
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• Curve on Borders
• Intersection Curve
• Project curve
• Create Isoparametric Curves
• Create Dashed Curves .
You could also model the geometry in another system and import it here.
Activities
In the Creating other types of continuous manufacturing features section, do the following activities:
• Creating debur manufacturing features for the whitehouse part
Projecting other types of continuous manufacturing features

Purpose
In this topic, you learn how to use general weld projection tools.
Objectives
• Use general continuous manufacturing projection tools.
Do I do this?
Projecting general continuous manufacturing features
You use the Project Continuous Mfg , located on the Process tab of the ribbon, to project a
continuous manufacturing feature to create a robotic path on a part.
Before executing Project Continuous Mfg, you specify a continuous robot compound operation.
This command projects the seams that appear in the Operation Tree as children of the specified
continuous robot compound operation.
Projection Parameters area of the Project Continuous Mfgs dialog box:
• Tolerance Based Spacing — The system places the projected locations according to the
o Maximal segment length — The maximum allowed distance between two locations created
when projecting continuous manufacturing features.
o Maximal tolerance — The maximum allowed distance between a location and the curve
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o Optimize locations creation for arc and line segments — When set (this is the default),
this option optimizes manufacturing feature projection on condition that all the locations in
the source manufacturing feature conform to the Arc tolerance and Minimal line length you
define. The system creates a projection using two locations for straight lines, three locations
for arcs, and five locations for circles. When this option is off, the system creates a projection
of consecutive locations, requiring a large amount of computer resources. After completing
the projection, the system sets the motion type of each location according to the segment
detection results for the curve. A location's motion type is determined by the way the robot
approaches the location. For circular curves, the system sets the last two points as circular
motion; for linear curves, the last point is set as linear motion. Locations projected by those
points are set with those motion types.
• Equal Distance Spacing — The system places the projected locations according to the following
parameters:
o Start Offset — The offset distance from the beginning of the manufacturing feature to the
first projected location.
o End Offset — The offset distance from the last projected location to the end of the
o Traverse distance — The distance between projected locations.
• Project on approximation only — Only JTs containing XTBRep (exact geometry) support
projecting on exact geometry. If the part exact geometry is not available in the JT file (for
example, 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. .
• Keep position on curve — If the manufacturing feature is not on the same plane as the part on
which you are projecting it, setting this option ensures that the projected locations remain on the
manufacturing feature. Clearing the option causes the system to project the locations on the part.
Activities
In the Projecting other types of continuous manufacturing section, do the following activities:
• Creating deburring paths (using Project Cont. Mfg)
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Modifying other types of continuous manufacturing features

Purpose
In this topic, you learn how to use several additional continuous manufacturing feature related tools.
Objectives

• Use additional general continuous manufacturing feature modification tools.
Do I do this?
Using the Location Manipulator
You use Location Manipulator to adjust the positions of via, weld, and seam locations. It is
useful when you wish to adjust a number of locations together, even if they are of different types.
• The Location Manipulator can show a different user interface, depending on what is
selected before it is opened:
o Selecting a single location displays the Location Manipulation dialog box:
o Selecting multiple locations or a seam displays the Multiple Locations Manipulation dialog
box:
• When multiple locations or a seam are selected, the Status column in the Locations list displays
one of the following statuses for each location:
o — The system has moved the location according to the instruction.
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o — The system has not moved the location. It remains in its original position. This can
only occur when Limit locations manipulation according to options is checked.
o — The system has moved the location as far as possible but a system limitation prevents
full implementation of the instruction. This can only occur when Rotate to maximum
allowed limitation is checked.
• This dialog box contains a toolbar with these commands:
o Reset Absolute Location — Resets the absolute locations of the selected locations to
their rotation and translation values as when they were projected.
o Snap to Maximum Allowed — If locations have exceeded their maximum values, this
function sets the exceeded value to its maximum allowed value.
o Flip Locations — You use it to flip locations on a surface 180 degrees around their
approach axes. The approach axis is defined in the Options dialog. Alternatively, you can flip
weld locations on solids and specify the parts that are included in the flip.
o Show Location Limits in Graphic Viewer — Display a cone-shaped icon in the Graphic
Viewer representing the allowed deviation limits for the location.
Using Insert Location Inside Seam
You use Insert Location Inside Seam — located on the Process tab of the ribbon, you use
it to add seam locations to seam operations. It is available when the selection is empty or when a
continuous location is selected. This command is useful for fine-tuning paths and debugging.
• Add new location — You can add the new location before or after the selected location in the
sequence, or automatically place the new location in the correct position on the path.
• Position — Also the position can be determined by selecting a point on the seam, entering the
distance to the a selected location, or the percentage between the selected location and the next
location (before or after).
Using Split Seam Operation
Split Seam Operation — located on the Process tab of the ribbon, you use this command to
split a robotic seam operation into two separate operations. If, for example, there are reachability or
accessibility issues for an operation’s assigned robot, you can split the problematic operation into two
separate operations and assign each operation to a different robot. You can only split operations
containing three or more locations.
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Water jet specific commands

Process Simulate can simulate continuous processes that move along a given curve. For example, in
water jet cutting, a water jet gun is mounted on a robot and cuts the specified part along a defined
curve (the macro path). While running the continuous operation, Triggers can be used to turn the
water jet on (just like paint paths). The robot follows the defined curve, and at the end of the path, the
water jet is toggled to Off.
The following continuous macro commands are available from the Process tab→Water Jet group:
• Create Macro — create a rectangular macro, circular macro, or slot macro from a single
location in a continuous operation.
• Edit Macro — Delete or change the macro associated to a continuous operation.
• Display Macros — show or hide macros for a selected continuous operation.
Macro projection visualization is supported only over parts with exact geometry.
Continuous macros can be created under any via location located under a continuous
feature operation.
Continuous macros require customized xml information with macro configuration.
This is nested in the \Tecnomatix\eMPower\Robotics\OLP\[Robot
Vendor]\MotionConfiguration folder.
If the selected operation has an assigned robot with a controller that supports motion
types, the motion type is set automatically and displayed in Process Type in the Path
Editor. Otherwise, to simulate macros, you must select the correct Process Type in the
Path Editor (the available values are obtained from the customized xml file). Failing this,
the system interprets the macro location as a regular via location.
Currently, continuous macros are only supported by ABB robots running custom controllers.
Activities
In the Modifying other types of continuous manufacturing features section, do the following activities:
• Modifying debur operations and seams
Review questions
Question
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continuous feature
applications
Add Location After Manipulate Location Insert Location Inside Seam Split Seam Operation Location
Manipulator
Summary
• How to project continuous MFG features to create continuous manufacturing robotic paths.
Lesson 17: Final steps for robotic path development
Purpose
To provide an introduction to modifying and optimizing robotic paths in Process Simulate.
This chapter contains alternatives for various activities based on the robotic application
(for example spot-weld, arc-weld, paint, and debur). You do not have time to cover all
the alternatives in this course, however performing one or two should be enough to get
the points across.
Objectives
• How to use several techniques to test the robot’s ability to reach locations in its path.
• Dynamic and static collision detection is discussed.
• Tools that can be used to modify paths so that collisions are avoided.
• Various buttons found on the Path toolbar and Operations menu that can be used to create via
locations.
• Several tools that can be used to modify a location in a path.
• Several tools that can be used to modify a path.
• Additional path (weld operation) creation tools.
• Several techniques to edit location attributes and provides some basic examples of locations
attributes from the Process Simulate default controller.
• How to do multiple robot work balancing using location attributes and Interference Zone.
• How to create swept volumes of an object moving along its path.
• What hard and soft joint limits are and how to set kinematic soft limits.
• Adding some events to your simulation.
• How to use setup and use external axis (joint). For example, a robot on a rail (7th axis) or gantry
is considered an external axis (joint) or a robot on a multi axis gantry system.
• Creating a Sequence of Simulative Operations.
• Procedure required to create a compound operation in Process Simulate.
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Lesson 17:17:FinalFinal
stepssteps for robotic
for robotic path path development
development
• How to create a basic sequence.
• Some other Robotics features.
Final steps for robotic path development
Test robot’s reachability to the locations

Purpose
In this topic, you learn how to use several techniques to test the robot’s ability to reach locations
in its path.
Objectives

• Understand robotic reach basics.
• Use Smart Place.
• Use the Robotics Viewer.
• Jump and move to a location.
• Use the TCP Tracker.
• Measure the length of a TCP track.
Do I do this?
Robotic reach basics

Another constraint you add to the process creation is the reachability of the robot. These steps must
be done before you can test the robot’s reachability:
• Bring robot into the study.
• Mount gun to robot (and define TCPF).
You can use these commands, located on the Robot tab of the ribbon, to check the reachability of
a robot to locations.
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• Method 1: Reach Test (Interactive method)
• Method 2: Smart Place — Static (Jumps to the locations)
Robotic reach test
Reach Test — located on the Robot tab of the ribbon, you can use it to test whether a robot
can reach all selected locations, and to optimize the study layout.
Typically, you should select either the robot or the part (with the locations associated to it
with the Placement Manipulator before opening Reach Test .
You can jump to a location by double-clicking a location in the Reach Test dialog box.
The selected locations are displayed in the Locations box, and a symbol is displayed in the R (reach)
box indicating whether the robot can reach the location. The symbols are as follows:
• The robot can reach the location. The location is colored blue in the Graphic Viewer.
• The robot has partial reachability to the location. The robot reaches the location, but must
rotate its TCPF to match the TCPF of the location.
• The robot has reachability to the location outside its working limits (but within its physical
limits).
• The robot has partial reachability to the location outside its working limits (but within its
physical limits). The robot reaches the location, but must rotate its TCPF to match the TCPF
of the location.
• The robot has full reachability to the location outside its physical limits.
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• The robot has partial reachability to the location outside its physical limits. The robot reaches
the location, but must rotate its TCPF to match the TCPF of the location.
• The robot cannot reach the location at all. The location is colored red in the Graphic Viewer.
Toggling the display of working limits in dialog boxes:
When this check box is selected, joint limit color indications are shown in these windows and dialog
boxes:
• Graphic Viewer
• Weld Distribution Center
• Reach Test
• Robot Viewer
• Joint Jog
• Pie Chart
• Smart Place
To activate it: choose File→Options , click the Motion tab, and select Indicate joint working
limits. Joint working limits can be set as a percentage of the total joint range, or a specific value.
Toggling the use of Location Information in static dialog boxes:
When this check box is selected, simulation information is automatically read from the location or
parent operation while using these static dialog boxes:
Simulation information includes the robot name, the gun, and TCPF on the location or
operation.
• Pie Chart
• Smart Place
• Reach Test
• Optimizing Weld Distribution
Therefore, some simulation information boxes in these dialog boxes are inactive and you are not
able to edit them.
However when this check box is deselected, you can enter simulation information in the simulation
information boxes to get a different result.
To activate it, choose File→Options , click the Motion tab, and select the Use location
information in static applications check box.
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Smart Place
Smart Place — located on the Robot tab of the ribbon, you can use it to calculate placements
within a specified search domain for a robot from which it can superimpose its TCPF on specified
locations. Each such calculated placement for the robot is a solution.
• This command creates grid points representing all possible solutions at the intervals specified.
• The tested grid points in the Search Results are colored to indicate the degree of success. The
Legend can be used to discern the success of placing the robot origin at each grid point and
reaching all the specified locations.
• If you can specified in the Options dialog box to Indicate joint working limits, the Legend
includes an out of working limits. Boxes highlighted on the Search Results that have a light
purple border, are reachable, but are outside the specified acceptable working limits.
• You can use the robot Smart Place command to find optimal locations for robots or fixtures.
If Indicate joint working limits was selected in File→Options , the Smart Place dialog box
looks like this:
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Smart Place modes

It can work in one of the following two modes:
• Robot Placement — You use it to determine the range of points from which a robot can reach a
selected group of weld, seam, and via locations, either fully, partially, or with a collision. This
enables you to position robots optimally.
• Fixture Placement — You use it to determine the range of points from which a selected group of
robots can reach selected fixtures (parts and resources), either fully, partially, or with collision,
while performing their associated operations. This enables you to position fixtures optimally
while maintaining robot reachability.
Robot Viewer
The Robot Viewer — located on the Robot tab of the ribbon.
The Robot Viewer contains the following panels:

• Joint Monitor — It generates and displays a graphical representation of their values at all points
of time in the simulation. The trace for each joint of the selected robot is displayed in a different
color. Each trace is comprised of finite points in time where measurements are taken. The higher
the sampling rate, the more accurate is the trace. See TR45315 Process Simulate Standalone
Robotics Advanced for more information
• Joint Status — It shows the current value for each joint of the selected robot (including external
joints) and their minimum and maximum values at given points in time. Alternatively, you can
display the current joint value as a percentage of the joint range, in which case, the minimum is
shown as 0% and the maximum as 100%.
• Digital Signals — See TR45215 Process Simulate Standalone Cyclic Event Evaluator (CEE)
for more information.
• Analog Signals — See TR45215 Process Simulate Standalone Cyclic Event Evaluator (CEE)
for more information.
• TCPF Speed Monitor — It dsplays a graph of the speed of the robot TCPF. In the Legend area,
you can set the color of the trace. The Statistics area displays the minimum and maximum
speeds of the robot TCPF. SeeTR45315 Process Simulate Standalone Robotics Advanced
for more information
• Joint Speed and Acceleration — It displays graphs of joint speed and acceleration. See for
more information
• Power Consumption — The graph above shows the current Power Consumption of a robot
during simulation in units of kW (kilowatts). See TR45315 Process Simulate Standalone Robotics
Advanced for more information.
Basic Usage:
In the Robot Viewer, choose the down arrow to the right of the Panels button and deselect
everything except Joint Status.
Click Settings to choose either Joint Values or Limits Percentages.
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Jumping and moving to a Location

There are several ways to get a robot to a location:
• Sequence Editor simulation controls
• Jump to Location —located on the Robot tab of the ribbon, you select the robot, then click
the desired location. Click this button again to get out of this “mode”.
• Move to Location — located on the Robot tab of the ribbon, you click a location and then
click this button.
• Jump Assigned Robot — located on the Robot tab of the ribbon, you click a location
and then click this button.
Create and measure a TCP Track
The TCP Tracker command, located on the Robot tab of the ribbon, records the motion
(trajectory) of the robot TCP frame as a curve and stores it as a robot specific TCP_track object.
The track shows as a modeled object in the Object Tree. the track is created for any robot motion
such as during a simulation or using Robot Jog.
The Curve Length command on the Graphic Viewer toolbar can be used to measure the length
of the TCP track and display it as a measurement in the Graphic Viewer.
Activities
In the Test robot’s reachability to the locations section, do the following activities:
Perform either the Spot, Drill/Rivet, Arc, Paint, or Debur activity. Then perform the
rest of the activities with that data.
• Spot — Testing reachability (method 2)
• Drill/Rivet — Testing reachability
• Arc — Testing reachability
• Paint — Testing reachability
• Debur — Testing reachability
• See the robot reachability locations
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Review questions
Question
Auto Placement Smart Reaching Smart Place Reach Test
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Dynamic and static collision detection

Purpose
In this topic, you review Process Simulate collision detection tools that were covered in detail earlier
in this course and learn about the dynamic collision report.
Objectives
• Recall collision basics.
• Recall how to use the Collision Viewer.
• Use the Dynamic Collision Report.
Do I do this?
Collision basics
These tools can temporally change the colors of objects in the Graphic Viewer and the Collision
Viewer.
There are three levels of detection granularity:
• Near Miss — Objects are highlighted in yellow if they come within a predefined clearance
envelope of each other
• Collision Contact — Objects can optionally be highlighted in red if they are touching each other
(or orange if near miss detection is activated).
• Collision Penetration — Objects are highlighted in red if they exceed the allowed penetration
depth with each other.
Collision detection types:

• Dynamic collisions — Collisions that occur during a simulation or while objects are being placed.
• Static collisions — Collisions that are occurring without moving the objects.
Collision options:
When a collision occurs the object’s color is always changed to red in the Graphic Viewer and the
Collision Viewer. Optionally a simulation can be stopped when a collision is detected and/or a sound
is played at regular intervals while in a collision state.
Collision Viewer
The Collision Viewer displays all current occurring collisions, near misses and contacts. It enables
you to define, detect and view collisions in the data currently displayed in the Graphic Viewer, as
well as view collision reports. The Collision Viewer is composed of two panes. The left pane can
be closed or opened by clicking Show/Hide Collision Sets .
To open the Collision Viewer:
• From the ribbon, choose View tab→Screen Layout group→ Viewer→Collision Viewer.
To close the Collision Viewer:

• Click Close in the right-hand corner of the dialog box.
Review of Collision Viewer toolbar:
• New Collision Set
• Remove Collision Set
• Edit Collision Set
• Fast Collision Set
• Emphasize Collision Set
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• Show/Hide Collision Sets
• Collision Options
• Collision Mode On/Off
• Freeze Viewer
• Show/Hide Colliding Contour
• Show Colliding Pair
• Export to Excel
• Show/Hide Contour View
• Filter Collision Results
• Collision Depth
• Color Colliding Objects
• Zoom To selected
Dynamic collision report

The Dynamic Collision Report records all the collisions that occur during simulation of the current
operation, according to the active collision set in the Collision Viewer. It enables you to do all of the
following:
• Jump directly to the time of a specific collision.
• Save the information in the Dynamic Collision Report in an Excel file for collaboration with other
users.
• View a detailed report for the colliding objects in the active collision set or for selected collision
pairs in the Dynamic Collision Report.
• Use the Dynamic Collision Report to display all the collisions in a simulation of an operation in
conjunction with the Sequence Editor and Collision Viewer to display all the current collisions.
Basic usage:
• Setup collision and near miss checking.
• From the Sequence Editor, set a current operation and click Dynamic Collision Report .
• In the Dynamic Collision Report dialog box, click Start Generating Report . Process Simulate
runs a simulation of the current operation and populates the Dynamic Collision Report dialog box.
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Editing location attributes

Purpose
In this topic, you learn several techniques to edit locations containing Process Simulate default
controller attributes.
Objectives

• Know the basic location attributes of the default controller. (You use other robot specific
controllers in the Advanced Robotics training).
• Use the Teach Pendant and Path Editor.
• Use Set Locations Properties in the Path Editor.
• Customize columns in the Path Editor.
• Use the rename tool to change location names.
• Be aware of the Apply Path Template Action command.
Do I do this?
Basic location attributes
The following attributes are for the default controller. More robot specific controllers are available and
are discussed in the TR45315 Process Simulate Standalone Advanced Robotics course.
• Motion Type – Describes how a robot moves to this location.
o Joint (PTP) – Typically causes the robot to move the quickest between locations (usually
resulting in a curved path). This motion type should be used where high speed and low
accuracy of the TCP trajectory is allowed.
o Linear (LIN) – Causes the robot to move straight to this location. This motion type should
be used where high accuracy of the TCP track is required; robot speed may be somewhat
curtailed.
o Circular (CIRC) – Causes the robot to move in an arc through three locations. This motion
type is used when the robot TCP is required to move along a circular arc; most often in
an arc-welding or sealing process.
• Zone – Also sometimes called accuracy, it describes how the robot approaches/arrives at
a location.
o Fine – causes the robot to slow and “arrive” at the location
o Medium and Course — affects how closely the robot needs to get a location before it is
considered “arrived”. These values are somewhere in between Fine and No Decel.
o No Decel – cause the robot to not slow and “approach” the location (However, arrival is
not a requirement).
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• Speed
o Speed for Joint (PTP) motion is measured as a percent of the maximum speed.
o Speed for Linear (PTP) or Circular (CIRC) motion is measured in mm/sec.
• Wait Time is measured in seconds.
• Can define a different Tool Frame (for gun on robot) or Remote TCP Frame (for an external
TCP) for the various location in a path.
More information on Tool Frame and Remote TCP Frame is discussed in the
TR42515 Process Simulate Standalone Advanced Robotics course.
Overview of techniques to edit location attributes

An important part of path development is setting location attributes (motion parameters) such as
Motion type, Zone, Speed, and Wait time.
In this training you use the default controller’s Teach Pendant, which is robot manufacturer
neutral.
You learn some OLP commands later in this course and in the Advanced Robotics training.
The Advanced Robotics training also contains detailed information about all other robot
controllers.
There are several tools to edit location attributes that are described in this lesson:
• Path Editor viewer
• Set Location Properties dialog box (in the Path Editor viewer)
• Teach Pendant dialog box
• Apply Path Template Action dialog box
• Rename Objects Tool dialog box
Path Editor
Path Editor viewer — The attributes of multiple locations are shown in spreadsheet. You customize
the columns (attributes) you want to see in the table based on the controller you are using. You can
do a majority of your path editing in this viewer. You use it to:
• Edit the attributes of one location at a time.
• Edit several locations at a time (based on selection or location type).
• Copy the attributes from one location to several others.
Custom columns in the Path Editor

You can change the columns (location attributes) shown in the Path Editor using the Customize
Columns dialog box. To do this:
• On the Path Editor, click Customize Columns .
• In the Customize Columns dialog box Available columns list, expand into the desired group of
attributes.
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The standard installation only includes the default controller (default controller
attributes). Installing other controllers adds their attributes to the Available columns
list. Your administrator can also add your company specific attributes to this list.
• Choose the attributes you want to see in the Path Editor.
This list of attributes can be saved and loaded for later use using these buttons: Load
Column Set and Save Column Set .
• Click OK.
Quickly set multiple location attributes
Set Location Properties — Use it to copy the attributes from one location to several others or
edit several locations at a time based on selection or location type.
Copy attributes from one location to several others
1. In the Path Editor, select some locations using the Ctrl key that you want to do a bulk attribute
change.
All the selected locations must be assigned to robots using the same controller.
2. Click Set Location Properties .
3. In the Set Locations Properties dialog box, click Obtain from Location to use the properties
of another location.
4. For the Obtain Properties from Location box, select the one with the attributes you want.
5. Select specific attributes to copy or select them all.
6. Push it over to the list at right by clicking .
7. Click Close.
Change the attributes of locations based on location type
1. In the Path Editor, select the path.
2. Click Set Location Properties .
3. Click the down arrow to the right of Location Type Filter and select a type such as Via.
4. In the Common properties area of the dialog box change an attribute such as Motion Type or
Zone.
5. Click Close.
Teach Pendant
Teach Pendant — There is a specific Teach Pendant dialog box for each robot controller (for
example ABB, Fanuc, Kuka, Kawasaki, Yaskawa, etc.). You use it to:
• Edit the attributes of one location at a time.
• Edit several locations at a time (based on selection).
• Copy the attributes from one location to several others.
The command is located on the Robot tab of the ribbon.
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Apply Path Template Action
Apply Path Template Action — You can define operation actions in an XML file and apply the
actions to multiple operations. You can define many actions in the XML template and apply them with
a single click, saving repetitive manual configuration, increasing productivity, and reducing errors.
For example, changing the attributes of all the locations in the path to better match your company
standards with the push of a button. You use it to:
• Modify the attributes and positions of several locations in a path by user defined techniques.
• Add locations to paths by user defined techniques.
This command is located on the Operation tab of the ribbon.
Here are some of the actions that can be performed:
• Perform an action on a location based on its placement in the path (for example all, first, last, etc.)
• Perform an action on a location based on the location type, process type, motion type, or
description.
• Set/remove the location type.
• Add/remove OLP commands.
• Change the location color.
• Change the location position.
• Add locations after other locations.
• Etc.
In this lesson you use an sample path template that was creating for the purpose of this
training course. You learn how to create a template file for the Apply Path Template
Action in the Advanced Robotics course. This tool does not work until you setup the
XML file for it. A sample XML is provided with the course training data. The file is named
RobotSim.xml and is located in the Sample Default Path Template folder
Rename Tool
Rename Objects Tool — You use it to perform bulk renaming any object using rules. Renaming a
large number of objects saves effort and increasing productivity. For example, if you have copied an
operation, you can rename all the duplicate locations with meaningful names in a single action
Located on the Home tab of the ribbon, s.
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Located on the Home tab of the ribbon, the Rename Objects Tool can make batch name
changes for a large number of objects, saving effort and increasing productivity. For example, if you
have copied an operation, you can rename all the duplicate locations with meaningful names in
a single action
Activities
In the Editing location attributes section, do the following activities:
• Editing location attributes
Review questions
Question
Operation Properties Sequence Editor Graphic Viewer Teach Pendant Path Editor
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Introduction to path modification (via locations)

Purpose
In this topic, you learn tools that can be used to modify paths so that collisions are avoided.
This lesson is not for drilling and riveting. In this situation you create waypoints instead of
via locations.
Objectives

• Use basic path modification tools.
Do I do this?
Path modification basics

In this topic, you create via locations in order to clear clamps and create pounce/clear locations. You
modify the path to avoid the collisions found in the previous topic.
These commands are found in the Operation tab of the ribbon:
• Manipulate a location — Allows manipulating a via location with a Manipulator Frame

and the object placed at the location. Must have a location selected first. (Most frequently used
location modification tool)
• Add Location After — A new location is added to the path after the selected location.
The flow object and Manipulator Frame are placed at the new location (superimposed on the
selected location) allowing you to place the new location.
• Add Location Before — A new location is added to the path before the selected location.
The flow object and Manipulator Frame are placed at the new location (superimposed on the
selected location) allowing you to place the new location.
Activities
In the Introduction to path modification (via locations) section, do the following activities:
• Adding start/end and approach/retract via locations in the path
Review questions
Question
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Deleting a location Calling GTAC, customer support Clicking Manipulate Location Clicking Insert
Location After Clicking Insert Location Before
Via location creation tools Location creation tools

Purpose
In this topic, you learn various buttons found on the Path toolbar and Operation menu that can be
used to create via locations. These tools are used to create and modify via locations (which are any
locations not created from a manufacturing feature.)
This lesson is not for drilling and riveting. In this situation you create waypoints instead of
via locations.
Objectives
• Use basic location creation tools.
Do I use this?
Via locations are the primary way to create clearance locations for all robotic applications except
for drilling and riveting. For drilling and riveting, you should use waypoints (and the Waypoint
Viewer) instead.
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Location creation basics

Selecting a path in the Graphic Viewer, or location operation on the Operation Tree, makes certain
commands available on the Operation tab of the ribbon.
Use these commands to add another location to a path:
• Add Location By Pick — Add a location using the mouse. You must have a path/operation
selected first. (Most frequently used location creation tool).
• Add Multiple Locations By Pick — Enter a mode to add multiple locations using the
mouse. You must have a path/operation selected first. (Most frequently used location creation
tool). Choose this command again to exit the location creation mode.
• Add Current Location — Add a location at the current position of the associated object.
You must have the operation set as the current operation.
Use these commands to add another location based on an existing location in a path:
• Add Location After — A new location is added to the robotic path after the selected
location. The TCPF of the robot and Manipulator Frame are placed at the new location
(superimposed on the selected location) allowing you to place the new location.
• Add Location Before — A new location is added to the robotic path before the selected
location. The TCPF of the robot and Manipulator Frame are placed at the new location
(superimposed on the selected location) allowing you to place the new location.
Activities
In the Location creation tools section, do the following activities:
• Creating collisions lists
• Using add location by pick
Review questions
Question
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Display Location Project Continuous Feature Operation Project Arcweld Add Current Location Add
Location After
Location modification commands

Purpose
In this topic, you learn several commands that can be used to modify a location in a path.
Objectives

• Use basic location modification commands.
• Use the Automatic Approach Angle command.
• Modify locations using the Path Editor.
• Perform path segment simulation using the Path Editor.
Via location modification basics

Use these tools to modify an existing location in a path:
• Manipulate location — This is one of the most basic commands. Allows manipulating a
via, weld, or seam location with a Manipulator Frame and the assigned robot tool placed at the
location. You must have a location selected first. (Frequently used location modification tool)
• Pie Chart — Allows manipulating a weld or rivet while considering the robot reachability.
• Automatic Approach Angle — See description below.
• Path Editor and the Teach Pendant. (These tools is discussed in the next topic).
• Like any other entity, a location can also be manipulated with these commands from the Graphic
Viewer toolbar: Placement Manipulator and Relocate .
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Automatic Approach Angle
The Automatic Approach Angle command can be used to rotate several weld or rivet
locations to a collision free approach angle, if one exists.
Automatic Approach Angle functionality:

• Robot — Ability to select robot; the mounted Gun is automatically selected as well
• Pose — Define the pose for collision analysis
• Locations list — Add and remove weld locations to the list of locations
• Apply – rotate all locations to the optimized approach angle
• View a location’s status using the Pie Chart
• Flip a location’s perpendicular by 180 degrees
Modifying locations using the Path Editor

The Path Editor can be used to change the position and orientation of the locations directly.
Add a path: select it and click Add Operation to Editor
Remove a path: select it and click Remove Item from Editor

Specifying which columns are shown in the Path Editor
• On the Path Editor, click Customize Columns .
• In the Customize Columns dialog box in the Available columns list, expand into the desired
group of attributes.
• Select the desired attributes.
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This list of attributes can be saved and loaded for later use using these buttons:
and .
• Click OK.
Path segment simulation
You may wish to concentrate on a specific segment of an operation, for example to optimize or debug
it. In this case, it is time-consuming and superfluous to simulate the operation from the start each
time. You can define the locations of interest as an operation segment. From the Path Editor, select
the sequential locations, and then click Path Segment Simulate .
When simulates a segment, the simulation runs from the first of the selected locations and finishes
at the last selected location.
• Changing the first or last segment locations or deleting them makes the segment
inactive.
• After using the Add Operation to Editor or Remove Item from Editor
commands makes the segment inactive.
• A segment must contain at least one location.
• The locations in a segment must be continuous.
Activities
In the Via location modification tools section, do the following activities:
• Simulating a segment of a path
• (Optional) Using Manipulate Location
• (Optional) Using the Automatic Approach Angle dialog box
• (Optional) Spot — Modify locations according to robot reach (pie chart)
Review questions
Question
Add Location After Add Current Location Delete Manipulate Location
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Path modification tools

Purpose
In this topic, you learn several tools that can be used to modify a path.
Objectives
• Know which features are supported in Process Simulate.
• Use basic path modification tools.
• Use Automatic Path Planner (APP) for robotic paths
• Modify paths using operation properties.
Do I do this?
Path modification tools basics

Use these commands from the Operation tab of the ribbon to modify an existing path:
• Shift Location Back — Shift location by one position towards the front of the path. Must
have a location selected first. (Least used location creation tool).
• Shift Location Forward — Shift location by one position towards the end of the path. Must
have a location selected first. (Least used location creation tool).
• Reverse Operation — Changes the order of the locations in the path to be the reverse. Must
have a path/operation selected first.
• Mirror operation — Creates a second path whose weld locations are reflected about a plane.
• Copy Location Orientation — Changes the orientation of the selected locations to match a
reference location. Uses one reference location and several target locations (For via locations)
• Interpolate Locations Orientation — Changes the orientation of the selected locations by

interpolating their approach vectors between reference locations. Uses two reference location
and several target locations (For via locations)
• Operation Properties — Allows displaying and modifying various properties of an operation
• →Flip Locations on Surface
• Align Locations (For weld locations)
Use these commands from the Process tab of the ribbon to modify an existing path:
• Duplicate Weld Operation — Creates a new weld operation with a similar weld definition to
the previous one. Covered in a later topic.
Use these commands from other parts of the software to modify an existing path:
• Sequence Editor — Drag and drop the operations into the desired order.
• Reorder by Links — changes the hierarchy (or display order in the tree) of operations to match
the sequence of operations. (Found by right-clicking in the Sequence Editor).
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Automatic Path Planner (APP) for robot paths
The Automatic Path Planner (APP), located in the Operation tab of the ribbon, is used to
generate collision free paths. The Automatic Path Planner algorithm works by dividing operations into
pairs of locations. For each pair, it first plans a collision-free path and then optimizes the planned path
to be a smooth, collision-free path.
The input to the APP is a simulative operation or a segment of a simulative operation (object flow
or robotic). The output of the APP is a collision free operation.
Automatic Path Planner is separate add-on license.
Automatic Path Planner may add or delete via locations while calculating collision-free
operation paths.
Setting the basic parameters:

• Fixed — Check this box to designate a location as mandatory. While calculating a collision-free
path, Automatic Path Planner deletes the optional via locations (and replaces them with new via
locations) but retains mandatory ones.
• Paths & Locations — List of sequential location from the same operation.
• Set Segments — By default, Automatic Path Planner runs on complete operations. However,
you can select specific segments (sets of two or more locations) on which to run Automatic Path
Planner, if, for example, you wish to investigate a specific part of a path. In the Automatic Path
Planner dialog box, select and right-click the desired locations.
Setting the advanced parameters:

• Calculation — The number of path optimization iterations that Automatic Path Planner performs.
Setting the slider for higher precision causes Automatic Path Planner to run more iterations and
more time is required to complete its calculations.
• Clearance — The allowed distance between the moving object and the colliding objects. Derived
from the Near Miss value of the active collision list.
• Dynamic Penetration — The number of path optimization iterations that Automatic Path Planner
performs. Setting the slider for higher precision causes Automatic Path Planner to run more
iterations and more time is required to complete its calculations.
• Ignore colliding fixed locations — If a segment is invalid due to a collision, Automatic Path
Planner calculates a path that includes the colliding locations. For colliding locations, the algorithm
finds the closest collision-free location and calculates a path from that collision-free location.
All the Automatic Path Planner options are saved for the next session of Process
Simulate.
How it works:
The APP goes through two iterations. The first iteration identifies problem areas in the path. The
second iteration deletes the optional locations and fixes the path (adding locations as needed).
Tips and techniques:
• The APP module utilizes a KINEO algorithm. There is a specific license that needs to be installed
in order to allow the use of the APP module.
KINEO is a Siemens PLM Software component for advanced collision detection and
clearance validation.
• The APP does not fix existing flow operation locations that are in a collision status.
• Since the last location is usually in collision (assembly position), it should be executed with an
additional via location that is free of collision.
Automatic Path Planner (APP) robot settings

Robotics Specific Settings
Optimization is an iterative process and may be performed for robotic operations either by:
• Cycle time (Find the quickest path) — The goal is to use time optimization when planning paths.
Select one of the following:
o Zone assignment — Attempts to shorten the cycle time of already collision-free paths
by assigning zones of varying size to the locations. It does not add, delete or manipulate
a path's locations. The zone assignment process typically runs much faster than Full
optimization and consumes less system resources.
o Full — Plans a collision-free path and optimizes the path cycle time by adding, removing and
manipulating locations and by assigning zones of various sizes.
This optimization process executes many simulations in the background. This process may
be time-consuming.
• Joint Travel (Find the shorted path) — The goal is to minimize joint travel when planning paths.
From the Qualityoptimization setting, select either Precise (adds more locations for higher
precision) or Quick (less precise because it uses fewer locations, but faster performance). This is
only displayed when weld operations are selected in the Automatic Path Planner dialog box.
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When activating this option, the system reduces the length of the path. It adds more
intermediate locations in order to fit the shape of the obstacles.
The Automatic Path Planner assigns zones of varying size to the locations in the path and then
runs a simulation (in the background). The robot is required to pass through the location zones
but is not necessarily expected to arrive at the exact location. Automatic Path Planner receives
collision feedback from the simulation. If there are collisions, Automatic Path Planner allocates
smaller zones and if not, it allocates larger zones.
• Robot Settings
o Joint Weights — This causes Automatic Path Planner to allocate higher priority to moving
joints with a higher relative weight. For example, when a workflow necessitates accessing
weld points in a crowded environment, you can assign a higher relative weight to a robot joint
that rotates the weld gun. This causes the Automatic Path Planner to select it over a joint
with a lower relative weight that moves the robot arm. The resulting path is more likely to
avoid collisions in a restricted area.
o Zones — you can specify which zones (accuracy) to use. They should be listed from
smallest to largest.
Since simulations execute in the background, the duration of Cycle Time

optimization is typically longer compared to Joint Travel optimization.
Modifying paths using operation properties

From either the Sequence Editor or the Operation Tree right-click the flow operation (path) and
choose Operation Properties .
The General tab of the Properties dialog box can be used to change the Name of the operation
and type a Comment.
Activities
In the Path modification tools section, do the following activities:
• (Instructor Demo) Using Copy Location Orientation
• (Instructor Demo) Using Interpolate Locations Orientation
• (Optional) Mini putting it all together
• (Instructor Demo) Using Reverse Operation
• (Optional) Reordering locations
• Spot — Using Automatic Path Planner for robot paths
Review questions
Question
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Create a new collision free path from scratch in Process Simulate. Control your car as you drive
through grid lock traffic. Automatically plan your way through a training course Modify an existing
path in Process Simulate and make it collision free.
Additional path creation tools

Purpose
In this topic, you learn additional path (robotic operation) creation tools.
Objectives
• Use the Duplicate Weld Operation command.
• Use the Replicate Arc Seam Operation command.
• Use the create Mirror operation command.
Overview of path creation tools
Spot Weld/Drill/Rivet Paths

There are several ways to create a new (robotic path) spot-weld operation, including:
• Create a new spot-weld operation, directly.
o From the ribbon, choose Operation tab→Create Operation group→New Operation
→New Weld Operation , associate spot-weld manufacturing features to it, and

project.
• To mirror an existing operation:
From the ribbon, choose Operation tab→Edit Path group→Mirror operation .
Continuous Feature Paths

There are several ways to create a new (robotic path) continuous feature operation, including:
• Create a new continuous feature operation, directly.
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o From the ribbon, choose Operation tab→Create Operation group→New Operation
→New Continuous Feature Operation , associate continuous manufacturing

features to it, and project.
• Duplicate an existing seam operation.

o From the ribbon, choose Operation tab→Continuous Edit Path group→Replicate Seam
Operation .
This tool only works with Continuous Feature Operations (not weld
operations).
Replicate an arc seam operation
1. Select a seam created using Project Arc Seam or Replicate Seam Operation in the
Graphic Viewer or Operation Tree.
2. From the ribbon, choose Operation tab→Continuous Edit Path group→Replicate Seam
Operation .
The Replicate Arc Seam Operation dialog box appears. The selected operation is
listed in Source operation and its Side is populated accordingly.
You can change your selection for Source operation by selecting another operation. If
you select a continuous operation that is not an arc seam operation, the dialog box
changes to the Replicate Continuous Seam Operation dialog box.
3. Select the Side option in the Target area.
4. In the Graphic Viewer, select a component on which to project the mfg feature. This component
acts as the "side wall" during projection. The command creates new mfg features and a new
seam operation and locations.
5. Choose Replicate.
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Replicate a continuous seam operation
1. Select a seam created using Project Continuous Mfg Features or Replicate Seam
Operation in the Graphic Viewer or Operation Tree.
2. From the ribbon, choose Operation tab→Continuous Edit Path group→Replicate Seam
Operation .
3. In the Target area, configure the following:
• For To frame, select the target frame.
• To assign the new seam to a part, select one of the following in the Assignment list:
o Same parts or faces - The new seam operation, its locations and its new mfg feature
are assigned to the same part as the source seam operation.
o No parts or faces - No assignment is made. If you wish to use the new seam as a
source seam for replication, the Replicate Continuous Seam Operation command
prompts you to make a manual assignment before launching.
o Selected parts - The new seam operation, its locations and its new mfg feature are
assigned to the part you select.
The Graphic Viewer displays the new frame in red and a yellow arrow
representing the replication vector starting at the source frame and ending at
the new target frame.
4. Set the number of desired Replications.
In the following example, Replications is set to 3; the source seam (red) is replicated
three times (black).
5. Choose Replicate.
The new seam operation is identical to the source and its name is that of the source
with a numerical enumerator suffix. All the locations of the source seam operation
are replicated in the new seam operation with the same names. For each location,
all configured parameters (robotic configuration, OLP commands, comments, etc.)
are preserved.
After replication, the Replicate Continuous Seam Operation dialog box remains open,
the source definitions remain unchanged, and the number of replications is reset to 1.
Activities
In the Additional path creation tools section, do the following activities:
• Arc/Paint/Debur — (Instructor Demo) Using Replicate Seam Operation
• Spot/Drill/Rivet — (Instructor Demo) Using Duplicate Weld Operation
• Spot/Drill/Rivet — Using Mirror
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Review questions
Question
TRUE FALSE
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Introduction to adding OLP commands to locations

Purpose
In this topic, you learn how to perform various tasks using OLP commands on locations of a robotic
simulative operation. In this lesson you only get an initial exposure to this ability. In the TR45315
Process Simulate Standalone Advanced Robotics course you fully cover this topic.
Objectives

• Drive devices to predefined poses using an OLP command on a location.
Steps for driving devices

• Define some poses for the destination mechanism, if not already defined
• Select the robotic path to add the OLP commands to
• Open the Teach Pendant
• Enter the device to drive and a state to drive it to
Activities
In the Introduction to adding OLP commands to locations section, do the following activity:
• Driving devices and waiting until a device is driven to move
Multiple robot simulation

Purpose
In this topic, you learn how to do multiple robot simulation.
In this course you learn how to create a simulation in standard mode. In the TR45115
Process Simulate Standalone Intermediate Robotics course you learn now to do work
balancing using location signals to setup robot interference zone.
Objectives

• Add a another robot and path to create a two robot simulation.
Activities
In the Multiple robot simulation section, do the following activities:
• Adding a second robot
• Two robot simulation
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Working with hard and soft limits
Purpose
In this topic, you learn what hard and soft joint limits are and how to set kinematic soft limits.
Objectives
• Understand the difference between hard and soft limits.
• Setup and use soft limits on a robot.
Hard limits
• Set the range from infinite motion to the correct range for that robot
• Set by the manufacturer of the robot
• Controlled by the parameters.e file or other kinematic joint limits
• Defined when the kinematics for the object is modeled in Process Simulate.
• Defined for the robot prototype (while modeling the robot, use the Kinematic Editor).
Soft limits
• Farther restrict the hard limit range of motion
• Used to avoid robot collisions with stationary objects in the study
• Set for a certain robot instance
• The default soft limits are the same as the hard limits
• Set soft limits using Joint Jog .
• To remove soft limits click Reset All Soft Limits from the Joint Jog dialog box
In Process Simulate, hard limits are what is set during modeling of the prototype, whereas
soft limits are set on an instance of the robot in the study.
On most 6 axis robots, joint 3 (which is dependent on joint 2) has a variable joint limit
and cannot have soft limits applied to it.
Activities
In the Working with hard and soft limits section, do the following activity:
• (Optional) Avoiding collisions with stationary objects
Review questions
Question1
Question2
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While not Modeling using the Joint Jog dialog box. In the Path Editor. While Modeling using the
Kinematic Editor dialog box. While not Modeling using the Joint Jog dialog box. In the Path Editor.
While Modeling using the Kinematic Editor dialog box.
Robotic swept volumes and interference zones

Purpose
In this topic, you learn how to create swept volumes of a robot moving along its path.
Objectives
• Create swept volumes.
• Create Process Simulate interference volumes.
• Create Process Simulate inference zones.
Process Simulate swept volumes
• The Swept Volume command, on the Robot tab of the ribbon, creates an object to represent
the robot operating space.
• The swept volume can be used to help position robots in optimal locations, especially when
robots participate in a single process and work on the same parts.
• Users can list multiple simulative operations in this command to produce multiple swept volume
objects.
• Can consider simulation events
• Can support both time-based (standard mode) and event-based simulation (line simulation mode)
You can create swept volumes in line simulation mode, and include resources and
dynamic part appearances. Swept volumes include any visible appearance that does
not change its visibility status during the simulation and that was not generated during
swept volume creation. Line simulation mode is covered in the TR45215 Process
Simulate Standalone Intermediate Robotics (CEE) course.
• The resulting objects are shown in the Volumes folder of the Object Tree.
Swept Volume Precision

Process Simulate supports a swept volume accuracy of up to 2 mm. However, users should be
aware that increasing accuracy to a low maximum error level (less than 10 mm) is likely to slow
down Swept Volume creation.
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When creating swept volumes with very high accuracy (very low maximum error), it is
recommended to change the setting of the computer paging file which is used when
accumulated memory consumption of all processes exceeds the RAM resources.
The operating system supports an initial paging file size, which it can enlarge or shrink on
demand.
It seems that the attempt to enlarge the process makes the computer unresponsive. It is
better to preserve a larger size, and disable the enlarging of the paging file by setting
a maximum size equal to the initial size.
It is recommended to set paging file size to 2X the computer RAM.
Process Simulate interference volumes
Robot path interference volumes
There are several commands in this category including the Interference Volume , Automatic
Interference Volume Creation , and the Interference Volume Query .
Learn More About the Interference Volume

An interference volume is the common volume of two intersecting swept volumes and is created
using the Interference Volume command.
You cannot make an interference volume of another interference volume.
Capabilities
• Represents the interference volume using a physical 3D volume.
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• The interference volume is a persistent object stored as a JT file.
• The Relation Viewer displays the relation between the origin operations and the interference
volume.
• Viewing and examining this object simplifies complex objects violation scenarios, enhances the
collision detection capabilities and enables a faster solution of the problem.
Learn more about automatic interference volume creation
The Swept Volume and Interference Volume commands can be time-consuming, and
due to the lack of direct relationships between a robot, its swept volumes, and its interference
volumes, the output may be difficult to analyze. The Automatic Interference Volume Creation
command accepts robotic operations and programs, creates swept volumes for these entities, and
creates interference volumes where swept volumes deriving from separate robots overlap each other.
The command then calculates the last location of the operation before entering the interference
volume and the first location after exiting the interference volume. These are the entry and exit
locations and the system marks them with OLP comments last location before the interference
volume and first location after interference volume.
Additionally, the query function provides tools to view the different relationships between the robot, its
swept volumes, and its interference volumes.
Typically, since Automatic Interference Volume Creation runs for an extended period of time, you
can invoke the command at the end of a work day and examine the results the next morning.
The Automatic Interference Volume Creation command:

• Does not add any safety clearance onto the swept volumes it creates. If this is
important for your analysis, use the Swept Volume and Interference Volume
commands.
• Resets all robotic operations before creating swept volumes. If you want to avoid this,
create a robotic program, and edit it accordingly.
• Stores simulation errors and warnings in a log file.
Learn more about the interference volume query
To query the interference volumes, choose Interference Volume Query and add the desired
interference volumes to the list.
The root of the query is the selected interference volume. Its name is a composite of the names of its
child swept volumes (in this example, IV_SV_R1_MH_W_Weld_Op1_SV_R2_MH_W_Weld_Op2).
Nested under each interference volume are the swept volumes whose overlap created the
interference volume. Nested under each swept volume is the robot and its operation/program whose
simulation created the swept volume. Nested under each operation, are the names of the entry
and exit locations calculated by the command.
IV is an abbreviation for interference volume and SV is an abbreviation for swept volume.
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• After adding interference volumes, the Interference Volume Query dialog box
adds notes to the display in the Graphic Viewer. The notes remain as long as the
interferences volumes are listed in the query and the query remains open.
• If you add an interference volume calculated by Swept Volume (and not by

Automatic Interference Volume Creation ), the query displays all the above
information excepting the entry and exit locations - these are unknown as long as
no simulation was run.
Click to highlight the query results in the Graphic Viewer.
For the interference volume in scope, the system colors the interference volume in red, the first swept
volume (and its robot, operation, and notes) in yellow, and the second swept volume (and its robot,
operation, and notes) in blue. All the other interference volumes are grayed out.
Process Simulate inference zones
The Interference Zone command can only be run with Weld Operations and
cannot be run with Pick and Place Operations .
• To open the command: From the ribbon, choose Robotics tab→Volumes group→Interference
Zone .
• An interference zone is the zone common to a weld operation and the swept volume previously
created from another robotic operation. This command can be used to analyze the robot safety
space for an area of a manufacturing facility.
• The command creates the interference zone by simulating a robotic operation and comparing it
with a swept volume object.
• Where the simulation results in a collision between the swept volume object and the robotic
operation, the command creates interference zones.
• The interference zone can be used to detect and visualize collisions that may occur during
the execution of robotic operations.
• The interference zone is detected when any object attached to the robot collides with the swept
volume or any attached object which is visible.
Use create 2D outline

When an industrial manufacturer needs to replicate a plant or part of it to another location, accuracy
in layout planning is a key factor. Layout planning applications use 2D contours "flattened" from the
3D data at the existing factory, including parts, resources, swept volumes, any objects with visual 3D
representation.
The Create 2D Outline command, on the Modeling tab of the ribbon, is used to select all relevant
objects and creates contours for each object on the plane you designate. This can be useful for
calculating the floor space required for an object (XY plane) or the height it reaches (XZ or YZ planes).
• The command is active when at least one object is in modeling scope.
• The Modeling scope box, on the Modeling tab of the ribbon, contains the currently modeled
part. However, you can change to any other modeled part. The new 2D contours are created in
the scope of this part.
• From any of the open viewers, select one or more objects for which to create 2D contours.
Any pre-selected objects are automatically displayed in the Objects list of the dialog. With
nothing selected, the dialog opens with an empty list. After opening the dialog, you can add or
remove objects.
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• You can select a plane on which to project the 2D contour. By default, the command projects
the outline on the floor (XY plane), but you can click one of the other options to change the
projection plane. The system draws the plane to enable you to see its area and angle before
you create the contour.
Activities
In the Robotic swept volumes and interference zones section, do the following activities:
• Using swept volumes
• Using inference zones
Adding events to a sequence of simulative operations

Purpose
In this topic, you learn to add some events to your simulation.
Objectives

• Understand that there are several event types available.
• Create a simulation using some of them.
• Compare and contrast the Attach command and the Attach event.
• Compare and contrast the Emphasize events and Emphasize presentation modes.
Introduction to events
Events can be added to operations and simulative operations. They are a way to make something
happen at a specific time during the simulation. Sometimes events just add a more polished look to
the simulation, and other times they are critical to creating an accurate simulation.
Actions performed by events during a simulation override similar actions performed by a

presentation mode.
There are several different types of events in Process Simulate:

• Attach Event — Attaches several objects to another object.
• Detach Event — Breaks the attachment.
• Display Event — Shows a blanked object during a simulation.
• Blank Event — Hides a displayed object during a simulation.
• View Point Event — Stores and applies the current viewpoint during a simulation.
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• Emphasize Event — Used to color specific objects or change their transparency during
simulation.
• De-emphasize Event — Used to undo the affects of the Emphasize Event.
• Pause Event — Temporarily stop the simulation. This type of event can be enabled or disabled.
• Activate Collision Sets Event — starts collision checking based on the specified collision sets.
• Deactivate Collision Sets Event — stops collision checking based on the specified collision sets.
Additional event types

Some event types are not shown on the Sequence Editor right-click, but can be accessed from the
ribbon by choosing Operation tab→Events group→New Event .
There are 19 options on this list, including these not found on the right click:
• Snapshot Event — Applies the viewpoint of a snapshot during a simulation (but nothing else
from the snapshot).
• Add to Group Event — Adds objects to a group.
• Remove from Group Event — Removes objects from a group
• Signal Event — Covered in theTR45215 Process Simulate Standalone Intermediate Robotics

(CEE) course
• Human Event — Covered in the TR45106 Process Simulate Standalone Human Simulation
course.
Event basics
To create an event:
You create events using one of these two techniques:
• Right-click an operation in the Gantt chart displayed in the Sequence Editor and select the
event type you want.
• Select an operation. From the ribbon, choose Operation tab→Events group→New Event
. Select the event type you want.
To edit an event:
Existing events are shown as red dots in the Gantt chart.
There are several things that can be done with an event:

• Drag the red dot on the Gantt chart to change the time when it occurs.
• Right-click on the red dot on the Gantt chart and choose Edit Event . Change its parameters
and click OK.
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• Right-click on the red dot on the Gantt chart and choose Create Opposite Event (for example
switch from Blank to Display or Attach to Detach).
• Right-click on the red dot on the Gantt chart and choose Copy .
• Right-click on the red dot on the Gantt chart and choose Delete .
The attach command versus the attach event

The Attach Command
• Choose the Attachment →Attach command from the Tools tab of the ribbon. This
command is independent of a sequence of operation. The only way to break this attachment is
to use the Detach command.
You can see if an object is attached to another object by selecting the object looking at
the list of Attachment commands on the ribbon. If the Attach command is

disabled, the object is already attached to an object and you can detach it if required. If
the Detach command is disabled, the object is not attached to another object
and you can attach it if required.
Specify the type of attachment, as follows:

• One Way: The attached objects can be moved independently of the object to which they are
attached. If you move the object to which the objects are attached, all the objects move together.
• Two Way: If you move the attached objects or the object to which the objects are attached, all
the objects move together.
The Attach Event

This event works just like the command, but it is performed during a simulation.
Global and local attachments

There are several types of attachments:
• Local attachment — tools and resources are attached in a study. This connection is lost
when you put the tools and resources into a new study.
• Global attachment — the attachment is saved in the database instead of the study. Global
attachments can be reused in any study based on the same resources.
• Local over global — In addition, even after creating a global attachment, you can a create
local attachment to investigate scenarios without canceling the global attachment.
• Mount — An attachment created by the Mount Tool command.
In the Object Tree, you can use Customize Columns to add the Attach To column to the viewer.
This causes the Attach To and T columns to be displayed. The T column indicates the type of
attachment: mount, local attachment, global attachment, or local over global.
Emphasize events versus emphasize presentation modes

The Emphasize Presentation Mode
This is useful for adding clarity and automation to simulations and for emphasizing relevant objects.
After creating a number of presentation mode templates, users can select which template to use for a
given simulation using the new toggle button command in the Sequence Editor.
For example, users can create a simulation template for disassembling a subassembly of an engine:
• Display the whole engine in light gray.
• Display the subassembly in a contrasting dark gray.
• In turn, highlight each part for disassembly in another color while disassembling it.
• Blank the parts when their disassembly is complete.
• Display the engine and highlight the next disassembled part.
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The Emphasize Event

The Emphasize event works just like the emphasize presentation mode, except you can specify
specific entities and start and stop times for it to be performed.
Activities
In the Adding events to a sequence of simulative operations section, do the following activities:
• (Instructor Demo) Adding an attach event
• (Optional) Adding a view point event
• (Optional) Add a pause event
• (Optional) Coloring events by type
Review questions
Question
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Activate Event Tolerance Event Pause Event View Point Event
Putting it all together

At the beginning of this class you had little or no knowledge of Process Simulate. Through class you
have been exposed to many Process Simulate features and had time to practice what you have
seen. You must continue to use this tool after class in conjunction with other users in your company,
additional training classes, and Siemens PLM Software services personnel in order to become
an expert.
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Where do you go from here?

If you want to learn about Process Simulate Standalone (eMServer compatible), try these classes:
• TR45101 – Process Simulate Standalone (eMServer compatible) Flow Simulation
• TR45106 – Process Simulate Standalone (eMServer compatible) Human Simulation
• TR45215 – Process Simulate Standalone (eMServer compatible) Intermediate Robotics (CEE)
• TR45315 – Process Simulate Standalone (eMServer compatible) Advanced Robotics (OLP)
Final notes
Normally at some point you would begin developing simulative operations (paths) and organizing
them within a process. However since the steps to develop and analyze paths for different types
of operations are a little different (and are a little different for each type of simulative operation),
there are other courses to describe it.
• Device and robotic processes – Covered in more detail in these courses:MT45115, MT45215,
and MT45315.
• Human process – Covered in more detail in this course: MT45106.
• Assembly processes without the constraint of a human or a robot – Covered in more detail
in this course: MT45101.
Summary
• How to use several techniques to test the robot’s ability to reach locations in its path.
• Dynamic and static collision detection is discussed.
• Tools that can be used to modify paths so that collisions are avoided.
• Various buttons found on the Path toolbar and Operations menu that can be used to create via
locations.
• Several tools that can be used to modify a location in a path.
• Several tools that can be used to modify a path.
• Additional path (robotic simulative operation) creation tools.
• Several techniques to edit location attributes and provides some basic examples of locations
attributes from the Process Simulate default controller.
• How to do signal I/O (without the Cyclic Event Evaluator).
• How to do multiple robot work balancing using location attributes and Interference Zone.
• How to create swept volumes of an object moving along its path.
• What hard and soft joint limits are and how to set kinematic soft limits.
• Adding some events to your simulation.
• How to use setup and use external axis (joint). For example, a robot on a rail (7th axis) or gantry
is considered an external axis (joint) or a robot on a multi axis gantry system.
• Procedure required to create a compound operation in Process Simulate.
• How to create a basic sequence.
• Some other Robotics features.
Appendix A: Basic robotics optional topics
Purpose
To provide additional information about modifying and optimizing robotic paths in Process Simulate.
This chapter contains alternatives and extensions for various activities based on the robotic
application (for example spot-weld, arc-weld, paint, and debur). You do not have time
to cover all the alternatives in this course.
Objectives

• Manually creating spot-weld manufacturing features
• Dual arm (synchronized) robotic operations.
• Creating sequences of simulative operations
• The process structure hierarchy
• Creating compound operations
• Creating a robotic sequence (method 1 and 2)
• Creating and updating spot-welds
• Using the roller hemming tool
• Using the OLP tools
• Other robotics features
MT45115-S-131 Process Simulate Standalone (eMServer Compatible) Basic Robotic Simulation Student Guide A-1
Appendix
Appendix A: A:
BasicBasic robotics
robotics optional
optional topics
topics
Manually creating arc-weld manufacturing features

Purpose
In this topic, you manually create arc-welding manufacturing features instead of using the automated
tool.
Objectives

• Manually create arc-welding manufacturing features.
Do I do this?
A-2 Process Simulate Standalone (eMServer Compatible) Basic Robotic Simulation Student Guide MT45115-S-131
Basic robotics optional topics
Creating manufacturing features manually

Here is an overview of what you need to do to create the manufacturing features manually. These
commands are located in the Modeling tab of the ribbon:
1. Use Set Modeling Scope .
2. Model the manufacturing feature geometry using (a CAD system or) a command such as:
• Curves →Curve on Borders .
• Curves →Intersection Curve
• Curve Dashed Curves .
• Curve Isoparametric Curves .
Appendix
Appendix A: A:
BasicBasic robotics
robotics optional
optional topics
topics
3. Use Create Continuous Mfg from Curves from the Process tab of the ribbon.
Activities
In the Manually creating arc-weld manufacturing features section, do the following activities:
• Creating arc manufacturing features for the whitehouse part manually
• Creating arc seams (using Project Arc Seam ) manually
Dual arm and coordinated motion applications

Purpose
In this lesson, you learn about dual arm and coordinated motion robotic applications.
Objectives

• Setting up dual arm or coordinated motion robots
• Dual arm and coordinated motion basics
• Creating a new concurrent robotic operation
Setting up dual arm and coordinated motion robots

You need to create a compound equipment object of type robot (with dummy kinematics and a
dummy BASEFRAME and TOOLFRAME) with the single arms inside. Use this compound equipment
(robot system) to create concurrent operations using the normal robotic operations of the single arms.
Modeling dual arm and cooperative robots
1. Create an equipment object.
2. Add a dummy joint to it.
3. Add a TCPF (and BASEFRAME) to it.
4. Add the two robots and position them in it.
5. Add their tools (guns), position and mount them.
6. End modeling the equipment.
Appendix
Appendix A: A:
BasicBasic robotics
robotics optional
optional topics
topics
Dual arm and coordinated motion basics
Dual robots and Robot Jog
If you select an Equipment prototype with two or more robots under it, running Robot Jog
opens the Robot Jog: DualArmRobot dialog box. Use it to define one robot as Master and the other
(or others) as Slave. By enabling Master Slave mode, the motion of the slave robot(s) tracks the
movements of the master. It is not possible to jog the slave robot(s) independently.
Simulating dual robots
Use Operation tab→Create Operation group→New Operation →New/Edit Concurrent
Robotic Operation to group multiple operations together to be performed by a dual-arm robot

or cooperative robots. Robots can work in one of the following motion modes:
• Synchronized — All the robots participating in the concurrent operation start and end each
operation segment at the same time (they are all synchronized with the slowest robot) but there
are no geometrical constraints between the robot paths. All the robot paths must have the same
number of motion segments for the simulation to run correctly. This mode can be used to move
two robot arms in parallel in order to reach a part at the same time.
• Asynchronous — You can add any number of operations to any of the robots. All the
robots begin their initial operations concurrently and then run all of their allocated operations
independently until they have completed running the operations.
• Cooperative — All the robots participating in the concurrent operation start and end each
operation segment at the same time, just like a synchronized operation. However, the TCP of
the robot defined as the slave robot is also linked to the master robot’s TCP and in addition to
following its own path, the slave robot’s TCP also tracks the master robot’s path. One robot is
defined as the master robot, and the other as a slave which works in the master robot’s coordinate
system. All the robot paths must have the same number of motion segments for the simulation to
run correctly. In this mode, the robots are also synchronized. For example, the master robot can
carry a part, while the slave tracks the master and performs welding on the part as it moves to its
destination. The slave dictates the motion constraints, for example, speed and acceleration.
• Load sharing — The master robot executes its program and the slave robots track the master
robot’s TCPF. For example, two robots might move a part together.
Selecting and viewing
Concurrent operations of dual arm robots are displayed in the Relations Viewer providing you with
a better understanding of their content, such as which operations and robotic arms are involved in
the concurrent operation, which are the master and slave robots (if any) and what are the motion
segments formed, and coupled by the concurrent robotic operation. You can select the motion
segment’s paired locations and this selection is visible in other viewers and synchronized with them.
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Creating a new concurrent robotic operation
1. From the ribbon, choose Operation tab→Create Operation group→New Operation
→New/Edit Concurrent Robotic Operation

In the New Concurrent Robotic Operation dialog box, the Equipment box is selected.
2. Select a robot to assign to the new operation. The robot must be defined as an Equipment
type object and have at least two other robots nested under it.
3. Select the Type you want from the list.
4. For the Scope, select the parent operation to this one.
5. Select the Referenced operations. This area of the dialog box is different, depending on the
operation Type selected.
• If you set Type to Synchronized, click the first Operations cell and select an operation. The
relevant Robots box is automatically populated with the name of the robot assigned to a
descendant of the robot equipment. Repeat this until you have selected all the required
operations.
• If you set Type to Asynchronous, click the first Operations box and select operations for all
the robots. The relevant Robots box is automatically populated with the name of the robot
assigned to the relevant operation. Repeat this until you have selected all the required
operations for all the robots. After selecting the operations, set the order of the operations
using the arrow buttons on the right.
• If you set Type to Cooperative, select a Master operation and then a Slave operation.
• If you set Type to Load Sharing, select a Master operation and then Slave robots.
6. Click OK.
Activities
In the Dual arm and coordinated motion applications section, do the following activities:
• Setting up and simulating synchronized robot motion
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Creating sequences of simulative operations

Purpose
In this topic, you learn the basics of creating a sequence of simulative operations.
Objectives

• Get an ideas how to organize your sequence of operations.
• See that there are several types of simulative operations available.
• See that colors can be added to operations and events in the Sequence Editor.
Overview
In the previous topics of this student guide, you simulated individual parts of an assembly process. A
sequence of simulative operations combines separate simulative operations into an entire assembly
process.
This process defines individual operations for the currently displayed assembly, combines them into a
sequence of operations, and simulates a selected sequence. The purpose of these commands is to
demonstrate and verify the feasibility of a complete assembly procedure in the dynamic simulated
environment, and to produce a detailed assembly report.
Process Simulate sequence of operations organization

A sequence of operations is made up of several operations and compound operation operations. For
example, here is a sequence of operations containing three locations that are grouped using two
compound operation, as shown in the following diagram:
• Location — a location represents a single movement of a human, object, or robot.
• Simulative Operation — Defines the procedure required to complete the compound operation.
An operation associates a part with a path, and assigns the amount of time it takes to complete
the procedure. (These have already been created in previous activities.)
• Sequence of Process (compound operation) — A group of operations that either occur at the
same time or are staggered throughout the compound operation's simulation time. It can be set
as the current operation and typically contains more than one operation or compound operation.
Types of simulative operations

There are several types of simulative operations:
• Object flow : An operation consisting of the movement of a part along its assembly path.
(Covered in this course).
• Device : An operation consisting of any mechanical device (for example a robot, human,
clamps, cart, etc.) moving from one pose to another. (Covered in just about all courses).
• Robotic: A compound operation consisting of a sequence of locations (positions) for the Robot
TCPF. These operations are represented using these , , , icons. (Covered in this ).
• Human: An operation or compound operation consisting of a single human motion or a series of

motions. These operations are represented using these , , , , icons. (Covered in
TR45106 Process Simulate Standalone Human Simulation course).
• Non-sim : An activity requiring time (but is not simulated) that you want to include in the
sequence of operations. These operations are represented using the icon. (Covered in the
TR45215 Process Simulate Standalone Cyclic Event Evaluator (CEE) course).
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Review of the process structure hierarchy

Purpose
In this topic, you review the basic hierarchy of the process structure.
Objectives

• See the basic process structure hierarchy.
Overview
• Process
o Operation
■ Activity
◊ Simulative Operation
• Location
Creating compound operations

This topic describes
Purpose
In this topic, you learn the procedure required to create a compound operation in Process Simulate.
Objectives

• Create and use compound operations.
Creating and linking compound operations

A compound operation is a group of operations that either occur at the same time or are staggered
throughout the compound operation's simulation time.
Two Ways to Create Compound Operations:
Both of these methods are available on the right-click of the Operation Tree:
• From the ribbon, choose Operation tab→Create Operation group→New Operation →New
Compound Operation .
• Or in the Sequence Editor, select several compound operations, and choose Group To
Compound from the Quick access toolbar.
You have to add Group To Compound to the Quick access toolbar using
Customize Quick Access Toolbar .
Two Ways to Link Compound Operations:
• Hold down the Ctrl key, choose more than one compound operation, and click Link .
• Or on the Gantt chart of the Sequence Editor, drag straight down in the middle of a compound
operation and drop the other end of the link on the succeeding compound.
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Creating a robotic sequence (method 1 and 2)

Purpose
In this topic, you learn how to create a basic sequence.
Objectives
• Method 1
• Method 2
• Comparing Methods of Work
Overview
Operations performed in a certain order make up a sequence. There are several types of operations
that were briefly discussed in the previous topic. Within each operation, multiple events can be
performed.
Creating a robotic sequence (method 1)

Create the sequence by adding drive device, wait device, send signal, and wait signal OLP
commands to the locations in the robotic simulative operation.
Creating a robotic sequence (method 2)

Instead of adding drive device, wait device, send signal, and wait signal OLP commands to the
locations; you could have created this same sequence using another method available in Process
Simulate:
1. Create a Device operation to close the clamps.
2. Create a Device operation to open the clamps.
3. Use the Sequence Editor define operation links in this order:

• Close clamps
• RoboticOperation 1
• RoboticOperation 2
• Open clamps
Process Simulate figures out the duration for you later when the simulation runs
Comparing methods of work

There are at least two ways to create this sequence of operations:
Method 1:
Notice that this sequence of operations only has two operations in the Gantt chart that appear to
happen at the same time. However, both robots simulate at different times, and the clamps open
and close within them.
Method 2:
Using this method you can visually see the time when each robot starts and stops; and the time it
takes for the clamps to open and close.
Which method is better depends on your preference and the way in which you would like to use
Process Simulate. The point is that Process Simulate is flexible to your needs
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Creating and updating spot-welds

Purpose
In this lesson, you learn about creating and updating spot-welds.
Objectives
• Create weld spots.
• Update weld spots.
Sources for discrete manufacturing features
Discrete manufacturing features, such as weld points or rivets, are always tied to one or
more parts. In order to “see” a Manufacturing feature in Process Simulate it must be
created and associated to a part or operation that is either associated to the study directly
or indirectly (indirectly means it's associated to a part that is associated to an operation
associated to the study).
For weld points and rivets:

• Imported from a spreadsheet (CSV)
o This is the most typical technique. See the next section for details
• Created directly in Process Simulate

These commands, located on the ribbon Process tab→Discrete group, only create WeldPoint
objects. You cannot choose to create custom object types:
o Create Weld Point by Coordinates — create a weld point at a location selected by one
of the standard frame specification methods.
o Create Weld Points — create multiple welds on the part where ever you select.
o Create WP on Robot’s TCPF — create a weld point at the current TCPF position of
the selected robot, or TCP of the selected gun, servo gun, or pneumatic servo gun. The
command is enabled when any of these is selected.
By default, manufacturing features show in the Graphic Viewer as a red square and are also
displayed in the Mfg Feature viewer.
Creating weld points (in Process Simulate)

Usually weld points are imported from the CAD system. However, in the early planning stages
information about weld points is not always available and you can therefore add weld points directly
in Process Simulate if required. Weld points are displayed both in the Graphic Viewer and in the
Operation Tree. Weld points are attached and assigned to parts.
If the created weld point was created on a part, that part is assigned to the weld point.
To create weld points:
1. From the ribbon, choose Process tab→Discrete group→Create Weld Points . In the Graphic
Viewer, the cursor changes to a cross hair .
2. From the Quick access toolbar, change the Pick Intent to Where Picked .
3. Click (on the part) in the Graphic Viewer where you want to create a weld point. The weld point is
indicated by a + symbol. The cursor remains as a crosshair .
4. Create further weld points as required.
5. From the ribbon, choose Process tab→Discrete groupCreate Weld Points again to return
the cursor to normal.
Multi-assign weld points
Assign Parts is used to simultaneously assign multiple weld points to multiple parts. You can
then select the single part to which the weld points are attached. Once the weld points are attached
to a specific part, they move relative to that part if the part is moved to a different location in the cell.
• From the ribbon, choose Process tab→Planning group→Assign Parts
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Automatic weld point assign
Automatic Parts Assignment is used to perform manual or automatic weld point assignment to
parts. It assigns based on closeness of parts to welds.
• From the ribbon, choose Process tab→Planning groupAutomatic Parts Assignment .
To use this tool:

1. Choose some weld points from the Graphic Viewer or Operation Tree.
2. From the ribbon, choose Process tab→Planning groupAutomatic Parts Assignment . The
Automatic Part Assignment dialog box is displayed, containing a list of all parts that have already
been assigned to the selected weld points, if any.
3. The following buttons are available in the toolbar of the Automatic Part Assignment dialog box:
• Search — Finds all the parts located within range (as defined in the Settings dialog
box) of the selected weld points and displays them in the table. The parts that have not yet
been assigned are displayed in gray italics.
• Shift Part Left — Shifts a part in the list to the left.
• Shift Part Right — Shifts a part in the list to the right.
• Remove Part — Removes a part from the list, even if it has already been assigned.
• Settings — Opens the Settings dialog box, which contains the distance and box size
boxes. Distance defines the search range for parts (based on the active unit, as defined
in Options). Any parts located less than this distance from a weld point are automatically
assigned to that weld point. Box Size defines the size of the box drawn around the weld
points in the Graphic Viewer when they are selected in the table.
• Assign — Assigns parts to the weld points selected in the table.
• Export to Excel — Exports the list to a CSV file, which can be viewed by Microsoft Excel.
• Filter Out Assigned — When selected, filters out weld points with assigned parts
from the list.
4. Choose Search to have the system find all the parts that are within range of the selected
weld points and display them in the table.
5. Review the list of parts, and either choose Assign to assign the part, or click Remove Part
to remove the part from the list. When a weld point in the list is selected, each part within
range is displayed in the list and in the Graphic Viewer in a different color.
Click Filter Out Assigned to filter out weld points that already have assigned
parts from the list
6. If required, choose Shift Part Left or Shift Part Right to modify the order of the parts
assigned to the weld points. By default, the part listed in the Part 1 column is defined as the
attached part (also known as the leading part). This is the part to which the weld point is actually
attached. If this part is moved in the Graphic Viewer, the weld point moves relative to it.
To choose a different part as the attached part, click in the Attach To column and
select a part from the displayed drop-down list
Update weld locations

• For Spot Welding:
Update Weld Locations Projection located on the Process tab of the ribbon, is used to
detect weld locations that may need to be re-projected. The command lists all weld locations
which are candidates for re-projection based on:
o Weld Point Change – weld points with positions that have changed since the corresponding
weld location was last projected.
o Part Change – part on to which the location was originally projected has changed Users
can then decide whether to re-project the locations, while maintaining their current approach
angle.
Clicking Update Weld Locations Projection when all the weld locations are up to date
produces the following message: “No locations were found requiring project update”.
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• For Continuous processes:
Update Continuous MFG , located on the Process tab of the ribbon, is used to detect
locations that may need to be re-projected. The command lists all locations which are candidates
for re-projection.
Creating robotic paths from NC paths

Purpose
In this lesson, you learn how to use the CLS Upload tool to upload a CLSF (cutter location source
file) from NX CAM to create a robotic path in Process Simulate.
Objectives
• Upload a CLS file to create a continuous feature operation with a seam for each tool pass.
Using CLS Upload
The CLS Upload is located in the Process tab of the ribbon.
To use it:
1. Select a robot to use the NC path.
2. From the ribbon, choose Process tab→Continuous group→CLS Upload .
3. For the Ref Frame, leave it blank.

The reference position for the CLS path coordinates. This parameter is optional if a Master
Part is selected. If the Ref Frame is not specified then the Master Part self origin is used as
reference position.
4. For the Master Part, choose the part to associate the locations from the CLSF file to.
5. For Process Type, choose the desired type such as Arc.

Select the appropriate continuous process type for the created seam operations or seam
manufacturing features. An empty selection means the process is undefined.
6. For Creation mode, select either Operations or Mfgs.

Determine whether to create seam operations or manufacturing features with geometry.
7. For Seam color Id, enter 31 (the default).
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Specify the PAINT/COLOR in the CLS file that distinguishes between seam locations (forming a
stroke) and via locations (linking strokes together).
8. For Circle direction, select CW (Clockwise).

Define whether the normal vector in the CIRCLE instruction defines a CW (Clockwise) or CCW
(Counterclockwise) rotation:
• CW should be selected if the CLS file comes from NX
• CCW should be selected if the CLS file comes from ProE
9. Specify your options, or take the defaults.

Create via locations — whether to create or not via locations between the seam operations
Display locations — whether to display locations on the paths
10. Select the Normal direction, or take the defaults.

• Away from part — the normal vector (IJK) defined in the cls file is used as normal axis
direction
• Toward the part — the opposite of the normal vector (IJK) defined in the cls file is used
as normal axis direction
11. Select the Orientation mode, or take the defaults.

Specify the direction of the movement axis. Any locatable object can be selected as an
orientation reference frame. If the chosen reference is not a frame, then its self origin is used
as reference frame.
• Tangent — the movement axis is tangent to the trajectory.
• Fixed — the movement axis is aligned to the same axis of the Orientation reframe.
• Toward point — the movement axis points to the center of the Orientation reframe.
• Tangent Zigzag — the movement axis is flipped (rotated by 180 degrees around the normal
axis) on every second stroke compared to the normal tangent mode.
If the computed movement axis is parallel to the normal axis, then an arbitrary
movement axis direction is used.
12. Select optimization parameters, if desired, or take the defaults.

Use the specified criteria to skip the import of some of the locations from the file. For example, if
they are too close together.
13. Click Upload.
14. Select the CLS file and continue.
A continuous feature operation is created with the robot assigned. It contains a seam for each
tool pass.
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Overview of the robotic tools

Purpose
In this topic, you learn how to use the various robotic tools.
Objectives
• Know what Adjust Location Orientation to Full Reach does.
• Know what Arc Continuous Positioning does.
• Know what Attach Seam Locations to Part does.
• Know what Convert to Via Location does.
• Know what Convert to Weld Location does.
• Know what Create Scheduler Operation does.
• Know what Create Seam Operation does.
• Know what Define Gun Main Joint does.
• Know what Insert Seam Location After does.
• Know what Mark Current Rail Value does.
• Know what Rail Jog with Locked TCPF does.
• Know what Set Gantry Positions does.
• Know what Shift Locations by TCP Offset does.
• Know what Shift Rail Value does.
• Know what Smooth Circular Motions does.
• Know what Smooth Rail does.
Robotics tools basics

Robotics Tools are a set of commands, located on the Robotics tab on the ribbon, which are
necessary to do several things, including to define attributes needed by the controllers for certain
robotic applications.
Detailed descriptions follow later in this lesson.
Discrete process tools
In the Discrete group of the Process tab:
• Adjust Location Orientations to Full Reach
• Convert to Via Location
• Convert to Weld Location
Continuous process tools
In the Arc group of the Process tab:
• Arc Continuous Positioning
In the Continuous group of the Process tab:
• Attach Seam Locations to Part
• Create Seam Operation
• Insert Seam Location After
Robot OLP tools
In the OLP group of the Robot tab:
• Create Scheduler Operation
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• Gun Main Joint
• Mark Current Rail Value
• Rail Jog with Locked TCPF
• Set Gantry Positions
• Shift Locations by TCP Offset
• Shift Rail Value
• Smooth Circular Motions
• Smooth External
• Smooth Rail
Adjust location orientation to full reach

This tool realigns the orientation of selected locations so that they are fully aligned with the robot
TCPF (for 4 and 5 axis machines).
To use it:
1. Select one or several robotic operations or robotic locations.
2. From the ribbon, choose Process tab→Discrete group→Adjust Location Orientations to

Full Reach .
3. The robot jumps to all locations. If jump is successful, the location orientation is updated to
match the robot TCPF orientation. The application first attempts to jump to the location first with
full reach, then with Align-Z, then with Align-X, then with Align-Y, and finally with Origin-Only.
Locations that are not reachable in all cases are left unchanged.
Arc continuous positioning

This tool automatically calculates optimal location external axes for the following types of positioners:
• Positioners with a single rotational axis
• Positioners with two perpendicular rotational axes
In order to get best welding results place the seams parallel to floor (horizontal) with welding
performed down-hand (for example the torch is located above the seam and its approach vector is
vertical). Any direction can be specified for the alignment of the location normal and any location
vector can be defined as normal. For positioners with two perpendicular rotation axes, an iterative
algorithm is used with a fixed accuracy of 0.08 deg.
To use it:
1. Select one or several locations or robotic operations which are associated to same robot. The
active robot should have one or several external axes and among external devices at least
one positioner should be available.
2. From the ribbon, choose Process tab→Arc group→Arc Continuous Positioning .
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The selected locations are displayed in locations grid.
3. Select appropriate Positioner to calculate seam locations external axes,
4. Select the Normal vector to define which orientation vector from the location should be aligned
with the same vector of the Target direction. (Default Z+)
5. Select the Movement vector to define which orientation vector from the location is tangent to
seam. (Default X+) Together with the Normal vector, it defines how to apply the Travel and
Work deviations.
6. Select the Target direction to select a frame for the target direction. The normal vector of the
selected frame is used as target direction. (The default is the World Frame).
7. Select the Travel deviation.

• A value of 0 means the location normal vector is aligned with the target direction.
• A value > 0 means the location normal vector is tilted towards the seam direction. (Positive
rotation around X+ in case Normal=Z+ and Movement Vector = X+).
• A value < 0 means the location normal vector is tilted backwards. (Negative rotation around
X+ in case Normal=Z+ and Movement Vector = X+).
8. Select the Work deviation

• A value of 0 means there is no deviation.
• A value > 0 value means the deviation to the right side when looking form start to end seam.
(Positive rotation around X+ in case Normal=Z+ and Movement Vector = X+).
• A value < 0 means the deviation to the left side when looking from start to end seam.
(Negative rotation around X+ in case Normal=Z+ and Movement Vector = X+).
9. Click OK. All selected locations external axis values are updated.
Attach seam locations to part

This tool allows the attachment of seam locations to a selected part.
To use it:
1. Select one or several locations. It is also possible to select operations (in this case all locations
inside the operations is considered selected).
2. From the ribbon, choose Process tab→Continuous group→Attach Seam Locations to Part
.
3. Select the part to attach the previously selected locations to. Only compound parts can be
selected.
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4. Click OK. the selected seam locations are attached to the selected part (via locations are ignored).
Convert to via location

This tool allows the conversion of weld locations or seam locations into robotic via locations.
To use it:
1. Choose one or several weld locations or seam locations. It is also possible to select weld or seam
operations (in this case all weld/seam locations inside the operations is considered selected).
2. From the ribbon, choose Process tab→Discrete group→Convert to Via Location .
The selected weld or seam locations are converted into via locations.
Convert to weld location

This tool allows the conversation of robotic via locations into weld locations.
To use it:
1. To enable the command, choose one or several via locations. It is also possible to choose weld
operations (in this case all via locations inside the operations is considered selected).
2. From the ribbon, choose Process tab→Discrete group→Convert to Weld Location .
3. In the Convert to Weld Location dialog box, you can choose the discrete process (SPOT, STUD,
etc.). This determines the discrete MFG type that is created.
4. Click Apply.
The selected via locations are converted into weld locations.
Create seam operation

This tool allows the conversion of robotic via locations into seam locations gathered into seam
operations.
To use it:
1. To enable the command, choose a list of robotic via locations inside a continuous operation
2. From the ribbon, choose Process tab→Continuous group→Create Seam Operation .
3. In the Create Seam Operation dialog box, you can choose the continuous process (GLUE, ARC,
PAINT, etc.). This determines the dummy continuous MFG type that is created.
Or, select an existing Seam Mfg. In this case, no dummy Mfg is created. Instead, the
created seam operations are linked to the selected Mfg.
4. Click OK.
The selected via locations are converted to seam locations and are put inside seam
operations.
Create a scheduler operation

This tool creation of scheduler operation inside selected compound operation.
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To use it:
1. select a compound operation.
2. From the ribbon, choose Robot tab→OLP group→Create Scheduler Operation .
3. In the Create Scheduler Operation dialog box, enter an operation name and select a robot to
assign it.
4. Click OK to create the scheduler operation.
Define gun main joint

This tool allows users to define the main joint of a servo or pneumatic servo gun (this step is required
for pneumatic servo gun simulation as well as for servo gun hot swap simulation, in case the gun is
modeled with more than one prismatic joint).
To use it:
1. Choose a servo or pneumatic servo gun.
2. From the ribbon, choose Robot tab→OLP group→Define Gun Main Joint .
3. In the Define Gun Main Joint dialog box, choose the Main Joint.
4. Click Apply to store your choice, or Remove to delete your choice.
Insert seam location after

This tool inserts a new seam location inside an existing seam operation.
To use it:
1. Select a seam operation.
2. From the ribbon, choose Process tab→Continuous group→Insert Seam Location After .
3. The new location is located half distance between the selected seam location and the next
seam location.
Mark current rail value

This tool allows the automatic setting of current rail value to a list of locations.
To use it:
1. Choose one or several locations (locations should belong to a robot on a rail). It is also possible
to choose operations (in this case all locations inside the operations is considered selected).
2. From the ribbon, choose Robot tab→OLP group→Mark Current Rail Value .
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The command creates/updates the rail value on all locations with the current rail
position.
Rail Jog with Locked TCPF

This tool allows jogging a rail while keeping the robot TCPF in a fixed position.
To use it:
1. Choose one location.
2. From the ribbon, choose Robot tab→OLP group→Rail Jog with Locked TCPF .
3. In the Rail Jog with Locked TCPF dialog box, you can jog the rail with the slider or by typing a
numerical value in the numeric control.
• You can change the step of the numeric control via the Step link
If robot cannot maintain its TCPF at the location, the Update Location button is
disabled.
• Reset reverts back the rail at the rail value as stored in the location external axes ("Reset" is
disabled in case the location does not have yet a rail value).
• Update Location updates the location external axes with the current rail value.
Set gantry positions

This tool allows the coping gantry offset from given robot reference pose to selected locations
external axes.
To use it:
1. Select one or several locations or robotic operations.
2. From the ribbon, choose Robot tab→OLP group→Set Gantry Positions .
The selected locations are displayed in locations grid.
3. Select a Robot pose from which the gantry offset is copied.
4. Select the desired calculation Method.

• Keep Absolute Cartesian Delta - The application measures the Cartesian delta between
the gantry flange and the robot TCPF (when the robot is in target posture and the gantry in
initial position) in the WORLD coordinate system. The application then offsets each location
by this absolute delta (in WORLD coordinate system) and tries to superimpose the gantry
flange to this offset position.
• Keep Relative Cartesian Delta - For the first location, the application uses the previous
method with absolute Cartesian delta. After the gantry is jumped to the first location solution,
the application computes the local offset between the gantry flange and the location in the
following local coordinate system:
o Centered on the location
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o Axis Z vertical upward
o Axis X: projection of the direction towards next location on the horizontal plane
For the next locations, the application recalculates a new local coordinate system and applies
the local offset to get the gantry flange target position
5. Click OK. All selected location external axis values are updated. The list of locations for which
the calculation failed are shown in a report.
Shift locations by TCP offset

This tool allows the realignment of locations created with a wrong robot TCPF.
To use it:
1. Select one or several locations and robotic operations (in the case of robotic operations, all
locations inside the operations are selected).
2. From the ribbon, choose Robot tab→OLP group→Shift Locations by TCP Offset .
3. Select the Wrong TCP and the Correct TCP (you can select frames or locations).
4. Select the desired Apply to filter:

• All Locations — the command is applied to all selected locations
• Only Via Locations — the command is applied only to via locations (weld and seam
locations are skipped)
5. Select the desired Update method:
• All — update both the translation and orientation part of the selected locations
• Translation — only update the translation part of the selected locations (orientation is
unchanged)
• Orientation — only update the orientation part of the selected locations (translation is
unchanged)
6. Click OK. All selected locations are shifted by the offset between the wrong and correct TCP. The
taught positions are also updated.
Shift rail value

This tool allows the shifting of rail value on a list of locations.
To use it:
1. Choose one or several locations (locations should belong to a robot on a rail). It is also possible
to choose operations (in this case all locations inside the operations is considered selected).
2. From the ribbon, choose Robot tab→OLP group→Shift Rail Value .
3. Enter the amount of mm you would like to shift the rail value on the selected locations (the
numeric control automatically limits the possible values so that no rail values on any of the
selected locations could be outside limits)
4. Click OK.
The rail value is updated accordingly on all selected locations (locations without
existing rail value is left unchanged).
Smooth circular motions

This tool allows the smoothing of circular motions by optimizing the position of circular via locations.
To use it:
1. Select one or several robotic operations.
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2. From the ribbon, choose Robot tab→OLP group→Smooth Circular Motions . The command
identifies circular motions.
3. The Smooth Circular Motions command moves circular via locations to the exact middle of the
arc (between circular start and circular end locations). It also updates circular via orientation to be
the half-way interpolation between the start and end locations orientations.
Smooth rail
This tool allows the automatic setting of rail values along a path.
To use it:
1. From the ribbon, choose Robot tab→OLP group→Smooth Rail .
2. In the Smooth Rail dialog box, select a start and an end location inside a robotic operation (path).
The selected first and last locations should already have an external axis value defined.
3. For Method, choose either Interpolate On Travel Distance or Project Locations on Rail Axis.
• Interpolate On Travel Distance - The application interpolates the rail values set on the
start and end locations with the relative Cartesian travel distance from the start location,
along the path
• Project Locations On Rail Axis - The application interpolates the rail values set on the start
and end locations with the relative positions of each locations along the rail.
4. Click OK or click Apply. The command creates/updates the rail values of all locations between
the selected ones.
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Other robotics features

Purpose
In this topic, you learn some other robotics features. These topics are here for reference, but are
not covered in this course.
Objectives

• The Weld Quality Report
• Creating Weld Points (in Process Simulate)
• Multi-Assigning Weld Points
• Automatic Weld Point Assign
• Update Weld Locations
• Unified Collision Settings
• Flip Location on Solid
• Supported CAD Formats
• Selected intermediate and advanced robotics topics (more topics not covered in the basic
robotics course).
Do I do this?
There are several reasons to create manufacturing features, including for spot-welding:
Spot-weld quality report
The Weld Quality Report command, located on the Process tab of the ribbon, helps users
analyze the quality of weld data, calculating and displaying weld points and weld locations with
information about their attributes and deviation. Major features of this tool include:
The Weld Quality Report can be used in studies running in standard mode (but not
for those running in line simulation mode).
• Display pairs of weld point MFG and the respective weld location.
• Display the position deviation between the weld point and the weld location.
• Display the off normal deviation between original projection and current projection.
• Setting to define the maximal allowed discrepancies for position and off normal.
• Mark potential issues like deviation that exceeds the maximal allowed discrepancies, missing
projection and multiple weld locations.
• Consider taught locations.
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• Synchronize with the Graphics Viewer, Object Tree, and MFG Viewer.
• Allow customizing the report columns to include additional information such as the connected
parts, operation name, assigned robot, weld point attributes and location robotic parameters.
• Ordering capabilities.
• Filtering capabilities: users can filter the report based on any column to display only important
data.
• Distance deviation preview.
• Export to Excel for further analysis or sharing. Export considers any filter that is applied or
removes all filters before exporting.
Using the Weld Quality Report

To open it:
1. Choose weld operations, compound operations, the process root node or spot manufacturing
features in the Operation Tree or Mfg Viewer.
2. From the ribbon, choose Process tab→Discrete group→Weld Quality Report .
The Weld Quality Report dialog box opens and is populated with the objects you
selected. The report calculates and displays values for all the parameters currently
displayed.
The Weld Quality Report dialog box displays information about weld point/weld location pairs. If
multiple locations are associated with the Mfg, the report displays a row for each one.
Distance and Off Normal cells are highlighted in red if their weld point discrepancies are greater
than the maximum discrepancies configured in the Settings dialog box Weld Location cells are
highlighted in red if there is a projection problem. In all these cases, relevant icons are displayed
in the Status column; hovering over the status icons displays a descriptive tooltip.
If the location is not projected, the status Not Taught becomes irrelevant, and is not
displayed in the tooltip.
If there are no issues and the location fits the weld point perfectly, the color of the row remains white
and there are no status warnings. If there are one or more issues, the background of the row is
colored gray and the column specific to the issue is colored red, to indicate deviance in distance or off
normal, as defined in the Settings dialog box.
There are three status categories: Calculation, Projection, and Taught Location Calculation,
as follows:
Calculation statuses
The specifications for these parameters are defined in the Settings dialog box.
• Off normal The angle between the normal vector of the original location and the current
normal vector of the location. This is measured from the perpendicular and is calculated
based upon the Weld Location Orientation, Perpendicular parameter in the Weld tab
of the Options dialog box.
• Distance The distance between the current weld location position and the weld point
position.
Projection statuses
• Missing Projected Location The weld point has a weld location that is not projected.
• Duplicated projection The weld point has multiple projected weld locations.
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Taught location calculation statuses

If a location is taught, the system uses the taught value when calculating Distance and Off
Normal and displays the following warning/errors:
• No taught location The weld location is not taught.
• Missing robot The weld point has no assigned robot or the robot tool frame is missing.
Only relevant for a mounted workpiece operation.
Gun — displays the name of the gun assigned to the parent operation (if such an assignment
has been made).
Frame of reference — You can calculate the data discrepancy relative to a different frame of
reference than the self frame
Customizable columns
To expand the functionality of this dialog box, you can change the columns that show in the
Weld Quality Report, by choosing Customize Columns and selecting an attribute from the
Weld Quality Report Fields list.
Creating weld points (in Process Simulate)

Usually weld points are imported from the CAD system. However, in the early planning stages
information about weld points is not always available and you can therefore add weld points directly
in Process Simulate if required. Weld points are displayed both in the Graphic Viewer and in the
Operation Tree. Weld points are attached and assigned to parts.
If the created weld point was created on a part, that part is assigned to the weld point.
To create weld points:
1. From the ribbon, choose Process tab→Discrete group→Create Weld Points . In the Graphic
Viewer, the cursor changes to a cross hair .
2. From the Quick access toolbar, change the Pick Intent to Where Picked .
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3. Click (on the part) in the Graphic Viewer where you want to create a weld point. The weld point is
indicated by a + symbol. The cursor remains as a crosshair .
4. Create further weld points as required.
5. From the ribbon, choose Process tab→Discrete groupCreate Weld Points again to return
the cursor to normal.
Multi-assign weld points
Assign Parts is used to simultaneously assign multiple weld points to multiple parts. You can
then select the single part to which the weld points are attached. Once the weld points are attached
to a specific part, they move relative to that part if the part is moved to a different location in the cell.
• From the ribbon, choose Process tab→Planning group→Assign Parts
Automatic weld point assign
Automatic Parts Assignment is used to perform manual or automatic weld point assignment to
parts. It assigns based on closeness of parts to welds.
• From the ribbon, choose Process tab→Planning groupAutomatic Parts Assignment .
To use this tool:
1. Choose some weld points from the Graphic Viewer or Operation Tree.
2. From the ribbon, choose Process tab→Planning groupAutomatic Parts Assignment . The
Automatic Part Assignment dialog box is displayed, containing a list of all parts that have already
been assigned to the selected weld points, if any.
3. The following buttons are available in the toolbar of the Automatic Part Assignment dialog box:
• Search — Finds all the parts located within range (as defined in the Settings dialog
box) of the selected weld points and displays them in the table. The parts that have not yet
been assigned are displayed in gray italics.
• Shift Part Left — Shifts a part in the list to the left.
• Shift Part Right — Shifts a part in the list to the right.
• Remove Part — Removes a part from the list, even if it has already been assigned.
• Settings — Opens the Settings dialog box, which contains the distance and box size
boxes. Distance defines the search range for parts (based on the active unit, as defined
in Options). Any parts located less than this distance from a weld point are automatically
assigned to that weld point. Box Size defines the size of the box drawn around the weld
points in the Graphic Viewer when they are selected in the table.
• Assign — Assigns parts to the weld points selected in the table.
• Export to Excel — Exports the list to a CSV file, which can be viewed by Microsoft Excel.
• Filter Out Assigned — When selected, filters out weld points with assigned parts
from the list.
4. Choose Search to have the system find all the parts that are within range of the selected
weld points and display them in the table.
5. Review the list of parts, and either choose Assign to assign the part, or click Remove Part
to remove the part from the list. When a weld point in the list is selected, each part within
range is displayed in the list and in the Graphic Viewer in a different color.
Click Filter Out Assigned to filter out weld points that already have assigned
parts from the list
6. If required, choose Shift Part Left or Shift Part Right to modify the order of the parts
assigned to the weld points. By default, the part listed in the Part 1 column is defined as the
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attached part (also known as the leading part). This is the part to which the weld point is actually
attached. If this part is moved in the Graphic Viewer, the weld point moves relative to it.
To choose a different part as the attached part, click in the Attach To column and
select a part from the displayed drop-down list
Update weld locations

• For Spot Welding:
Update Weld Locations Projection located on the Process tab of the ribbon, is used to
detect weld locations that may need to be re-projected. The command lists all weld locations
which are candidates for re-projection based on:
o Weld Point Change – weld points with positions that have changed since the corresponding
weld location was last projected.
o Part Change – part on to which the location was originally projected has changed Users
can then decide whether to re-project the locations, while maintaining their current approach
angle.
Clicking Update Weld Locations Projection when all the weld locations are up to date
produces the following message: “No locations were found requiring project update”.
• For Continuous processes:
Update Continuous MFG , located on the Process tab of the ribbon, is used to detect
locations that may need to be re-projected. The command lists all locations which are candidates
for re-projection.
Unified collision settings

Functionality
• One collision set for all weld applications (Smart Place , Automatic Approach Angle ,
Weld Distribution Center , Pie Chart )
• Choose between default collision set or collision viewer active sets
• Define default collision set with or without self collision lists
• Improved behavior of ignoring gun tip collision: during welding only at weld location and between
gun and welded part only
• Previous behavior of constant exclude is optional
• Detection sphere range can be set by the user

• Prevent errors by clear and consistent collision detection
• Save time with default collision set
• Increase process quality and save planning time – detect only valid gun tip collisions
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Flip location on solid
From the ribbon, choose Operation tab→Edit Path group→Flip Locations →Flip Locations On
Solid command is described here.
This command is different from Flip Locations →Flip Locations On Surface discussed
earlier.
Functionality
• Flip weld locations consider assigned parts and their thickness
• Auto-detect external surfaces
• Show assigned parts
• Ability to consider additional parts

• Support solid modeled CAD data
• Using part thickness information leads to precise results
• Save time by minimizing required weld location manipulations
Supported CAD formats

It is assumed that most CAD data, such as parts and resources, are modeled in CAD applications
and then used in Process Simulate. Process Simulate the following CAD formats:
• NX8.5 (using Import CAD files )
• CATIA Method 1: PLM Components bi-directional translator (does not require a CATIA license)
o CATIA V5 — R8 to V5-6R2013 SP2
o CGR — R10 to V5-6R2013 SP2
• CATIA Method 2: CAD translator or Import CAD files (requires a CATIA license)
o V5 — V5R21 SP1
o V4 – 4.2.4
• Pro/E Method 1: PLM Components translator (does not require a Pro/E license)
o Pro/E WildFire 4, WildFire 5, Creo 1, Creo 2
• Pro/E Method 2: CAD translator or Import CAD files (requires a Pro/E license)
o Pro/E version 16 - Wildfire 5
• SolidWorks Method 1: PLM Components translator (does not require a SolidWorks license)
o SolidWorks 2011, 2012, 2013
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• IGES 5.3 (using Import CAD files )
• AutoCAD DXF (using Import CAD files )
• STEP AP203, AP214 (using Import CAD files )
• JT version 9.6 (using Import CAD files )
• STL (using Importer.exe)
• Robface (using Importer.exe)
• Robcad .co
Prior versions may also be supported.
Cell and component preview images

To create a preview image of a cell:
1. Start Process Simulate.
2. Choose File→Options .
3. In the Options dialog box, choose the General tab.

The Process Simulate Options dialog box:
4. Make sure the Capture preview upon Save psz check box is checked.
5. Click OK.
6. Now, each time that you Save a cell, a preview image is created.
To create a preview images of a library of components:
1. Start Process Simulate.
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2. Use Customize Quick Access Toolbar to add the command to it, if it is not already there.
3. From the Quick access toolbar choose .
4. Choose the desired folder under the library root.
5. Click OK.
Selected intermediate and advanced robotics topics (More topics not covered
in the basic robotics course)
For a more complete list of topics and information on

thee courses, see the Tecnomatix course catalog online at
training.industrysoftware.automation.siemens.com/finder/ilt_list.cfm
These topics are covered in the TR45215 Process Simulate Standalone Cyclic Event Evaluator
(CEE) course:
• Creation of smart components and logic blocks
• Simulation of logic
• Event-based simulation
• Gripper Operations
• Etc.
These topics are covered in the TR45315 Process Simulate Standalone Advanced Robotics course:
• Robot Configuration (Solutions and Turns)
• Robotic Path Templates
• RCS Setup
• Enhanced Robot specific controllers
• Development of customization XMLs
• RRS Simulation
• Robot Program Tool
• Robot Program Editing
• Upload, download, etc.
• Etc.
Summary
• Creating sequences of simulative operations
• The process structure hierarchy
• Creating compound operations
• Creating a robotic sequence (method 1 and 2)
• Creating and updating spot-welds
• Using the roller hemming tool
• Using the OLP tools
• Other robotics features
Index
A Available Types for Display by Type . . . 2-31
Accessing Online Help and Release

B
Notes . . . . . . . . . . . . . . . . . . . . . . . 2-58
Add 7th axis to a robot . . . . . . . . . . . 14-21 Basic concepts . . . . . . . . . . . . . . . . . . 1-1
Add a fancy graphics background . . . . . 2-46 Basic definitions . . . . . . . . . . . . . . . . . . 1-3
Adding commands to the Quick Access Basic kinematics . . . . . . . . . . . . . . . . . 8-3
Toolbar . . . . . . . . . . . . . . . . . . . . . . 1-32 Basic location attributes . . . . . . . . . . 17-21
Adding events to a sequence of simulative Basic methodology and purpose . . . . . . . 1-3
operations . . . . . . . . . . . . . . . . . . . 17-69 Basic modeling tools . . . . . . . . . . . . . . . 7-4
Adding kinematics to a simple robot . . . 8-31 Basic object types . . . . . . . . . . . . . . . 1-16
Adding text in the Graphic Viewer . . . . . 5-12 Basic options setup . . . . . . . . . . . . . . 1-15
Additional commands . . . . . . . . . . . . . 2-53 Basic principles . . . . . . . . . . . . . . . . . 11-4
Additional event types . . . . . . . . . . . . 17-71 Basic Relocate command usage . . . . . . 3-19
Additional general continuous manufacturing Basic robotic simulation course
feature creation tools . . . . . . . . . . . . . 16-9 overview . . . . . . . . . . . . . . . . . . . . . . 19
Additional path creation tools . . . . . . . 17-49 Basic robotics optional topics . . . . . . . . . A-1
Adjust Location Orientation to Full Basic section cutting usage . . . . . . . . . 5-36
Reach . . . . . . . . . . . . . . . . . . . . . . . A-26 Basic techniques for creating frames . . . . 3-8
Advanced cable parameters and Basic viewing command usage . . . . . . . 2-15
settings . . . . . . . . . . . . . . . . . . . . . . 5-45 Basics . . . . . . . . . . . . . . . . . . . . . . . 1-23
Advanced Relocate command usage . . 3-20 Basics of cables . . . . . . . . . . . . . . . . . 5-41
Advanced techniques for creating Begin using point clouds . . . . . . . . . . . 2-49
frames . . . . . . . . . . . . . . . . . . . . . . . 3-9 Branching basics . . . . . . . . . . . . . . . . 8-23
Analysis tools and data . . . . . . . . . . . . . 5-1
Apply Path Template Action . . . . . . . . 17-26
C
Arc continuous positioning . . . . . . . . . . A-26
Arc weld basics . . . . . . . . . . . . . . . . . 14-2 Cam joint basics . . . . . . . . . . . . . . . . . 9-28
Arc-weld continuous feature Cam joint function example . . . . . . . . . 9-28
applications . . . . . . . . . . . . . . . . . . . 14-1 Cell and component preview images . . . A-52
Arc-weld continuous manufacturing features Changing select behavior and creating
and operations . . . . . . . . . . . . . . . . . 14-8 frames . . . . . . . . . . . . . . . . . . . . . . . 3-7
Arc-weld projection tools . . . . . . . . . . 14-16 Changing units . . . . . . . . . . . . . . . . . . 2-33
Attach seam locations to part . . . . . . . . A-29 Client system root . . . . . . . . . . . . . . . . 6-6
Automatic Approach Angle . . . . . . . . 17-38 Collapse to selection . . . . . . . . . . . . . . 2-55
Automatic Path Planner (APP) for Robot Collision basics . . . . . . . . . . . . . . . . 17-16
Paths . . . . . . . . . . . . . . . . . . . . . . 17-44 Collision detection and near miss
Automatic Path Planner (APP) Robot setup . . . . . . . . . . . . . . . . . . . . . . . 5-29
Settings . . . . . . . . . . . . . . . . . . . . . 17-45 Collision detection basics . . . . . . . . . . 5-19
Automatic weld point assign . . . . . A-18, A-46 Collision factors . . . . . . . . . . . . . . . . . 5-33
Automatically setting the location Collision introduction . . . . . . . . . . . . . . 5-25
attributes . . . . . . . . . . . . . . . . . . . . 14-17 Collision report level . . . . . . . . . . . . . . 5-30
MT45115-S-131 Process Simulate Standalone (eMServer Compatible) Basic Robotic Simulation Student Guide Index-1
Index
Index
Collision Sets (List Pairs) . . . . . . . . . . . 5-21 Creating device operations . . . . . . . . . . 4-6

Collision Viewer . . . . . . . . . . . . 5-20, 17-17 Creating dimensions . . . . . . . . . . . . . . 2-35
Common modeling commands used to create Creating manufacturing features
manufacturing features . . . . . . . . . . . 16-9 manually . . . . . . . . . . . . . . . . . . . . . . A-3
Comparing methods of work . . . . . . . . A-14 Creating paint continuous operations . . 15-11
Complete kinematic basics . . . . . . . . . . 9-3 Creating paths from continuous manufacturing
Compound equipment (optional) . . . . . . 9-31 features . . . . . . . . . . . . . . . . . . . . . 14-13
Configuring levels of detection Creating rivet manufacturing features . . 12-5
granularity . . . . . . . . . . . . . . . . . . . . 5-27 Creating robotic paths from NC paths . . A-21
Continuous location constraints . . . . . 14-13, Creating sequences of simulative
15-15, 16-8 operations . . . . . . . . . . . . . . . . . . . . A-10
Convert to via location . . . . . . . . . . . . . A-30 Creating study (again) . . . . . . . . . . . . 10-10
Convert to Weld Location . . . . . . . . . . A-30 Creating Weld Points . . . . . . . . . A-17, A-45
Crank basics . . . . . . . . . . . . . . . . . . . 8-15 Custom columns in the Path Editor . . . 17-23
Crank types . . . . . . . . . . . . . . . . . . . . 8-18 Customizing the mouse . . . . . . . . . . . . 2-16
Create 3D HTML output . . . . . . . . . . . 5-49 Customizing the Quick Access Toolbar and
Create a scheduler operation . . . . . . . . A-31 ribbon . . . . . . . . . . . . . . . . . . . . . . . 1-31
Create drilling and riveting operations . . 12-6 Customizing the ribbon . . . . . . . . . . . . 1-32
Create seam operation . . . . . . . . . . . . A-31 Customizing the right-click menus . . . . . 1-33
Creating a basic robotic path . . . . . . . . 4-17 Customizing the user configuration . . . . 1-31
Creating a Compound Operation . . . . . A-13 Cutting sections with section planes . . . 5-36
Creating a new concurrent robotic Cutting sections with section volumes . . 5-40
operation . . . . . . . . . . . . . . . . . . . . . . A-8
Creating a new PSZ (no database) . . . . . 6-3 D
Creating a new PSZ that can update a eMS
database in the future . . . . . . . . . . . . . 6-3 Data structure . . . . . . . . . . . . . . . . . . 1-15
Creating a robotic sequence (method 1 and Define an object as a gripper (discussion
2) . . . . . . . . . . . . . . . . . . . . . . . . . . A-14 only) . . . . . . . . . . . . . . . . . . . 11-34, 13-3
Creating a robotic sequence (method Define an Object As a Servo Gun (Discussion
1) . . . . . . . . . . . . . . . . . . . . . . . . . . A-14 Only) . . . . . . . . . . . . . . . . . . . . . . 11-56
Creating a robotic sequence (method Define gun main joint . . . . . . . . . . . . . A-32
2) . . . . . . . . . . . . . . . . . . . . . . . . . . A-14 Defining an object as a tool . . . . . . . . . 8-26
Creating a rough mounted workpiece (pedestal Defining Speed and Acceleration . . . . . 8-25
welding) path . . . . . . . . . . . . . . . . . 11-41 Defining the cam joint . . . . . . . . . . . . . 9-28
Creating a Study . . . . . . . . . . . . . . . . 1-19 Defining the train joint . . . . . . . . . . . . . 9-25
Creating and editing in the kinematic Defining variable joint limits . . . . . . . . . 9-18
editor . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Description of joint dependencies . . . . . 8-11
Creating and editing more arc-weld continuous Design targets . . . . . . . . . . . . . . . . . . 11-3
manufacturing feature paths . . . . . . . 14-24 Designing a Spot-Welding Line . . . . . . . 11-2
Creating and Linking Compound Direct kinematics . . . . . . . . . . . . . . . . 4-11
Operations . . . . . . . . . . . . . . . . . . . . A-13 Discussion of steps to add poses to an
Creating and projecting paint manufacturing object . . . . . . . . . . . . . . . . . . 11-34, 13-3
features . . . . . . . . . . . . . . . . . . . . . 15-11 Display by type Basics . . . . . . . . . . . . 2-30
Creating and updating spot-welds . . . . . A-16 Display or hide the floor . . . . . . . . . . . . 2-56
Creating and Using Snapshots . . . . . . . . 5-5 Display Tooltips . . . . . . . . . . . . . . . . . 2-56
Creating appropriate brush geometry . . 15-16 Do I do this? . . . 1-19, 7-2, 10-10, 11-4, 11-7,
Creating Arc-weld continuous 11-14, 11-19, 11-23, 11-36, 11-49, 12-4–12-5,
operations . . . . . . . . . . . . . . . . . . . . 14-8 13-5, 13-7, 14-7–14-8, 14-13, 14-19, 14-24,
Creating cables . . . . . . . . . . . . . . . . . 5-44 15-6, 15-11, 15-19, 16-5–16-6, 16-11, 16-14,
17-3, 17-16, 17-20, 17-30, 17-42, A-2, A-40
Index-2 Process Simulate Standalone (eMServer Compatible) Basic Robotic Simulation Student Guide MT45115-S-131
Index
Do I use this? . . . . . . . . . . . . . . 5-19, 5-48, Fundamentals of kinematics . . . . . . . . . . 4-2

12-12, 13-2, 15-7, 15-30, 17-33
Docked and floating viewers . . . . . . . . 1-38 G
Docking Viewers . . . . . . . . . . . . . . . . 1-38
Drilling and riveting (fastening) General kinematics usage commands (part
overview . . . . . . . . . . . . . . . . . . . . . 12-2 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Drilling and riveting applications . . . . . . 12-1 General kinematics usage commands (part
Dual arm and coordinated motion 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
applications . . . . . . . . . . . . . . . . . . . . A-5 General robotics . . . . . . . . . . . . . . . . . 10-1
Dual arm and coordinated motion Geometric Gun Search Basics . . . . . . 11-53
basics . . . . . . . . . . . . . . . . . . . . . . . . A-6 Global and local attachments . . . 9-36, 17-73
Dynamic and Static Collision Graphic Viewer control overview . . . . . . . 2-8
Detection . . . . . . . . . . . . . . . . . . . . 17-16 Graphic Viewer overview . . . . . . . . . . . . 2-2
Dynamic clipping overview . . . . . . . . . . 2-41 Graphic Viewer text usage . . . . . . . . . . 5-12
Dynamic collision report . . . . . . . . . . 17-18 Graphical visualization . . . . . . . . . . . . 2-38
Graphical visualization and
performance . . . . . . . . . . . . . . . . . . 2-38
E
Graphical visualization setup . . . . . . . . 2-39
Editing a weld path . . . . . . . . . . . . . . 11-14 Graphics background options . . . . . . . . 2-10
Editing location attributes . . . . . . . . . . 17-20 Gun cloud . . . . . . . . . . . . . . . . . . . . 11-20
Emphasize events versus emphasize
presentation modes . . . . . . . . . . . . 17-73 H
Entity selection . . . . . . . . . . . . . . . . . 2-20
Environment . . . . . . . . . . . . . . . . . . . . 2-1 Hard limits . . . . . . . . . . . . . . . . . . . . 17-58
Event basics . . . . . . . . . . . . . . . . . . 17-71 High-level robotics flow charts . . . . . . . 10-4
Examining object types . . . . . . . . . . . . 1-16 Highlighting and Selecting in the Graphic
Example of a non-parallel pantograph (or four Viewer . . . . . . . . . . . . . . . . . . . . . . 2-20
bar linkage) . . . . . . . . . . . . . . . . . . . . 9-5 How do I define a gun for searching? . . 8-28
Example of a parallel pantograph (or four bar How is inverse kinematics like the Relocate
linkage) . . . . . . . . . . . . . . . . . . . . . . . 9-4 command? . . . . . . . . . . . . . . . . . . . 4-10
Example of a prismatic screw (or slider
linkage) . . . . . . . . . . . . . . . . . . . . . . . 9-6 I
Expand to selection . . . . . . . . . . . . . . 2-54
Implementation notes . . . . . . . . . . . . . 9-22
External axes usage . . . . . . . . . . . . . 14-21
Importing CAD files in Process Simulate . . 6-7
External axis basics . . . . . . . . . . . . . 14-20
Importing Mfg Features . . . . . . . . . . . 10-17
External axis definition . . . . . . . . . . . . . 9-2
Inference zones . . . . . . . . . . . . . . . . 17-66
External TCP Usage Differences . . . . 11-42
Insert seam location after . . . . . . . . . . A-33
Instance Basics . . . . . . . . . . . . . . . . . 1-18
F Introduction . . . . . . . . . . . . . . . . . . . . 1-23
Factors that affect collision detection . . . 5-33 Introduction to adding OLP commands to
Fast Placement usage . . . . . . . . . . . . . 3-4 locations . . . . . . . . . . . . . . . . . . . . 17-56
Files used in Process Simulate Standalone Introduction to Collision Detection . . . . . 5-19
- eMS compatible . . . . . . . . . . . . . . . . 6-5 Introduction to Display By Type . . . . . . 2-30
Final notes . . . . . . . . . . . . . . . . . . . 17-78 Introduction to events . . . . . . . . . . . . 17-69
Final steps for robotic path Introduction to Fast Placement and Restore
development . . . . . . . . . . . . . . . . . . 17-1 Object Initial Position . . . . . . . . . . . . . . 3-4
Finding the view control menus . . . . . . . 2-8 Introduction to joint dependency . . . . . . 8-11
First Draw the Kinematic Tree . . . . . . . 8-16 Introduction to kinematic cranks . . . . . . 8-15
Function basics . . . . . . . . . . . . . . . . . 9-20 Introduction to path modification . . . . . 17-30
Function definitions . . . . . . . . . . . . . . . 9-20 Introduction to Pedestal Welding . . . . . 11-41
Index
Index
Introduction to placement . . . . . . . . . . . 3-2 M

Introduction to Placement Manipulator . . 3-13
Introduction to Relocate . . . . . . . . . . . 3-18 Manually creating arc-weld manufacturing
Introduction to selection filters features . . . . . . . . . . . . . . . . . . . . . . . A-2
(optional) . . . . . . . . . . . . . . . . . . . . . 2-27 Manufacturing feature
Introduction to Studies . . . . . . . . . . . . 1-20 representation . . . . . . . . . . . . . . . . 10-15
Introduction to the graphical user Manufacturing feature types . . . . . . . . 10-15
interface . . . . . . . . . . . . . . . . . 1-12, 1-23 Mark current rail value . . . . . . . . . . . . . A-33
Introduction to the training manual Markup Editor toolbar . . . . . . . . . . . . . . 5-9
structure . . . . . . . . . . . . . . . . . . . . . . 1-2 Markup Editor usage . . . . . . . . . . . . . . . 5-9
Introduction to variable joint limits . . . . . 9-16 Material handling (pick and place)
Introduction to weld gun search . . . . . 11-53 operations . . . . . . . . . . . . . . . 11-40, 13-7
Inverse kinematics . . . . . . . . . . . . . . . 4-11 Material handling applications . . . . . . . 13-1
Inverse kinematics definition . . . . . . . . 8-32 Material handling setup . . . . . . . . . . . . 13-5
Inverse kinematics description . . . . . . . 8-35 Measurement and Units . . . . . . . . . . . 2-33
Inverse kinematics device creation and Meshes . . . . . . . . . . . . . . . . . . . . . . 15-9
usage . . . . . . . . . . . . . . . . . . . . . . . 8-32 Methodology to define a kinematic
Inverse kinematics review . . . . . . . . . . 4-10 device . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Modeling a more complex object
(optional) . . . . . . . . . . . . . . . . . . . . . 7-20
J Modeling and kinematics functionality . . . 7-4
Modeling basics . . . . . . . . . . . . . . . . . . 7-1
Joint dependency basics . . . . . . . . . . . 8-11 Modeling concepts . . . . . . . . . . . . . . . . 7-8
Joint jog basics . . . . . . . . . . . . . . . . . 4-14 Modeling gun shanks (optional) . . . . . . 7-18
Jumping and moving to a Location . . . 17-12 Modeling overview . . . . . . . . . . . . . . . . 7-8
Jumping to a location basics . . . . . . . 11-46 Modifying locations using the Path
Editor . . . . . . . . . . . . . . . . . . . . . . 17-39
K Modifying paths using operation
properties . . . . . . . . . . . . . . . . . . . 17-46
Kinematic branching . . . . . . . . . . . . . . 8-23 Modifying the weld location
Kinematic functions . . . . . . . . . . . . . . 8-12 orientation . . . . . . . . . . . . . . . . . . . 11-14
Kinematics background . . . . . . . . . . . . . 8-2 More continuous robotic applications . . . 16-2
Kinematics background basics . . . . . . . . 8-2 More external axis commands . . . . . . 14-22
Kinematics basics . . . . . . . . . . . . . 4-2, 8-1 More Kinematic Branching and Cranks . . 9-3
Kinematics basics summary . . . . . . . . . . 8-9 More modeling topics . . . . . . . . . . . . . . 7-6
More on Collision Detection . . . . . . . . . 5-25
More on kinematic functions . . . . . . . . . 9-20
L More section cutting usage . . . . . . . . . 5-40
More topics (not covered in class) . . . . . 9-37
Level of Kinematic Inverse . . . . . . . . . . 4-12 Mount tool . . . . . . . . . . . . . . . . . . . . 11-37
Libraries of Parts and Resources Mouse movement options . . . . . . . . . . 2-11
(prototypes) . . . . . . . . . . . . . . . . . . . 1-18 Multi Sections and gun cloud . . . . . . . 11-19
Linear measurement . . . . . . . . . . . . . . 2-34 Multi-Assign Weld Points . . . . . . . A-17, A-46
Links and joints cranks . . . . . . . . . . . . 8-17 Multiple robot simulation . . . . . . . . . . 17-57
Links and joints of four bar cranks . . . . . 8-19
Links and joints of three point cranks . . . 8-21
Location creation basics . . . . . . . . . . 17-34 N
Location creation tools . . . . . . . . . . . 17-33
Location modification basics . . . . . . . 17-37 Navigating waypoints in the Waypoint
Location modification tools . . . . . . . . . 17-37 Viewer . . . . . . . . . . . . . . . . . . . . . 12-12
Index
O Placement commands . . . . . . . . . . . . . . 3-1

Placement Manipulator advanced
Object Tree viewer . . . . . . . . . . . . . . . 1-28 options . . . . . . . . . . . . . . . . . . . . . . 3-15
Object Tree viewer nodes . . . . . . . . . . 1-28 Placement Manipulator basic options . . 3-14
On demand window viewing . . . . . . . . . 1-40 Point Clouds . . . . . . . . . . . . . . . . . . . 2-47
Online help . . . . . . . . . . . . . . . . . . . . 2-59 Pose definition basics . . . . . . . . . . . . . 8-28
Operation Tree viewer . . . . . . . . . . . . . 1-27 Principles of inverse kinematics . . . . . . 4-10
Optionally, manage point clouds . . . . . . 2-50 Process methodology . . . . . . . . . . . . . 11-4
Orienting workpiece locations . . . . . . . 11-49 Process methodology, revisited . . . . . 11-31
Other continuous feature applications . . 16-1 Process Simulate interference
Other notes . . . . . . . . . . . . . . . . . . . . 7-11 volumes . . . . . . . . . . . . . . . . . . . . 17-63
Other robotics features . . . . . . . . . . . . A-40 Process Simulate Standalone - eMS
Other selected basic topics . . . . . . . . . . 6-1 compatible . . . . . . . . . . . . . . . . . . . . . 6-5
Other selected modeling and kinematics Projecting arc-weld continuous manufacturing
topics . . . . . . . . . . . . . . . . . . . . . . . . 9-1 features . . . . . . . . . . . . . . . . . . . . . 14-14
Overview of arc-weld robotic Projecting general continuous manufacturing
applications . . . . . . . . . . . . . . . . . . . 14-2 features . . . . . . . . . . . . . . . . . . . . . 16-11
Overview of drilling and riveting Projecting spot manufacturing
applications . . . . . . . . . . . . . . . . . . . 12-2 features . . . . . . . . . . . . . . . . . . . . . . 11-7
Overview of gripper creation Projecting weld locations . . . . . . 11-10, 12-9
(optional) . . . . . . . . . . . . . . . . 11-34, 13-3 PRRR offset slider . . . . . . . . . . . . . . . 9-11
Overview of other continuous robotic PRRR slider . . . . . . . . . . . . . . . . . . . . 9-9
applications . . . . . . . . . . . . . . . . . . . 16-2 Putting it all together . . . . . . . . . . . . . 17-77
Overview of paint continuous robotic
applications . . . . . . . . . . . . . . . . . . . 15-2
Overview of paint coverage simulation Q
setup . . . . . . . . . . . . . . . . . . . . . . . 15-7 Quick Help Topics . . . . . . . . . . . . . . . 2-58
Overview of path creation tools . . . . . . 17-49 Quick introduction to kinematics . . . . . . . 4-1
Overview of performance options . . . . . 2-42 Quickly set multiple location
Overview of techniques to edit location attributes . . . . . . . . . . . . . . . . . . . . 17-24
attributes . . . . . . . . . . . . . . . . . . . . 17-23
Overview of the basics . . . . . . . . . . . . . 7-3
Overview of the paint coverage simulation R
process . . . . . . . . . . . . . . . . . . . . . 15-30 Rail Jog with Locked TCPF . . . . . . . . . A-34
Overview of the placement tools . . . . . . . 3-2 Rails, gantries, and positioners (external axis)
Overview of the robotic tools . . . . . . . . A-24 definition . . . . . . . . . . . . . . . . . . . . . . 9-2
Record a Video . . . . . . . . . . . . . . . . . 5-48
P Recording simulations to an .AVI file and 3D
HTML . . . . . . . . . . . . . . . . . . . . . . . 5-48
Paint brushes . . . . . . . . . . . . . . . . . . 15-8 Reference frame definitions . . . . . . . . . 3-13
Paint continuous feature applications . . 15-1 Release notes . . . . . . . . . . . . . . . . . . 2-60
Paint coverage settings . . . . . . . . . . . 15-31 Relocate command overview . . . . . . . . 3-18
Painting basics . . . . . . . . . . . . . . . . . 15-2 Rename Tool . . . . . . . . . . . . . . . . . . 17-27
Path Editor . . . . . . . . . . . . . . . . . . . 17-23 Replicate a Continuous Seam
Path modification basics . . . . . . . . . . 17-30 Operation . . . . . . . . . . . . . . . . . . . 17-52
Path modification tools . . . . . . . . . . . 17-42 Replicate an arc seam operation . . . . 17-50
Path Modification Tools Basics . . . . . . 17-42 Resetting and Saving Customizations . . 1-35
Path segment simulation . . . . . . . . . . 17-40 Review of the Process Structure
Pick and place basics . . . . . . . . 11-40, 13-9 Hierarchy . . . . . . . . . . . . . . . . . . . . A-12
Pie Chart . . . . . . . . . . . . . . . . . . . . 11-50 Right-click menus . . . . . . . . . . . . . . . . . 2-4
Index
Index
Robot jog basics . . . . . . . . . . . . 4-15, 8-33 Seventh axis and more (external axis
Robot tool example of kinematic usage) . . . . . . . . . . . . . . . . . . . . . 14-19
branching . . . . . . . . . . . . . . . . . . . . 8-23 Shift locations by TCP offset . . . . . . . . A-36
Robot Viewer . . . . . . . . . . . . . . . . . . 17-10 Shift rail value . . . . . . . . . . . . . . . . . . A-37
Robotic principles . . . . . . . . . . . . . . . 11-31 Simple robot kinematics basics . . . . . . . 8-31
Robotic reach basics . . . . . . . . . . . . . 17-3 Simulating paint coverage and more . . 15-30
Robotic reach test . . . . . . . . . . 11-43, 17-4 Simulation Monitor . . . . . . . . . . . . . . . 10-8
Robotic Swept Volumes and Interference Simulation of paint coverage . . . . . . . 15-30
Zones . . . . . . . . . . . . . . . . . . . . . . 17-61 Simulation Time Interval and Videos . . . 5-49
Robotics applications . . . . . . . . . . . . . 10-2 Slider crank . . . . . . . . . . . . . . . . . . . . 8-19
Robotics introduction . . . . . . . . . . . . . 10-2 Smart Place . . . . . . . . . . . . . . . . . . . 17-8
Robotics overview . . . . . . . . . . . . . . . 10-2 Smart Place modes . . . . . . . . . . . . . 17-10
Robotics tools basics . . . . . . . . . . . . . A-24 Smooth circular motions . . . . . . . . . . . A-37
Rotation methods . . . . . . . . . . . . . . . . 2-12 Smooth rail . . . . . . . . . . . . . . . 14-22, A-38
RPRR offset slider . . . . . . . . . . . . . . . 9-12 Snapshot usage . . . . . . . . . . . . . . . . . . 5-5
RRRP offset slider . . . . . . . . . . . . . . . 9-14 Soft limits . . . . . . . . . . . . . . . . . . . . 17-58
RRRP slider . . . . . . . . . . . . . . . . . . . . 9-8 Solid creating with primitives . . . . . . . . 7-13
Rules of Thumb . . . . . . . . . . . . . . . . . 5-22 Solid Creation Basics . . . . . . . . . . . . . 7-13
Solid modeling overview . . . . . . . . . . . 7-10
S Sources for basic manufacturing feature
orientation . . . . . . . . . . . . 11-8, 12-6, 16-7
Save/restore window layouts . . . . . . . . 1-40 Sources for continuous manufacturing
Scene/Scenario data storage . . . . . . . . . 5-2 features . . . . . . . . . . . . . . . . . . . . . 10-20
Searching for objects . . . . . . . . . . . . . 2-54 Sources for discrete manufacturing
Section plane alignment tools . . . . . . . . 5-37 features . . . . . . . . . . . . . . . . . 10-17, A-16
Selected intermediate and advanced robotics Specific object visualization . . . . . . . . . 2-39
topics (More topics not covered in the basic Speed and acceleration basics . . . . . . . 8-25
robotics course) . . . . . . . . . . . . . . . . A-54 Spot Weld Quality Report . . . . . . . . . . A-41
Selected Process Simulate features . . . . 6-9 Spot welding applications . . . . . . . . . . 11-1
Selection filter basics . . . . . . . . . . . . . 2-27 Spot welding basics . . . . . . . . . . . . . . 11-2
Selection techniques . . . . . . . . . . . . . . 2-20 Spot Welding Primer (Optional Topic) . . 11-2
Selection toolbar . . . . . . . . . . . . . . . . 5-22 Starting and Exiting Process Simulate
Sequence of Operations Organization . . A-10 Standalone . . . . . . . . . . . . . . . . . . . 1-11
Servo Gun Definitions . . . . . . . . . . . . 11-56 Starting out . . . . . . . . . . . . . . . . . . . . . 7-3
Servo Gun Usage . . . . . . . . . . . . . . . 11-55 Starting Process Simulate Standalone . . 1-11
Servo guns . . . . . . . . . . . . . . . . . . . 11-55 Status and title bars . . . . . . . . . . . . . . 1-25
Set gantry positions . . . . . . . . . . . . . . A-34 Steps for creating multi sections . . . . . 11-19
Setting pick intent . . . . . . . . . . . . . . 3-7, 7-6 Steps for driving devices . . . . . . . . . . 17-56
Setting pick level refresher . . . . . . . . . . . 3-8 Steps to create a continuous feature
Setting up a Mounted Workpiece operations . . . . . . . . . . . . . . . . . . . . 16-7
Path . . . . . . . . . . . . . . . . . . . . . . . 11-42 Steps to orienting the locations . . . . . . 11-49
Setting up and simulating waypoints . . 12-15 Stereo visualization . . . . . . . . . . . . . . 2-40
Setting up dual arm and cooperative Storing Pictures of the Scene . . . . . . . . 5-18
robots . . . . . . . . . . . . . . . . . . . . . . . 9-36 Strategic planning . . . . . . . . . . . . . . . 11-6
Setting up dual arm and coordinated motion Study Data . . . . . . . . . . . . . . . . . . . . . 5-2
robots . . . . . . . . . . . . . . . . . . . . . . . . A-5 Study data administrative note . . . . . . . . 5-3
Setting up paint brushes and meshes . . 15-7 Study/scene setup . . . . . . . . . . . . . . 11-36
Setting up the material handling . . . . . . 13-6 Supported CAD formats . . . . . . . . . . . A-51
Setting up the study/scene . . . . . . . . . 11-37 Swept volumes . . . . . . . . . . . . . . . . 17-61
Index
T Using the Location Manipulator . . . . . 15-19,

TCP Tracker . . . . . . . . . . . . . . . . . . 17-12 16-14
Teach Pendant . . . . . . . . . . . . . . . . . 17-25 Using the Markup Editor . . . . . . . . . . . . 5-9
Test robot’s reachability to the Using the Teach Pendant to start/stop
locations . . . . . . . . . . . . . . . . . . . . . 17-3 painting . . . . . . . . . . . . . . . . . . . . . 15-23
Texture Maps . . . . . . . . . . . . . . . . . . . 2-46 Using the working frame to build . . . . . . 7-20
The attach command versus the attach Using wireframe to create solids
event . . . . . . . . . . . . . . . . . . . . . . 17-72 (optional) . . . . . . . . . . . . . . . . . . . . . 7-16
The four basic object types . . . . . . . . . . 1-8
The Process: From least constraints to most V
constraints . . . . . . . . . . . . . . . . . . . 11-31
Variable joint limits . . . . . . . . . . . . . . . 9-16
The Prototype and Instance
Variable joint limits graph . . . . . . . . . . . 9-18
Relationship . . . . . . . . . . . . . . . . . . . 1-18
Verifying location orientation . . . . . . . 14-25
Toggling all objects’ visualization . . . . . 2-38
View Control and Graphic Viewer Setup . . 2-8
Tool definition . . . . . . . . . . . . . . . . . . 8-26
View control with a space mouse . . . . . 2-14
Tool definition basics . . . . . . . . . . . . . . 8-26
View control with the mouse . . . . . . . . . 2-13
Toolbar manipulation . . . . . . . . . . . . . . 2-53
Viewer area . . . . . . . . . . . . . . . . . . . . 1-25
Tools used . . . . . . . . . . . . . . . . 7-18, 7-20
Viewer overview . . . . . . . . . . . . . . . . . 1-26
Train joint basics . . . . . . . . . . . . . . . . 9-24
Viewing and selecting PMI . . . . . . . . . . 2-23
Train joint function example . . . . . . . . . 9-24
Viewing manufacturing features . . . . . 10-16
Training introduction . . . . . . . . . . . . . . . 1-2
Tree viewer basics . . . . . . . . . . . . . . . . 2-3
Types of simulative operations . . . . . . . A-11 W
Typical inputs . . . . . . . . . . . . . . . . . . . 1-6 Water jet specific commands . . . . . . . 16-18
Typical outputs . . . . . . . . . . . . . . . . . . . 1-7 Waypoints and the Waypoint Viewer . . 12-12
Typical Process Simulate usage . . . . . . . 1-8 Ways of creating and placing objects in
modeling . . . . . . . . . . . . . . . . . . . . . 7-21
U Ways of using Process Simulate . . . . . . . 6-2
Unified collision settings . . . . . . . . . . . A-48 WDC primary functionality . . . . . . . . . 11-25
Update weld locations . . . . . . . . . A-19, A-48 WDC settings . . . . . . . . . . . . . . . . . 11-27
Updating back to the eMS database . . . . 6-8 Weld distribution center (WDC) . . . . . 11-23
Use create 2D outline . . . . . . . . . . . . 17-67 Weld Distribution Center overview . . . 11-24
Using auto save . . . . . . . . . . . . . . . . 10-21 Weld location constraints . . . . . . . 11-8, 12-7
Using Cables . . . . . . . . . . . . . . . . . . . 5-41 What is a simulation? . . . . . . . . . . . . . . 1-5
Using CLS Upload . . . . . . . . . . . . . . . A-21 What is Process Simulate? . . . . . . . . . . 1-3
Using Continuous Process Generator for Where do you go from here? . . . . . . . 17-78
arc-welding . . . . . . . . . . . . . . . . . . 14-10 Window layout basics . . . . . . . . . . . . . 1-38
Using Continuous Process Generator for Window manipulation . . . . . . . . . . . . . 2-53
painting . . . . . . . . . . . . . . . . . . . . . 15-14 Wireframe basics . . . . . . . . . . . . . . . . 7-16
Using Insert Location Inside Seam . . . 15-21, Working with groups . . . . . . . . . . . . . . . 2-5
16-16 Working with hard and soft limits . . . . . 17-58
Using inverse kinematics . . . . . . . . . . . 4-14 Working with the main branch . . . . . . . . 9-3
Using Process Simulate Standalone . . . . 6-2 Working with viewers . . . . . . . . . . . . . . 2-2
Using Split Seam Operation . . . 15-22, 16-17 Working with waypoints . . . . . . . . . . . 12-16
Reference tear-out pages
These reference tear-out pages are provided for your convenience.
Course agenda
Day 1 Morning
Introduction
Course overview
Lesson 1 Basic concepts
Afternoon
Lesson 2 Process Simulate environment
Day 2 Morning
Lesson 3 Placement commands
Lesson 4 Introduction to kinematics
Afternoon
Lesson 5 Process Simulate analysis tools and study data
Lesson 6 Other selected topics
Day 3 Morning
Lesson 7 Modeling and kinematics overview
Lesson 8 Modeling basics
Lesson 9 Kinematics basics
Afternoon
Lesson 9 Kinematics basics (continued)
Lesson 10 Other selected modeling & kinematics topics
Lesson 11 General robotics
Day 4 Morning/Afternoon
Lesson 12 Spot-welding applications
Lesson 13 Material handling applications
Lesson 14 Arc-welding applications
Lesson 15 Other continuous applications
Day 5 Morning
Lesson 16 Final steps for robotic path development
Afternoon
Lesson 17 Final steps for robotic path development (continued)
Appendix (optional
Optionally, discuss topics from the appendix
topics)
Classroom data sheet
This table is provided so students can record their classroom setup, as described by the instructor.
Optionally, instructors may hand out a preprinted data sheet.
Data item Data value
OS user ID
OS password
User number
Process Simulate installation folder
System root folder

Student user IDs and numbers
A user ID and the associated number is assigned to each student in class.
• Your user number is applied when performing various activities in class.
User number User Id Password

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Instructor user ID and number
This user ID and number is reserved for use by instructors:
User number User Id Password

10
Course evaluation
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SIEMENS

Proprietary and restricted rights notice

Tecnomatix copyright, proprietary, and restricted rights notice . . . . . . . . . . . . . . . . . . . . . 2

Basic robotic simulation course overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Basic concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Training introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Viewer overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

Process Simulate Standalone environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Working with viewers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Introduction to selection filters (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Placement commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Introduction to placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Introduction to Fast Placement and Restore Object Initial Position . . . . . . . . . . . . . . . . . . . . . 3-4

Quick introduction to kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Fundamentals of kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Process Simulate analysis tools and study data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Study data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Creating cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

Other selected basic topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Modeling basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Kinematics basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Kinematics background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Other selected modeling and kinematics topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Rails, gantries, and positioners (external axis) definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Equipment basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32

General robotics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Spot welding applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Drilling and riveting applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

Overview of drilling and riveting applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

Material handling applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

Do I use this? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

Arc-weld continuous feature applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

Overview of arc-weld robotic applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

Paint continuous feature applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

Overview of paint continuous robotic applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2

Using Insert Location Inside Seam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-21

Other continuous feature applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

Final steps for robotic path development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1

Jumping and moving to a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-12

Replicate a continuous seam operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-52

Basic robotics optional topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Manually creating arc-weld manufacturing features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Creating a robotic sequence (method 1 and 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14

o Creating sequences of simulative operations

o Video and picture output

• Defining kinematic devices

• Defining and simulating robotic spot-welding

o Ped. welding and Gun on robot path development

• Defining and simulating robotic continuous applications

• Defining and simulating robotic material handling

o Pick and place path development

o Swept volumes, 7th axis, etc.

• Previous experience with a 3D system is recommended.

• A basic knowledge of robotics is suggested.

• TR45101 – Process Simulate Standalone (eMServer Compatible) Part Flow Simulation

• TR45106 – Process Simulate Standalone (eMServer Compatible) Human Simulation

• TR45115 – Process Simulate Standalone (eMServer Compatible) Basic Robotic Simulation

• TR45215 – Process Simulate Standalone (eMServer Compatible) Intermediate Robotics

• TR45315 – Process Simulate Standalone (eMServer Compatible) Advanced Robotics

To provide an introduction to Process Simulate Standalone.

After you complete this chapter, you should be familiar with:

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

• The concept of prototype and instances.