delmia dpm m7 - tool validation

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1 Create the Working

Environment

2Create the Process

Plan

3 Create the Simulation

Enhance the

SimulationAnalyze the movements

Create Output

files

45

6Tool

Validation

Optional

7

Module 7

Tool Validation

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7 Tool Validation

Module OverviewThis module is optional because it requires an additional license. It is also heavily

dependent upon prerequisite skills in Snap, Clash Detection, Move Activities, Viewpoint Changes, Visibility Activities.

For the Human verification, the license MHMC – SB (Human Modeling Complete –Shareable) must be loaded and available for use.With Tool validation it is possible to check for fit and operational interferences between

the tool and the product. This information can influence the choice and sequencing of tooling operations.

Assembly operations that require human interface present an added dimension to the simulation study. For this module, the initial aspects of human interaction using a hand and forearm are brought into the validation procedure. For in depth coverage of human factors simulation, the user is directed to the course Human Solutions.

Objectives Perform basic tool validationPerform validation with clash detectionPerform persistent validation with move activityPerform validation with human influence

3 hours

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Workbenches and Toolbars used in this Module

Workbenches

Toolbars

Inst.Inst.

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Tool Validation7

D

Add Human Hand

Validation

A

3 hours

Perform a Basic Tool Validation Study.

Attach Human Hand to Tool

Perform Basic Tool Validation

Inst.Inst.

Perform Tool Validation with Clash Detection Create

Persistent Tool Validation

C

B

Create a Move Activity for the Validation

Add Clash Detection to a Basic Validation Study.

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Basic Visual Inspection Method

A

Inst.Inst.

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7 Tool Validation About Basic Tool Validation

The ability to include the tooling in the simulation study adds a depth of detail that enhances the return on investment for the organization with very little additional time and expense.

More about Tool Validation can be found in the On-Line documentation

Many organizations keep tooling libraries or catalogs. From these, or from a custom catalog, tooling can be selected, tested and verified as the optimal choice for the situation. Interferences with the tooling and the freedom of movement can be inspected.

This process step details a Basic Tool Validation. A basic visual validation is the quickest way to see the tooling and test movements. However, it does not highlight interferences or capture the condition.

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Perform Basic Tool Validation Tool Validation

Basic Tool Validation - Procedure

7

A basic validation will present a general visualization of the context without the ability to capture information.

NOTE: A tool validation can be performed at any point in the construction of a simulation.

1 Open a simulation and identify a location for a tool validation study.

If tooling was brought into the simulation as a resource when the environment was constructed, then there is no need to locate it with the catalog browser.

Navigate to the tooling library, catalog, or repository.

Open the Catalog Browser. 2

3

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7 Tool Validation


4 Select the tool that you wish to use for the tool validation study.

5 Drag the tool from the Catalog to the world. Click once to set the tool in the environment, then close the Catalog Browser.

If the tool is already in the environment, select the it from the ResourceList in the PPR tree.

6

Activate the Snap command, use the Define Plane Mode to snap the tool to the part.

RECALL: Multiple clicks will create multiple instances of the object in the world and in the PPR tree. For error recovery, highlight the extra object and use the remove from PPR icon.

1. 2.

3.

4.

Inst.Inst.5.

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7 Tool Validation Basic Tool Validation - Procedure

7

Set the snap angle if necessary. For this example the tool is required to be at right angles to the part.

8

The tool will snap to the part and show the Snap Options box. DO NOT CLOSE the dialog box.

9

Activate the Place manipulator at snapped location function.

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Tool Validation

10


7

If the tool was brought in via the catalog browser, an instance of the tool remains in the PPR tree unless it is removed.

11

12

Use the compass manipulator to rotate the tool and observe the interferences.

View the condition from different angles to draw conclusions regarding this tool’s acceptability for this situation.

Select Cancel when finished with the visual examination. There is no need to keep the tool snapped to the product.

13 Repeat the process for any additional tools.

Interference with the wire


NOTE: Use the Undo command to remove a snap operation and leave the tool free for another validation.

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Basic Tool Validation – Exercise

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Master Exercise – 3.5 HP Engine3.5 HP Engine (Step 32): Perform a Basic Tool Validation

20 min.

Scope: In this exercise you will practice performing a basic tool validation.

Conditions: V5 and DPM Assembly Process Simulation workbench must be open.Access to the files in R16 DPM Assembly / PROJECT DATA.Familiarity with the snap functions is expected.

In this exercise you will:Snap tool to partManipulate tool and observe interference conditions

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Do It Yourself (1/4)

Starting point Ending point

Load: R16 DPM Assembly / Project Data / Process / Simulation4

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Conduct a basic tool validation for the adjustable wrench and engine head bolt 1.

1. Activate Snap. 2. Select the Adjustable Wrench from the

ResourceList in the PPR tree. Use Reframe on to move to the wrench in the world view.

3. Choose the Define Plane Mode. 4. Set the plane to the inside area of the

wrench. 5. Select OK.

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6. Select the Head Bolt.1 from the PPR tree. Use Reframe on to move the world view to the bolt.

7. Zoom into the bolt and select a plane where the wrench will snap to.

8. Click OK.

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9. Use the Alternate directions function to re-orient the wrench relative to the snap location.

10. Activate Place manipulator at snapped location.

11. Set the snap angle to 90 degrees.

12. Use the compass manipulator to move the wrench and observe freedom of movement for the wrench.

13. Cancel the Snap Option.

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Conduct Tool Validation with Clash Detection

B

Add Clash Detection to a Basic Tool ValidationCreate a Tool Clash Analysis

Inst.Inst.

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Perform Tool Validation with Clash Detection

7 Tool Validation About Tool Validation with Clash Detection

This process step adds Clash Detection to a basic tool validation. There are two methods. Clash detection can be added as Dynamic Clash for the visualization of the condition, or as Clash Analysis for those situations where a report is desirable.

Method 1 Turns on Dynamic Clash and conducts a basic validation. The validation remains uncaptured but speeds the evaluation of the tool and adds the visualization of the interferences.

Method 2 Adds a full Clash Analysis. A preview and complete analysis, including the ability to export a report is obtained.

The activities in this section draw upon the knowledge gained in the Clash Detection section of the “Analyze the Movements” module.


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7 Tool Validation Method 1. Tool Validation with Dynamic Clash - Procedure

1

2

Repeat the procedure for a basic tool validation study.

• Bring in tool.

• Snap to part.

NEW. Instead of closing the snap option with cancel, Click OK to accept the snap.

A validation with dynamic clash will highlight the interferences for better visualization.

For a multi-unit tool (such as a socket wrench), snap the first piece (socket) to the part. Then attach the second piece ( wrench body) to the first piece.

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Tool Validation

5

Method 1. Tool Validation with Dynamic Clash - Procedure

7

Double click on the world compass and select Snap Automatically to Selected Object.

4

3


Click to locate the compass on the tool.

The compass will locate at the point of origin. Move the compass to the snap point.

Activate Dynamic Clash Activate Analysis Mode 6 7

Move the tool using the compass and note the interferences highlighted in red.

8

NOTE: Use the Undo command to remove a snap operation and leave the tool free for another validation. Inst.Inst.

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Tool Validation Method 2. Tool Validation with Clash Analysis - Procedure

7

A validation with clash analysis will capture and report the interferences.


1 Repeat the procedure for tool validation with dynamic clash.

• Bring in tool.

• Snap to part.

• Click OK.

• IF a multi-unit tool is being used, bring in the next piece and attach to the first piece.

• Turn on Clash Detection and Analysis Mode.

2 Snap the compass to the tool.

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7 Tool Validation

Method 2. Tool Validation with Clash Analysis - Procedure

3 Manipulate the tool with the compass until a clash is encountered.

Leave the tool in the clash condition and click on Clash 4

5 The normal Check Clash dialog box appears. Select Between two selections and pick the tool and the part(s) where the interference is apparent.

6 Note: review for this function is in the module “Analyze the Movements”

Click Apply to activate the analysis.

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7 Tool Validation Method 2. Tool Validation with Clash Analysis - Procedure

7 The analysis and the preview window become visible.

8 Recall that the analysis can be inspected in the results window and exported as an .XML report via the export as icon.

Inst.Inst.

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Tool Validation with Clash – Exercises

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Master Exercise – 3.5 HP Engine3.5 HP Engine (Step 33): Perform a Tool Validation with Clash Detection

20 min.

Scope: These exercises offer practice in Tool validation using the clash functionalities.

Conditions: V5 and DPM Assembly Process Simulation workbench must be open.Access to the files in R16 DPM Assembly / PROJECT DATA.Familiarity with snap and with clash functions is expected.

In this exercise you will:Import tools.Check tool sufficiency for part.Check for collisions in movement of tool.Obtain clash analysis.

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Starting pointEnding point


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Perform Tool Validation with Clash.

Practice Test three screwdrivers for suitability.

1. Use Auto Sync or run the simulation until the carburetor is attached to the engine but is clear of surrounding parts. • If you choose to run the simulation, click

Pause when the condition above is met. 2. Visually locate all 6 screws and notice the type (flat

or phillips). • Carb Bolts long• Carb Bolts.1• Carb Bolts.2• Carb Bolts.3• Carb Bolts.4• Carb Bolts.5

3. Turn on Dynamic Clash and Analysis Mode .

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Perform Tool Validation with Clash.

4. Use Catalog Browser to locate the screwdrivers in the tools library. R15 DPM Assembly / Project data / catalog / Hand Tools Catalog.

5. Select the FH Reg screwdriver and bring it into the world. 6. Snap the screwdriver to Carb Bolts long.7. Move the compass to the snap point. 8. Manipulate the screwdriver with the compass and determine if there are any clashes that

prevent the use of this tool for the assembly. 9. Repeat the process on the other screws. 10. Repeat validating with the Short Thk and Thk FH screwdrivers. 11. Use the matrix to organize your validation study.

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Do It Yourself (4/4)Perform Tool Validation with Clash.

FH_Reg Short_Thk Thk_FH

Carb bolts long Viable Not Viable Not Viable

Carb bolts.1 Not Viable Not Viable Not Viable

Carb bolts.2 Viable Viable Viable

Carb bolts.3 Viable Not Viable Not Viable



Instructor: Remove this cover for author’s study results

Indicate if the tool is:

• Viable / Not Viable

NOTE: Use the Undo command and leave the tool free

to remove a snap operation for another validation.

12. Select one clash condition, activate an analysis and create an .xml report of the condition. Inst.Inst.

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Create Persistent Tool

Validation B

Create Move Activity for Tooling

Inst.Inst.

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Validation 7 Tool Validation

About Persistent Tool Validation

Persistent tool validation is used where there is a design or manufacturing issue involving tooling that presents a need for frequent checking. By creating a persistent tooling validation within the simulation, changes in product or process can be tested against the tooling choices on an on-going basis.

The activities in this section draw upon the knowledge gained in creating move activities in the “Create the Simulation” module.


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Persistent Tool Validation - ProcedureA Persistent Tool Validation becomes part of the simulation.

1 Open the simulation that will contain the tooling validation.

2

Choose the location for the tooling validation study.

Under the process activity that involves the identified location, create a move activity.

Use the catalog browser to bring in the tool or tools that will be validated. Recall that they will be listed in the ResourceList once they are in the world. Position it (them) in a convenient location.

3

4

NOTE: The tool must move to the validation location and also move away so that the simulation can continue to run in its original condition.

This procedure will create two move activities. One movement tothe location, and another movement away from the location.

NOTE: Smart Target is very useful for positioning the tool.

Turn on Clash Detection and Analysis Mode.

5

Inst.Inst.

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Persistent Tool Validation - Procedure

6 Recall the Create Move Activity Procedure, and make a move activity that will place the tool at the validation location.

1. Select Create Move Activity Icon.

2. Select Process Activity node.

3. Decide Position ( Before, As Child, or After).

4. Select tool from ResourceList and check the preview window.

5. Close Shuttle.

6. Move the tool to the validation location, recording the shots as you go.

7. Close the track when finished.

7 Repeat the Create Move Activity Procedure, and make a move activity that will remove the tool from the validation location.

Inst.Inst.

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Tool ValidationPersistent Tool Validation - Procedure

7

Create a Pause or Delay activity after the tool has moved to thevalidation location. This will permit the viewer to have time toexamine the tooling at the validation point.


Validation

Add a viewpoint change so that the tooling is clearly visible as it moves to the validation point.

10

9

8

RECALL:

• Highlight Process Activity.

• Highlight icon.

• Decide location (Before, As Child, or After).

• Manipulate view to new location.

• Close by clicking OK in the Activity Creation Option dialog box.

RECALL:

• Follow the same process.

• The Delay activity requires input for the length of time of the delay.

Run the simulation .

Inst.Inst.

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Persistent Tool Validation - Procedure

Additional move activities can be created to use the same tool to check additional locations, or, to use different tools to check the same location.

RECALL: Adjustments to sequencing can be made using the Pert Chart.

11 Compile the simulation and save it as a replay for later reference .

Inst.Inst.

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Persistent Tool Validation – Exercises

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Master Exercise – 3.5 HP Engine3.5 HP Engine (Step 34): Perform a Persistent Tool Validation

20 min.

Scope: This exercise offers practice in creating move activities for the inclusion of tool validation within a simulation .

Conditions: V5 and DPM Assembly Process Simulation workbench must be open.Access to the files in R16 DPM Assembly / PROJECT DATA.Pre-requisite skills in creating move activities, smart target, and

creating viewpoint and pause/delay activities is expected.

In this exercise you will:Modify an existing simulation to include a tool validation.Create move activities for tools.Create viewpoint changes.Create a pause activity.

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Create a Persistent Tool Validation.

Practice Create a persistent tool validation for the long narrow flat head screw driver against the Carburetor bolts listed.

1. Use Auto Sync or run the simulation until the carburetor is attached to the engine but is clear of surrounding parts. • If you choose to run the simulation, click

Pause when the condition above is met. 2. Visually locate the Carburetor bolts listed.

• Carb Bolts long• Carb Bolts.1• Carb Bolts.2• Carb Bolts.3

3. Turn on Dynamic Clash and Analysis Mode .

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4. Use Catalog Browser to locate the Lng Narrow screwdriver in the tools library. R16 DPM Assembly / Project data / catalog / Hand Tools Catalog.

5. Select the LNG Narrow screwdriver and bring it into the world.

6. Highlight the Carburetor Assembly process activity node in the PPR tree.

7. Create a move activity that moves the Lng Narrow screwdriver to Carb Bolts long. • Use Smart target to position the tool in the correct

alignment to the screw. • Don’t forget to record the shots.

8. Close the move activity with OK in the Track dialog box.9. Right click on the move activity and select Properties. 10. Rename the move activity to Move Screwdriver to Carb bolts

long.

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11. Create second move activity that moves the screwdriver from Carb bolts long to Carb bolts.1.

12. Right click on the move activity and select Properties.

13. Rename the move activity to Move Screwdriver to Carbbolts 1.

15. Create third move activity that moves the screwdriver from Carb bolts.1 to Carb bolts.2


17. Rename the move activity to Move Screwdriver to Carbbolts 2.

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18. Create fourth move activity that moves the screwdriver from Carb bolts.2 to Carbbolts.3


20. Rename the move activity to Move Screwdriver to Carb bolts 3.

21. Create fifth move activity that moves the screwdriver from Carb bolts. 4 to the second workbench.


23. Rename the move activity to Move Screwdriver to workbench.

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Do It Yourself (6/6)Create a Persistent Tool Validation.

24. Return to the first move activity for Carb bolt long, and insert a viewpoint change that will permit an observation of the screwdriver at the verification point.

25. Continue to add viewpoint changes for all of the screwdriver move activities, including the final move to the workbench.

26. Return to the first move activity for Carb bolt long, and insert a delay activity of 5 seconds.

27. Add a delay activity of 10 seconds to the Carb bolts.1 verification.

28. Add a delay activity of 5 seconds to the Carbbolts.2 verification.

29. Add a pause activity at the Carb bolts3 verification.

30. Run the simulation. Use the Pert Chart to adjust any changes in sequencing.

31. Compile the simulation and give the replay a unique name.

Save As: R16 DPM Assembly / Project Data / Process / Tool Validation

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DAdd Human

Hand Validation

Add a Human Hand to the Validation

Inst.Inst.

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Add Human Hand

Validation7 Tool Validation

About Add Human Hand Validation

This process step adds depth to the validation study by providing the influence of a human hand in conjunction with the tooling being validated. It is not designed to be a full ergonomic study; instead, it represents another level of assembly complexity relative to the tooling. Its purpose is to generate a more complete view of the intended assembly process.

With dynamic clash detection enabled, the hand as well as the tooling can be evaluated for interference.

This type of study requires that a persistent validation study has been, or is being, constructed.

The activities in this section draw upon the knowledge gained in Creating Viewpoint changes in the Enhance the Simulation module.


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Tool Validation

1

Bring the Human Forearm to the Tool - Procedure

7

2

A hand for the validation study can be obtained from the Ergonomics Design and Analysis configuration on the Human Builder workbench.

Open the Human Builder workbench.

A tool validation with the human hand adds another perspective to the assembly simulation.

Locate the Manikin Tools toolbar and click on the Insert a new manikin icon.

Add Human Hand

Validation

3 The New Manikin dialog box appears.

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Add Human Hand

Validation

Tool Validation 7


4

5Go to the Optional

tab and select a right or left forearm from the drop down list under Model .

6

Set the Father product by clicking on the Product node of the PPR tree.

A human forearm appears on the screen.

Name it and Save it in a convenient location. Inst.Inst.

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Add Human Hand

Validation

Tool Validation 7


7 Open the DPM Assembly project in which the tooling validation study is being conducted. If a persistent tooling validation has already been built, use Auto sync to set the simulation to the point where the tooling enters the simulation. If not, then associate the hand with the tooling when the move activity is created.

Turn on clash detection and position the hand near the tooling. Make sure the entire forearm product is highlighted in the PPR tree.

8 Use the Insert a Resource command from the Insert menu or the icon. Navigate to the location where the forearm was saved and insert it into the world.

9

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Add Human Hand

Validation

Tool Validation 7


11

Close the box when complete.

13 In the Grasping box, use the up or down arrows to set the position of the grasp.

14

Set the type of grasp needed by selecting the appropriate radio button. For the example shown, a cylindrical grasp is required.

Return to the Start menu and access the Ergonomics configuration again. Open the Human Task Simulation workbench.

10

12

Select the Standard Pose icon from the Manikin Posture toolbar.

The Standard pose dialog box will open indicating the hand grasp function.

Inst.Inst.

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Add Human Hand

Validation

Tool Validation 7


16 The forearm grasp and location is maintained by saving it in the state desired. Select Save Initial State from the Simulation toolbar.

15 Return to the DPM Assembly workbench and make any positioning adjustments necessary.

17

18

Select the radio button that prompts for Selected Products and Resources only.

Select the forearm product from the PPR tree. Click OK to close.

Inst.Inst.

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Add Human Hand

Validation

Tool Validation 7

Perform Multiple Checks with Edit Shuttles - Procedure

1

asdfasdf.

3

Highlight the second move activity for the tool and right click to show the drop down menu.

At the bottom of the list is a description of the move activity. Select it and the menu will expand. Click on the Edit Shuttle option.

2

9

The Edit Shuttle dialog box and the preview window will open.

If the same tool is used to perform multiple validations, the hand can be associated with each check point by editing the shuttle of the move activity to include 2 products (both the tool and the hand).

Inst.Inst.

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Add Human Hand

Validation

Tool Validation 7

Perform Multiple Checks with Edit Shuttles - Procedure

4 Notice that the Selection box indicates 1 product. Click on the forearm and the box will change to indicate 2 products. The hand will also appear in the preview window.

5 Select OK and the hand will be associated with the tool at the second move activity.

6 Repeat this process for any additional move activities with this tool.

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Add Human Hand

Validation

Tool Validation 7

Use Visibility Activities - Procedure

Once the forearm is brought into the world it is visible for the entire simulation unless visibility activities are inserted to control the timing of the appearance.

1

Since, the tooling validation is concerned only with the hand in relation to the tool, the hand should appear only when the tooling enters the simulation. It should also disappear when the tooling check is completed, allowing the simulation to continue to run without visual complications.

Insert visibility activities to hide or show the human forearm at appropriate points in the simulation.

Recall the create visibility activity procedure:

1. Select the Create Visibility Activity icon.

2. Select the insertion point.

3. Select the product(s) from the PPR tree.

4. Choose whether the product(s) will be Hidden or Shown.

5. Make any color or opaqueness adjustments desired.

6. Select OK.

Inst.Inst.

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Tool Validation with Human Hand –Exercises

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Master Exercise – 3.5 HP Engine3.5 HP Engine (Step 35): Tool Validation with Human Hand

20 min.

Scope: This exercise offers practice in creating move activities for the inclusion of a human hand with the tool validation.

Conditions: V5 and DPM Assembly Process Simulation workbench must be open.Access to the files in R16 DPM Assembly / PROJECT DATA.Pre-requisite skills in creating move activities, viewpoint changes, and

visibility activities.

In this exercise you will:Modify an existing simulation to include a human hand with the tool validation.Edit the shuttle of existing move activities. Insert visibility activities.

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Load: R16 DPM Assembly / Project Data / Process / Tool Validation

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Practice 1 Incorporate the human hand with the persistent tool validation created earlier.

1. Access the Human Builder workbench and Manikin Tools toolbar. 2. Set the Father product by clicking on the PPR tree product node. 3. Go to the Options tab and select Left Forearm. 4. Save the forearm as Human Hand in R16 DPM Assembly/ Project Data/ Resources.5. Return to DPM Assembly workbench and insert the resource (hand) into the environment. 6. Use autosync to set the simulation to the first move activity with the tool. The screwdriver

is positioned at carb bolt long. 7. Turn on dynamic clash.8. Move the forearm close to the screwdriver. 9. Highlight the forearm and open the Human Task Simulation workbench.10. Select Standard Pose from the Manikin Posture toolbar. 11. Set the dialog box for a cylindrical grasp and use the arrows to set the grasp closure. 12. Make positional adjustments for the hand on the tool. 13. Save the initial state of the Selected products (Forearm).

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Practice 1 Incorporate the human hand with the persistent tool validation created earlier.

14. Highlight the second move activity of the screwdriver, Screwdriver to Carb bolts.1.15. Edit the shuttle of this move activity to include 2 products (Screwdriver and hand).16. Repeat the edit of the shuttle for each of the remaining screws.

• Screwdriver to Carb bolts.2.• Screwdriver to Carb bolts.3.• Screwdriver to workbench.

17. Create the following visibility activities.• Hide the forearm at the start of the simulation.• Show the forearm when the screwdriver meets Carb bolts.

Long.• Hide the forearm when the screwdriver is on the workbench.

18. Run the simulation with clash detection on. 19. Make any adjustments to the visibility activities in the Pert Chart.20. Make any viewpoint changes that are desired. 21. Compile the simulation into Tooling Replay.

Save As: R16 DPM Assembly / Project Data / Process / Tool Validation_hand

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7 Tool Validation – Module Summary

SummaryThe ability to check the tooling within the simulation offers an advantage to the

implementation of a manufacturing plan. Tools can be easily inserted and removed from the world once their suitability is checked, or, they can remain as part of the simulation for future reference and communication.

Where tooling involves the use of humans, it is useful to gain an initial perspective on this element. Detecting collisions between tooling and human components prior to manufacturing launch adds significant value to the tooling validation study.

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delmia dpm m7 - tool validation

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