An Open and Shut Case An Open and Shut Case for Flexible Componentsfor Flexible Components

Michael MongilioMichael MongilioJHU Applied Physics Lab, Laurel, MDJHU Applied Physics Lab, Laurel, MDSwales Aerospace, Beltsville, MDSwales Aerospace, Beltsville, MD

What Are Flexible Components?What Are Flexible Components?

In the Physical World:In the Physical World:– An item whose shape is non-rigid. It’s shape can be An item whose shape is non-rigid. It’s shape can be

changed as it is used in an assembly by bending, changed as it is used in an assembly by bending, twisting, stretching, hinged movement, etc.twisting, stretching, hinged movement, etc.

In the Pro/ENGINEER World:In the Pro/ENGINEER World:– A component in an assembly whose representation has A component in an assembly whose representation has

been changed compared to its stand alone been changed compared to its stand alone configuration without creating a new model name or configuration without creating a new model name or instance. The variation only exists in the context of the instance. The variation only exists in the context of the assembly in which it has been changed.assembly in which it has been changed.

The Need for Flexible ComponentsThe Need for Flexible Components

There are many occasions when a component There are many occasions when a component needs to be added to an assembly but it won’t needs to be added to an assembly but it won’t look like its standalone representation.look like its standalone representation. A spring – In the assembly, it may be extended, A spring – In the assembly, it may be extended,

compressed, or twistedcompressed, or twisted

An electronic component – In the assembly, its leads An electronic component – In the assembly, its leads may be bent or trimmedmay be bent or trimmed

A Hinge Sub-assembly – In the assembly, the hinge A Hinge Sub-assembly – In the assembly, the hinge may be in any position from opened to closed.may be in any position from opened to closed.

Other ExamplesOther Examples

Compression of a RivetCompression of a Rivet

Compression of a Gasket or Other ElastomersCompression of a Gasket or Other Elastomers

Ropes, Straps, Hoist CablesRopes, Straps, Hoist Cables

Covers, Safe Pins Removed at AssemblyCovers, Safe Pins Removed at Assembly

Flex Circuits – Printed WiringFlex Circuits – Printed Wiring

Family Table Instance MethodFamily Table Instance Method

Each Variation could be created as a new Each Variation could be created as a new instance on a family tableinstance on a family table+ Instance Shows Correct Configuration of DesignInstance Shows Correct Configuration of Design

+ Can be Automatically Substituted for Generic in Can be Automatically Substituted for Generic in AssemblyAssembly

– Variation restricted to discrete dimensional valuesVariation restricted to discrete dimensional values

– Each variation (instance) is a new part number, giving Each variation (instance) is a new part number, giving incorrect Bill of Materials informationincorrect Bill of Materials information

– Variation can only be created at the sub-assembly in Variation can only be created at the sub-assembly in which the component is a direct member. which the component is a direct member.

Flexible Component MethodFlexible Component Method

Define Component FlexibilityDefine Component Flexibility+ Variation is Created Only at the Assembly Where it is Variation is Created Only at the Assembly Where it is

Needed.Needed.

+ Variation can be discrete values or measurement of Variation can be discrete values or measurement of assembly conditionassembly condition

+ Variation does not create a new part number. Bill of Variation does not create a new part number. Bill of Materials reports correctlyMaterials reports correctly

+ Variation can transcend the assembly hierarchy. Variation can transcend the assembly hierarchy. Flexibility can be defined on a component multiple Flexibility can be defined on a component multiple levels deep with out affecting the in-between sub-levels deep with out affecting the in-between sub-assemblies. assemblies.

Part FlexibilityPart Flexibility

Defining Flexibility “On the Fly”Defining Flexibility “On the Fly”– Select the component to be made flexibleSelect the component to be made flexible

(model tree or graphics window)(model tree or graphics window)

– Right click > Make FlexibleRight click > Make Flexible

Part Flexibility – Dimensional VariationPart Flexibility – Dimensional Variation

Select Dimension to Vary and New Value Select Dimension to Vary and New Value

Part Flexibility – Dimensional VariationPart Flexibility – Dimensional Variation

Model regenerates to new dimensionModel regenerates to new dimension Name in Model Tree is UnaffectedName in Model Tree is Unaffected

Part Flexibility – Dimensional VariationPart Flexibility – Dimensional Variation

Name and Quantity on Parts List is CorrectName and Quantity on Parts List is Correct

Dimensional Variation - MeasuredDimensional Variation - Measured The Dimensional Variation Desired May Not be a Fixed The Dimensional Variation Desired May Not be a Fixed

ValueValue

When Establishing Variability, the Dimensional Variation When Establishing Variability, the Dimensional Variation May Be Determined by a MeasurementMay Be Determined by a Measurement– DistanceDistance

– Curve LengthCurve Length

– AngleAngle

– AreaArea

– DiameterDiameter

Dimensional Variation - MeasuredDimensional Variation - Measured

Spring Adjusts to Measured DistanceSpring Adjusts to Measured Distance

Dimensional Variation - MeasuredDimensional Variation - Measured Spring Height Adjusts Automatically When Gap Height IncreasesSpring Height Adjusts Automatically When Gap Height Increases

(Make the Original Model Correctly)(Make the Original Model Correctly)

As a Spring Elongates, the Coils Should Stretch.As a Spring Elongates, the Coils Should Stretch.

Associated ParameterAssociated Parameter

Allows Varied Item Dimension to be Controlled Allows Varied Item Dimension to be Controlled by a Relation or a Family Tableby a Relation or a Family Table– Add Column for Assoc ParamAdd Column for Assoc Param

Associated ParameterAssociated Parameter Specify a Name for the Associated ParameterSpecify a Name for the Associated Parameter

The Parameter is Accessed from the Relations Menu or The Parameter is Accessed from the Relations Menu or the Family Table Menu as a the Family Table Menu as a ComponentComponent Parameter Parameter

Part Flexibility – Feature VariationPart Flexibility – Feature Variation Example: Capacitors with different lead configurationsExample: Capacitors with different lead configurations

Part Flexibility – Feature VariationPart Flexibility – Feature Variation

All Lead Configurations are Modeled in PartAll Lead Configurations are Modeled in Part

Part Flexibility – Feature VariationPart Flexibility – Feature Variation Select Features TabSelect Features Tab Suppress or Resume Appropriate FeaturesSuppress or Resume Appropriate Features

Part Flexibility – All OptionsPart Flexibility – All Options

DimensionsDimensions

FeaturesFeatures

Geom. TolsGeom. Tols

ParametersParameters

Surf FinishSurf Finish

Assembly FlexibilityAssembly Flexibility In Addition to the Varied Items of Part Flexibility, In Addition to the Varied Items of Part Flexibility,

Assembly Flexibility Can Suppress or Resume Assembly Flexibility Can Suppress or Resume ComponentsComponents

Varied Items can be Selected from the Assembly Varied Items can be Selected from the Assembly Itself or from any Sub-Assembly Component at Itself or from any Sub-Assembly Component at any Sub-Assembly Levelany Sub-Assembly Level

Assembly FlexibilityAssembly Flexibility

Dimensional Modification to Sub-AssemblyDimensional Modification to Sub-Assembly

Assembly FlexibilityAssembly Flexibility

Dimensional ModificationDimensional Modification

This Hinge Angle Set to 45ºOriginal

Hinge Assembly

This Hinge Remains Unchanged

Assembly FlexibilityAssembly Flexibility

Set Second Hinge to Measure First Hinge AngleSet Second Hinge to Measure First Hinge Angle

Where to Establish FlexibilityWhere to Establish Flexibility ARRAY-HINGE Flexible in SOLAR-ARRAY Sub-assemblyARRAY-HINGE Flexible in SOLAR-ARRAY Sub-assembly

Both Arrays are Deployed at SPACECRAFT AssemblyBoth Arrays are Deployed at SPACECRAFT Assembly

Multi-Assembly Level FlexibilityMulti-Assembly Level Flexibility SOLAR-ARRAY Sub-Assembly Flexible at SPACECRAFT SOLAR-ARRAY Sub-Assembly Flexible at SPACECRAFT

AssemblyAssembly

Multi-Assembly Level FlexibilityMulti-Assembly Level Flexibility Select Dimensions from Lower Level Sub-Assembly Select Dimensions from Lower Level Sub-Assembly

ARRAY-HINGEARRAY-HINGE

Multi-Assembly Level FlexibilityMulti-Assembly Level Flexibility One SOLAR-ARRAY Deploys while Other Can be Shown StowedOne SOLAR-ARRAY Deploys while Other Can be Shown Stowed

This Sub-Assembly and Components are Flexible

This Sub-Assembly is Not

(How Would It be Done with a Family Table?)(How Would It be Done with a Family Table?)

Create a Family Table of the HINGE-ASSEM with Create a Family Table of the HINGE-ASSEM with Three Instances for 0Three Instances for 0°, 45° and 180°°, 45° and 180°

Create a Family Table of the SOLAR-ARRAY Sub-Create a Family Table of the SOLAR-ARRAY Sub-Assembly with an Open and Closed Instance. Add Assembly with an Open and Closed Instance. Add Each HINGE-ASSEM and Substitute with the Each HINGE-ASSEM and Substitute with the Appropriate InstanceAppropriate Instance

Create a Family Table of the SPACECRAFT Create a Family Table of the SPACECRAFT Assembly with an Open and Closed Instance. Add Assembly with an Open and Closed Instance. Add Each SOLAR-ARRAY and Substitute with the Each SOLAR-ARRAY and Substitute with the Appropriate InstanceAppropriate Instance

But what if I want to show partial deployment with But what if I want to show partial deployment with other angles?other angles?

Setting Up FlexibilitySetting Up Flexibility Flexibility Can be Pre-Defined in a ModelFlexibility Can be Pre-Defined in a Model

By Pre-Defining the Flexibility, the Variable Items are By Pre-Defining the Flexibility, the Variable Items are Stored in a Dialog Box for Easy AccessStored in a Dialog Box for Easy Access

Other Users Will Not Have to “Hunt” Through the Other Users Will Not Have to “Hunt” Through the Model to Establish its FlexibilityModel to Establish its Flexibility

When Making the Component Flexible, the Same When Making the Component Flexible, the Same Dialog Box Appears, but the Varied Items are Already Dialog Box Appears, but the Varied Items are Already PopulatedPopulated

Additional Items that Weren’t Pre-Defined Can Still be Additional Items that Weren’t Pre-Defined Can Still be AddedAdded

Setting Up FlexibilitySetting Up Flexibility

With the Model Active – With the Model Active –

Edit > Setup > FlexibilityEdit > Setup > Flexibility

Add the items Add the items (dimensions, features, (dimensions, features, etc.) which can be varied.etc.) which can be varied.