Large assemblies presentation - Barry

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First Slide

HANDLING LARGE ASSEMBLIES

USING SOLIDWORKS 2004

TIPS AND TECHNIQUES

Senthil Kumar

Manager, Engineering Services

Shaji Shereef

Sr. Engineer & CSWP

Barry-Wehmiller Companies, Inc.

Our Beginnings...

Founded in 1885

Today...

22 Facilities

23 acquisitions in the past 15 years

2600+ Employees

350+ employees Dedicated to

Consulting

Large & Diverse Client Base

Revenues of $500MM

Privately Held

Barry-Wehmiller Companies, Inc.

Organizational Chart

Barry-Wehmiller Companies, Inc.

Barry-Wehmiller Packaging Group Barry-Wehmiller Consulting Group Barry-Wehmiller Corrugated Group

Design Group BWIR

Packaging Industry

Integrators

IT and Engineering

Services

Consulting Group Facts

Employs 300+ Consulting Professionals with broad industry experience.

Provided Clients with 450,000+ consulting hours in the last year.

Executed hundreds of projects.

2003 Revenue of $100M.

Acquired an offshore consulting business to expand our resources and to provide cost effective services to our global clients.

Services offered

Product Design

Automation / API Programming

Modeling, Drafting and Analysis Support

Legacy Data Conversion

PDM Integration

Controls Design

– PLC, SCADA and Schematics

Representative Clients

HANDLING LARGE ASSEMBLIES

USING SOLIDWORKS 2004

TIPS AND TECHNIQUES

Overview

Define large assembly

Problems faced

Understand the issues and reasons

How to improve performance of a large assembly

– Hardware

– Modeling features

– Drafting features

– Productivity tools

– Best practices

– System options

How do you define a large assembly?

Any assembly which slows down your machine can be called a large assembly .

This could be 100 parts for someone and

10,000 parts for the other.

An assembly with 100 simple parts responds faster than an assembly with

100 complex parts.

Complex parts mean parts with a lot of external references, curved surfaces, sweeps, loft features and more number of faces.

Problems encountered with large assemblies

Slow

Unstable

System Crashes

Understand the issues and reasons

Optimizing large assembly performance boils down to reducing the amount of work the CPU, memory and disk drive have to do.

The goal is to take available hardware and do more with large assemblies (solve / evaluate designs).

To improve large assembly performance we need to

Reduce memory usage

Accelerate retrieval time

Improve regeneration time

Increase display speed

But how?

We can optimize the performance by understanding the following in context of a large assembly.

Hardware

Modeling features

Drafting features

Productivity tools

Best practices

System options

hardware

Hardware

First and the most influencing factor on large assembly performance is the hardware.

Nothing could substitute for sheer system power!!

RAM

Faster Video Card

CPU Speed

Faster Data Transfer

Network

Service Packs

Swap Space

Modeling features

Modeling Features…

Resolved / Suppressed / Lightweight features

Modeling Features…

Comparison of Components Suppression States

Resolved Lightweight Suppressed Hidden

Loaded in memory

Visible

Features available in FeatureManager design tree

Yes

Yes

Yes

Partially

Yes **

Yes ***

No

No

No

Yes

No

No

Faces and edges accessible for adding mates

Mates solved

In-context features solved

Assembly features solved

Considered in global operations

May be edited in-context

Load and rebuild speed

Display speed

Yes

Yes

Yes *

Yes

Yes

Yes

Normal

Normal

Yes ***

Yes

Yes

Yes

On demand **

Yes ***

Faster

Normal

No

No

No

No

No

No

Faster

Faster

No

Yes

Yes

Yes

Yes

No

Normal

Faster

*

**

***

In-context features on resolved parts that reference lightweight parts update automatically.

Global operations include Mass Properties, Interference Detection, Exploded View, Advanced Selection and

Advanced Show/Hide, solving equations, displaying section views, and exporting to other file formats. When lightweight components are present, the software prompts you to either resolve them, or cancel the operation.

Lightweight components are resolved automatically when selected for this operation.

Modeling Features…

The sketch can be used to define the location and angle for interrelated assembly components.

Unnecessary assembly components can be hidden or suppressed to minimize the visual clutter and the required system overhead.

This helps to improve performance and allows the designer to effectively focus on the task at hand.

Assembly Layout Sketch

Modeling Features…

Advanced Show / Hide features

Modeling Features…

Envelopes

Advanced component Selection (inside, outside, crossing)

Modeling Features…

Organize Parts in Assemblies

Use Folders

Organize Features in Parts

Organize Mates for better control

Drafting features

Drafting features…

Lightweight Drawings

Lightweight drawings are analogous to lightweight assemblies.

When a drawing is lightweight, only a subset of its model data is loaded in memory. The remaining model data is loaded as needed.

Drafting features…

With lightweight drawings, you can:

Create all types of drawing views

Attach annotations to models in views

Specify edge properties

Highlight and dynamically select edges and vertices

Set drawings of sub-assemblies to lightweight or resolved

Drafting features…

Detached drawings

The term RapidDraft has been replaced by Detached. Detached drawings are those that do not need their associated models when opened.

Productivity tools

Productivity tools…

SolidWorks Task Scheduler

Unattended Automation Of:

Drawing creation

Publish eDrawings

File import/export

Printing

Updates

Custom scripts

Productivity tools… eDrawings

Use eDrawings for communication.

Multi-sheet drawing with

6 sheets and 32 drawing views, 11MB

(part+drawing), becomes

2MB edrawing… (82% smaller..)

Best practices

Best practices in part modeling…

Fully Defined Sketches

Use Fully Defined Sketches whenever possible

Do not use Over Defined or

Under Defined sketches

Best practices…

Image Quality

Use Lower settings for Image

Quality for faster loading

Best practices…

Rebuild Errors

Always resolve rebuild errors

Best practices…

Shaded View

Use shaded view without edges

Shaded view with edges

Shaded view without edges

Best practices…

Advanced Features

Minimize use of advanced features like Sweep, Loft etc., if possible

These features take more regeneration time

Use simple features wherever possible

Best practices…

Functional Dimensions for Purchased Parts

Model the purchased parts with minimum details (Ex: Bearings, Motors etc,)

Best Practices…

Model purchased items as Parts than Assembly

Best practices…

Configurations

Configurations are the most powerful tool to manage large

Assemblies

Use simplified configurations for parts and assemblies

Default configuration

Simple configuration

Best practices…

Geometry Pattern

Use geometry pattern wherever possible

Geometry pattern increases regeneration speed

It also helps loading assemblies faster

Best practices…

Number of Steps in Feature Tree

Try to reduce the number of steps in feature tree

Plan ahead before modeling to reduce the number of features

Combine features sensibly (mirror bodies etc..)

Best practices…

External References

Remove all external references once the design is completed

Lock the external references whenever possible

Best practices…

Fillets & Chamfers

Add fillets & chamfers at the end of the of the model whenever possible

Suppress fillets & chamfers in simplified configurations

Combine fillets of equal size

Best practices…

Cosmetic Features

Try to avoid modeling of conventional threading

Use cosmetic threads representation

Avoid too much cosmetic features which are not needed all the time in the design

<100 KB >900 KB

Best practices…

Helix

Use only representation

Best practices…

Company Logos, Text etc

Use simplified representation for company logos, text etc

Best Practices…

Configuration for Fasteners

Make configuration to suppress fasteners in an assembly,

It improves the file loading time

Configuration With Fasteners

Configuration Without Fasteners

Best Practices…

Lightweight and Configure Options

Use lightweight & select configuration while opening an assembly

System options

System Options…

Large assembly mode

When working with large assemblies take advantage of the large assembly mode and customize the settings to increase the performance

How to switch on/off large assembly mode??

Other options to improve large assembly performance.

Verification of rebuild (Switch-Off)

Image Quality Settings. (Set it as low as you can work with)

samples

Rollstand frame and Splicer

6000 components

Model II - Rollstand

3000 components

Slitter Scorer Machine

Over 5000 components

Process machinery line

Over 10,000 components

Wrap up..

So…. thoughtfully developed best practices, effective utilization of configurations and understanding the innovative features available with SolidWorks 2004 will help you to design larger assemblies without compromising the performance.

Questions ?

Thank You…

Contacts:

jim.webb@bwir.com

senthil.kumar@bwir.com

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