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                                 an Industrial Project Report
submitted to the International Institute of Information Technology in partial fulfilment of the
                         requirements for the award of the degree of

                               MASTER OF TECHNOLOGY
                                IT in BUILDING SCIENCE

                                AMIT KUMAR SARAN
                                 (Roll No. - 200110001)

                                    Under the guidance of

           Mr. Subhash A. Upadhyaya Dr. Pradeep Kumar Ramancharla
             Project Leader(TCS)         Assistant Professor(IIIT)
              Project Details
Duration        : October 2002 to February 2003
Location        : EDS PLM Solutions Center
                  TCS, Secunderabad
Guide           : Dr. Pradeep K. Ramancharla
                 Assistant Professor, IIIT Hyderabad.

                 Mr. Subhash A. Upadhyaya
                 Project Leader, TCS Hyderabad
Domain of Project: CAD/CAE
Prog. Languages : UniGraphics Open API,
                   UI Styler & ‘C’
      Brief Description of The Project
The project work includes two modules:

Development   of a GUI for the existing Plug/Slot Weld

A   module for performance enhancement of the Spot Weld Feature

The modules are developed in HP-UX environment using
UniGraphics Open API, UI Styler and 'C' programing Language.

The project work also includes extensive work in Solid Modeling,
Assembly Modeling and Study of UniGraphics Knowledge Fusion

Due to the strict guidelines of Tata Consultancy Services (EDS
PLM Solutions Center), Secunderabad the complete details of the
work is not provided.
Design & Development of a GUI for
 the existing PLUG/SLOT Weld in
     Unigraphics using UFUNC

          (MODULE – I)
A Plug/Slot Weld
 Provision to select faces in two separate face sets
 Provision for selection of hole/slot edges only
 Dialog items and Navigation button Sensitivity
 Face Selection and Edges Highlighting Issues
  (Simultaneous Selection of Edges belong to slot

 Geometry Selection Issues
 Provision for display of cue and status messages
The GUI for Plug/Slot Weld
   The Structure used is :-

    typedef struct WELD_plug_slot_data_s
       tag_t      face;     /* Top face of top plate */
       tag_t      opp_face; /* Top face of bottom plate */
       int        num_edges; /* Number of edges selected */
       tag_t      *edges;    /* List of edges selected */
     } WELD_plug_slot_data_t, *WELD_plug_slot_data_p_t;
              Methodology continued…

 Selection   CallBack
 a) Dialog items and Navigation button Sensitivity
     issues are taken care of

 b) Face Selection and Edges Highlighting issues
     are taken care of.

 c) Display of cue and status messages are also
     taken care of.

 d) After selecting relevant faces/edges, they are put
     to respective list/tag pointer.
            Methodology continued….

 Filter   Procedure
  a) Geometry Selection issues are taken care of
Performance Improvement of the
     existing SPOT WELD

         (MODULE – II)
What is A Spot Weld
          Problem Statement
In huge assemblies, if number of spot weld points
are more and user requires to create new spot
points, it slows down the performance
          Problem Description

 It takes a significant amount of time to
  assign 'ID' on each weld point.
 If we observe carefully, the weld points are
  created first and then spot ID's are assigned.
  It takes more time to assign the Weld ID's

   Weld ID's should be unique
    (No     duplicate      ID's      are      allowed)

   Weld ID's should be within the preference
    minimum/maximum range

   If some of the weld points are deleted, there will
    be a 'gap' in ID's and these gaps need to be filled
    when we assign ID's for newly created spot welds
       Scope of Improvement

 Reduce the 'feature cycling' time
 Reduce the number of time the whole
  assembly is cycled
              Possible Solution

   Using a static List pointer

   Creating a Weld ID Manager
                 Final Solution
   We have created a Weld ID Manager
    typedef struct id_manager_s
       tag_t object_tag; /* tag of weld feature */
       char *ind_id;     /* assigned ID for the weld
                            feature */
       struct id_manager_s *next; /* next pointer */
     } id_manager_t, *id_manager_p_t;
                 Solution continued…

Once the user creates some new spot features

 ID    Manager     is    initialized  by     cycling   the
  whole part only once
 While assigning the individual ID’s we’ll search the Weld
  ID Manager
   Lowest possible ID is assigned and pushed into
    the ID Manager along with its tag
    We have tested it with an existing part file having
    693 spot features. Then we tried to create 15 new
    spot features.

   The old program takes 56 minutes to assign ID‘s to

   new program takes less than 30 seconds to assign
    the ID's

   satisfy all the required conditions mentioned in the
    previous slide
Part File Used for Testing The
 Performance of Spot Weld
Assembly Modeling
     What is Assembly Modeling?
  Assembly is an integrated Unigraphics application
  that facilitates:
 The construction of assemblies of parts
 The modeling of individual parts within the
  context of the assembly
 The production of parts lists for assembly
    Assembly Modeling Philosophy
   Object-oriented      data    management
    architecture is used to support the team-
    oriented assembly modeling environment

   The goal is to produce a product modeling
    system for real-life products, typically
    designed by teams working concurrently on
    assemblies of thousands of parts
    Types of Assembly Model Design

   Bottom-Up Design

   Top-Down Design
      Reducing Complex Assembly

   Using Reference Sets

   Erasing an Entire Component or Sub-assembly

   Suppressing Features and Components
UniGraphics Knowledge Fusion
              What is UG/KF

Unigraphics Knowledge Fusion(UG/KF) is the
integration of Unigraphics CAD/CAM/CAE software
and Knowledge Based.

UG/KF fully complements Unigraphics' traditional
strengths in interactive design of complex geometric
models and assemblies, and the tools for user
customization that have been available with UG/Open.
              What is UG/KF continued …

UG/KF enables the user to develop applications and
control Unigraphics objects via engineering rules that
extend beyond a purely geometric nature.

These engineering rules may involve engineering
calculations such as non-geometric physical properties,
analysis results, sensitivity, optimization plan, goal
seeking iterations, aesthetics, product, process and work
breakdown structures, etc.

For example, requirements based on physical properties
such as force, torque, heat, etc. may be captured as part of
a UG model.
        How UG/KF can help Engineers and
     With UG/KF, engineers and designers will be able to
     construct a reusable knowledge base. They will be able

1.   Utilize user knowledge bases that already exist in
     external databases, spreadsheets, handbooks, custom
     software etc, during the engineering process.

2.   Use rules to enable model definition, checking, advising,
     optimization, enforcement of design rules , etc.
     How UG/KF can help Engineers and Designers

3.    Make external (non-UG) software tools
      available to the engineering process, i.e.,
      optimization and analysis.

4.    Capture and enforce company best practices.

5.    Virtual Model Development i.e. Extend the
      Unigraphics data model by easily creating
      custom modeling features that are controlled by

Performance enhancement for the existing spot weld
feature of UG Weld finds great relevance in
engineering as it reduces the consumption of
computing resources as well as the time involved for
computations significantly. The module developed for
performance enhancement as part of this project
reduces the time for creating the spot weld feature by
almost 56 times and the CPU usage significantly.
Tests for the same were conducted and the results
were validated under technical supervision.
Presently the IDs are stored as Strings in the Weld
ID manager. This increases the complexity in
retrieving the lowest possible ID from the ID
manager. As further work ID’s can be stored as
integers in ascending order and while assigning
the attributes to the spots the same can be
converted to Strings.

The current module creates the ID Manager and
deletes it once ‘Apply’ or ‘OK’ is pressed. As
future development the ID Manager can be created
by invoking the Spot Weld Dialog and deleted as
soon as the Dialog is exited.
Thank You

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