A MODULE FOR PERFORMANCE IMPROVEMENT
OF SPOT WELD FEATURE
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)
Duration : October 2002 to February 2003
Location : EDS PLM Solutions Center
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;
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.
a) Geometry Selection issues are taken care of
Performance Improvement of the
existing SPOT WELD
(MODULE – II)
What is A Spot Weld
In huge assemblies, if number of spot weld points
are more and user requires to create new spot
points, it slows down the performance
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
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
Using a static List pointer
Creating a Weld ID Manager
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
struct id_manager_s *next; /* next pointer */
} id_manager_t, *id_manager_p_t;
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
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
The old program takes 56 minutes to assign ID‘s to
new program takes less than 30 seconds to assign
satisfy all the required conditions mentioned in the
Part File Used for Testing The
Performance of Spot Weld
What is Assembly Modeling?
Assembly is an integrated Unigraphics application
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
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.