3DRealize Classic component library manual

3DRealize 3.1.3 Classic component library manual 20060516

Introduction
FlexLink 3DRealize is a three-dimensional sales support tool and simulation software. The program is created to support sales work and concept engineers. The user can design, visualize and simulate different concepts to a customer interactively using a prebuild plug-andplay component library. FlexLink 3DRealize works in a normal PC and it is easy to use. Layout design: To create a layout or a system, each visual component is first placed into the 3D World using dragand-drop mechanism. Each component can be modified by using the components parameters to create the required result. Components are then snapped into place using plug-and-play mechanism. The component interface controls the connectivity between components and handles material flow, signals and other communications automatically. During layout design, it is possible to check distances between machinery, display measurements and foot-print dimensions and access product documentation. Also plant layouts can be imported and three-dimensional layout can be exported to CAD systems. When the layout is ready, you can create high-quality pictures for quotes and presentations. You can also share your layout easily with other designers or members of the project organization. Simulation: The simplicity of Flex3DRealize comes from re-usable visual component models (modules, components etc.). These represent individual modules or components and encapsulate their actual intelligence (behaviors, logics, interface etc.). In this way simulation can be easily added to layout. Flex3DRealize is discrete-event 3D simulation software. A simulation models (mimics) a real-world system on the computer. The key part of every simulation is the use of varying (random) inputs. For example an amount of pallets in a system can be adjusted to reach maximal capacity (output). If the desired output is not reached, You can change other parameters or the layout.

Product Family FlexLink 3DCreate: Authors modules and components from available engineering data (3D CAD, brochures and technical specifications) and then publishes them for distribution. FlexLink 3DRealize: Configures existing modules and components into valid working 3D simulation layouts for analysis, demonstration, and presentation. FlexLink 3DRealizeR: Configures existing modules and components into valid working 3D simulation layouts for analysis, demonstration, presentation and robot simulation. FlexLink 3DVideo: A simple lightweight stand-alone application for interactive viewing of visual components and configured layouts.

Hardware requirements Operating system: 3DRealize works on Windows 2000 with service pack 1 (or higher) and Windows XP. You can install and run 3DRealize on other Windows platforms (Windows 98/ME/SE, Windows NT, Windows 2003 server), but these are unsupported platforms. 3DRealize will not work (or install) on Windows 95. Minimum hardware: CPU 1000MHz, RAM 256MB, OpenGL compatible graphics of 800x600 resolution and 16bit color depth. Recommended hardware: CPU > 1000MHz, RAM 512MB, OpenGL compatible graphics of 1024x768 resolution and 24-bit color depth. Also required: A two button mouse, a valid E-mail address (license information is sent using eMail), 100MB of hard drive. Highly recommended: A hardware accelerated OpenGL graphics card (such as NVidia GeForce or ATI Radeon), Internet connection You can install and run 3DCreate on other Windows platforms (Windows 98/ME/SE, Windows NT, Windows 2003 server), but these are unsupported platforms. 3DCreate will not work (or install) on Windows 95.

Installation
3DRealize installation. The size of the installation file is about 28 Mb. Program requires about 100MB of Hard Drive.

During installation, default paths and setting are recommended to use.

Activation
3DRealize activation. You can purchase the product key from FlexLink IT-HelpDesk.

Component installation
Installing component packages. Simulation components of different product families are distributed in component packages. Component package automatically installs the components to your 3DRealize. To install a component package, start the program, click Open from toolbar or select File -> open from menu bar. You can also drag and drop the component library file from a file browser to the 3DRealize window.

From the Component Package File -window, you can see a list of components in a package. You can see the name of the component and the path, where it will be installed. The tick box before each name indicates if you already have the component installed. If not or the current component is older than the new one, the tick box is checked and the component will be installed. Target eCat is the electronic catalogue where the components will be installed. This should always be automatic. Components will be installed to C:\Visual Components\3.0\eCat folder. If components are not visible in the eCat / Local Components after the installation, please press F5 to refresh the eCat (or right click over the eCat and select Refresh eCatalogue).

Support and Uninstallation

Support If support is needed, please read the manual, 3DRealize help, see the example layouts and practices and discuss with other users. If the problem is not solved please send email to jarkko. soikkeli@flexlink.com or in urgent matters, please call +358-40-5624 718 (06.00 20.00 GMT). Removing 3DRealize Uninstallation of 3DRealize can be started from: 1. Start -> Programs -> Visual Components oy -> Uninstall 3DRealize 2. Settings -> Control Panel -> Add/Remove Programs. Un-installation steps: Confirm your uninstallation request.

Transferring license. If the license should be transferred to another user, please go to Visual Components web site: http://licensor.visualcomponents.net/licensor/transfer and fill the information required. After license transfer the license key can be used again.

User interface

1. Menu Bar: The menu bar allows you to access the functionality of 3DRealize. 2. Tool Bar: The tool bar displays the most frequently used commands. 3. Simulation Controls: The simulation player has controls similar to a standard CD or cassette player. 4. Tabbed Panel: The tabbed panels select different contexts. 5. 3DWorld: The 3DWorld is a three dimensional display area. 6. Message Panel: The message panel displays the messages. 7. Status Bar: The status bar displays the selection mode and the name of the selected object. It also has different toggle option buttons. 8. Dynamic Tool Bar: The dynamic tool bar displays the possible options of an active command. Context Sensitive Menu: Context sensitive right-click pop-up menu gives access to commands that can be used in the given context.

3D World navigation and object manipulation

You can navigate either using the tool bar icons or using shortcut keys. If you activate a navigation command from a tool bar icon, you can end navigation by pressing space or selecting an other command. When navigation is activated using a shortcut, the last command that was active when navigation started is automatically activated when navigation ends. Orbit: (hold down ctrl + left mouse button and drag) Orbits the viewpoint around the center of interest. Pan: (hold down alt + left mouse button and drag) Moves the viewpoint along a view plane parallel with the screen. Zoom: ( hold down shift + left mouse button and drag) Moves the viewpoint closer or further away from the center of interest. Fill: (ctrl + shift + F) Fills the 3DWorld with the layout in the current pose. Center View: (shift + mouse button) Click on the point of interest in the 3DWorld and the camera centers to that point. ( Note: It is possible to pick only to real geometry, not to floor. ) Orbiting and zooming happens around the current point of interest. 3DRealize is object-oriented. Every action can be described as: -select an object -apply an operation on it. Select: You select an object simply by picking with left mouse button in the 3DWorld while Select is active from Toolbar. The current object is automatically unselected when you pick a new one. Select multiple objects either by holding down the shift and ctrl keys when picking or draw a selection rectangle with holding left mouse button and dragging. Trans (translate object): Move the object by dragging the desired handle (red, green, blue). Object must be selected (Select). Rot (rotate object): Rotate the object by dragging the desired handle (red, green, blue). Object must be selected (Select).

eCat
eCat (Electronic catalogue) Electronic Catalogue (eCat) has two purposes: -allows fast access to a components and layouts -links layout components to the actual component files. There are two types of eCats, Local and Web. Local eCat has only references to files stored on the machines hard disks or on the network drives. Web eCat entries are references to web pages that contain links to components or layouts. eCat folder is predefined and should not be changed. As a default, eCat points to the folder: c:\Visual Components\eCat All components are automatically installed under that folder. (Web eCat is not in use) Local eCat mapping file is (re)generated when you select menu bar->Tools->Refresh Component Map. Note: You have to regenerate the map file if you add or remove component files in the directories used in local ecat. eCat shows each repository as a separate folder.

Retriecing component and layouts

Changing parameters

Connecting components

Saving the layout

Connecting two components with matching interfaces. To remove a connected component from a layout, use always PnP function. If Trans is used, connection between components is not disconnected,

Saving the layout When saving, all connections between the components are saved in the layout file (same with the property values). The components themselves are not saved in the layout file, only the references to the components. This accounts for the usually small size of the layout file. Modifications to components geometry are saved to the component files. You can save layouts either from the Toolbar or menubar->File->Save Use credits to store additional information about the layout such as who made it. Company logo can be modified in a separate dialog (access by clicking right mouse button on the icon area).

Running simulation and common tasks

Running the simulation Simulation Time: Displays the current simulation time. The unit used is displayed if you rest the cursor for a few seconds on the display. Run/Pause: Toggles between playing and pausing the simulation. Reset: Resets the simulation Sim Speed: Controls the speed of the simulation. Move the slider left to slow down the simulation and right to speed it up. Adjusting the speed has no effect on the Importing CAD geometry: File > Import imports various 3D formats into 3D window. Imported geometries will not take part to simulation. You can also import components and layouts into existing layout. Exporting geometry to CAD: File > Export > Layout Geometry saves the geometries in the layout to a CAD file. Grouping selections: Edit > Groups. Groups are a way to collect multiple components under one selection. The components are not connected to each other by any means, not hierarchically or through interfaces. The group is simply a way to make a multi selection with one single selection. No other selection type e.g. frames can be grouped. The groups can not be nested, meaning that groups can not contain groups. A component can belong to only one group. Top view / layout view: To create a top layout view, change the view to Top from View > Standard views > Top and enable the Orthogonal view from View > Orthogonal view. Auto resize floor / change floor grid settings: You can enable auto resize and change the grid settings from View > Settings > 3D World.

Common tasks Exporting component package: The component package command saves all the components used in the layout into an installable component package file. This is useful when you need to send a layout to others who may not have all the components used. (Remember, layouts do not have the components, only references to them.) The component package file does not include the layout, only the components used Exporting images: File -> Export -> Bitmap saves a high resolution image of the current layout as shown in the 3D window to a file.

Common tasks
Measuring distances: Tools > Measure measures a distance (x- y- and z-differences) between two points in the 3DWorld. The two points are selected using snap filters. The measure command returns the difference in the x, y and z direction between the two points and the distance between the two points. All results are given in millimetres. The result is shown beside the measured points in the 3D World and in the message panel. Displaying footprint: Tools > Footprint displays the bounding area on the XYplane of the current layout. Copy / Paste selection: Edit > Copy (ctrl-C) copies the current selection to the clipboard. Edit > Paste (ctrl-V) pastes the clipboard into the selected location. If the selection contains only parent components, the selection can be connected as one set with PnP. Abstract connection (signal connection): Abstract connection is used to connect signals and other data between components and robots: 1. Select the component 2. Select PnP and Connect Abstract interfaces 3. Select the another component 4. if one of the components have more than one matching interface, Connection Editor-window appears, from where you can select desired interfaces. 5. Click Connect (or Unconnect) 6. White line indicates the abstract connection Connection editor lists all possible signal combinations. It is good to keep a track of the connections also with pen and paper. Interfaces can be considered as a real electric wire connection. Hierarchical Connection: Hierarchical connections are used to create dependencies between any components. Connection creates Parent / Child relations, where child component follows all the movements and translations of its parent: 1. Select the component 2. Select PnP and Set Parent Node For Selected Component 3. Select the another component 4. Blue arrow indicates the relationship Repeat connection to remove relationship. Accurate object manipulation: There are three ways to translate and orbit components: 1. Translation and orbit with handles. This is the most common way to locate components in 3DWorld. Translation and rotation are done with the mouse. 2. Translate command dynamic toolbar. Rotation and transformation can be also handled from dynamic toolbat when function is selected. You can also type evaluations into fields.

3. Translate along vector: Accurate translation can be done by selecting a point from object to be translated and after that by selecting another point from target component. Component is translated based on these to points (vector).

General layout creation

Classic component library introduction

Classic components package is a component package for 3DRealize 3.1.3 Component package includes basic conveyors, functions and tools for creating conveyor systems from FlexLinks products. Components are parametric and with plug-and-play -function. Library includes parametric conveyor components, elements, functions and modules. It also includes components which can be used as a products, trays or pallets in a simulation.

Component library -Conveyors

Conveyors: Component package includes a set of parametric conveyors to simulate different solutions and product families. All conveyor work with PnP -function and have common parameters: Name: Lx_Length: Bx_Angle: Bx_Radius: Bx_Direction: Bx_Wheelbend: TrackHeight: Speed: Capacity: Start: End: IdlerDiameter: BeamWidth: BeamHeight: Name of the component (text/string) Length of a conveyor section (mm) Angle of a bend (degrees) Radius of a bend (mm) Direction of a bend (left/right toggle) Visibility of a wheelbend (toggle) Height of the start of the conveyor from a floor level (mm) Speed of the conveyor (mm/s) Capacity of a conveyor (how many components can be on a con veyor at a same time, integer) Appearance of the start of a conveyor (drop-down list) Appearance of the end of a conveyor (drop-down list) Diameter of a idler wheel/unit (mm) Width of the conveyor beam (mm) Height of the conveyor beam (mm)

Dimensions: Dimensions are always in millimeters, angles are degrees, speeds are in mm/s, accelerations are in mm/s2, volumes are mm3, areas mm2 and times are seconds (if not noted otherwice).

Component library -Elements

Classic components package contains elements for creating conveyor segments and modules, which cant be done with the normal classic conveyor modules (from the component library). Most common use for the elements is to add idlers, beams and motors to the start or to the end of a function- or conveyor component.

The parameters of the element-components are similar to conveyor components. All elements behave as a conveyors.

Idler and conveyor elements are used to connect two process -functions to a conveyor component. Element Idler & Motor is used to add the idler component to the start of the conveyor segment.

Component library -Functions, modules and components

Functions: Beside actual conveyor components, component library includes functions for different purposes. Functions are pieces of conveyor track that can be connected to other functions or conveyors. They also share some of the conveyor parameters, but they have several special parameters, which are introduced separately. Functions can handle: -Creation of components into system (ramp-up, infeed point or upstream process machine) -Routing components in a system (diverting and merging points, pushers, product initialization) -Processing components in a system (manual, semi-automatic and automatic workstations) -Collecting information from a system (statistics, counters) Functions are parametric and highly flexible, so you can use same component for different solutions. Modules: Modules in the library are generic machines for different purposes, e.g. buffers and lifters. Modules are parametric and described separately.

Components: The actual products moving in a system are called components, or dynamic components. Dynamic components are created at a start of the simulation and are the active part of the simulation. Component can be ready product, pallet, container, bottle etc. and it can contain some sort of intelligence or escort memory, like barcode or RFID-tag. If component carries infromation, that information can be read, write and rewrite during simulation. Same infromation can be used in desicions and in routing.

Component library -Conveyors

Conveyor component with single horizontal bend

Parameters and selections for the appearance of the conveyors start and end -piece.

Conveyor component with single vertical bend

Component library -Conveyors

Conveyor component with two horizontal bends and selections for the appearance of the conveyors start and end -piece.

Conveyor component with two vertical bends.

Component library -Conveyors

Component for creating alpine conveyors. Incline -parameter can be also negative for creating decline alpine. BendDriveUnit, CommonShaft and ShaftHeight -parameters can be used to create a common drive for single alpine.

Straight conveyor component. If shorter piece of straight conveyor/beam than 400mm is needed, use Element -beam component from elements.

Component library -Conveyors

Wedge conveyor component. Overlap -parameter defines the overlap over the input/output conveyor in millimeters. This overlap is not taken account in dimensions. If wedge rotates component upsidedown, ProductHeight -parameter is redused from the conveyors total height.

Component library -Creator

Creator -function creates products or dynamic components at a start of the simulation. User can define, how often components are created (DelayProducts, seconds), are products created in batches (Batchlength) and how long delay in seconds there are between the batches (DelayBatch). Also the total amount of products can be adjusted (althought the batches are always finished). From Creator -parameter tab, user can select the dynamic components geometry and the size can be adjusted with products Length, Width and Height -parameters. Products can be also equipped with escort memory (like RFID or barcode), when a unique production route can be initialized inside each product created.

Component library -Creator

Component can be browsed from Creator -parameter tab, and if predefined component is selected, products color and dimensions can be adjusted.

Component library -Route

Route: In simulation each product can have a unique route. This route is initialized to product when it is created or it is reinitialized in Function -Initialization component. Route includes the information from every serial or parallel production step the product must reach and finish in order to finalize its production. When a product reaches its last production step, and the route is updated, route starts from the beginning. Routes structure: When product is initialised in Creator or in a function, route may be stamped into products escort memory. Route is build up from production step IDs, which can be serial or parallel. Serial steps are separated with > sign and parallel steps with / sign. Also the quantity and color of a product is defined in Creator and Initialization -functions. After initialization, product tries to reach or find the first ID (or IDs) defined in its route. Crossing -components can route products from track to another using components next ID, and process points can identify the correct component from the flow to be processed based on the ID -value. When product with route is processed and the route is updated, product continues its production trying to reach the next ID/IDs in its route. Example route in Creator or in Initialization -function: 3,green,Kitting>assembly1>assembly2>test1/test2>packing quantity,color,actual route (note: only the actual route is carried in escort memory) After initialization of this route, products ID, which it tries to reach, is Kitting. If the product reaches a process point where the route is updated, products first production step is finished and it continues its route trying to reach ID assembly1. test1 and test2 IDs are parallel production steps, so for the product, it does not matter which one it will reach. After the packing production step, route will start from the beginning: (Products next ID is highlighted) -Kitting>assembly1>assembly2>test1/test2>packing: -Kitting>assembly1>assembly2>test1/test2>packing: -Kitting>assembly1>assembly2>test1/test2>packing: -Kitting>assembly1>assembly2>test1/test2>packing: -Kitting>assembly1>assembly2>test1/test2>packing: -Kitting>assembly1>assembly2>test1/test2>packing: Kitting reached assembly1 reached assembly2 reached test1 OR test2 reached packing reached Route starts from the beginning.

Quantity -parameter is used to determine, how many of this type of products will be initialized before moving forward into the next route. Color -parameters helps the user to identify different batches in production.

Component library -Crossing

Crossing component is used to transfer components from a conveyor (track) to another. Crossing can handle one product at a time with a frequency (in seconds) defined by with InputFrequency -parameter. Crossing has several parameters: Blocking: Defines if the free track used if the another track is blocked for any reason, or will the crossing be blocked until there is capacity on output conveyor. Priority: Defines if one of the tracks has priority in crossing (selected track will be served by crossing always, if there are products coming). With BatchLength -selection crossing serves single track for the amount of products defined in BatchLength -parameter. TrackAToTrackB: These parameters define how many products arriving from track A are routed to track B. If e.g. Track1ToTrack2 parameter is 2 and Track1ToTrack1 parameter is 6, first, two products arriving from track 1 are routed to track 2, and after that, six products arriving from track1 will continue on track 1. Both tracks have their own parameters and they will work independently. IDsBehindTrackX: Comma separated list of IDs located behind track. If products next ID in route is listed, corresponding track is used.

Component library -Route

Component library -Crossing

Component library -BatchCreator and Frequency

BatchCreator -function is used to create batches or trains from the component flow. Creator will collect components until the amount of BatchLength -parameter is reached or time defined in TimeOut -parameter is reached (in seconds). After this, time defined in AccumulationDelay -parameter is spent (to minimize gaps between products) and train is sent forward. BatchCreator will wait until the whole train is left from the conveyor, until new batch is started to create.

Function -Frequency is used to separate components from each other. Function will release one pallet with frequency defined with Frequency -parameter (in seconds).

Component library -Process and Initialization

Process function is used to simulate automatic, semi-automatic or manual work. Product will stop in this function for a time defined in ProcessTime -parameter. Processtime may have variation (Variation -parameter, e.g. processtime of 10 seconds with variation of 3 seconds will result random time between 7-13 seconds). ID-parameter can be used to identify the workstation. If ID is used, only products with route, searching the same ID (next ID is same in product and in ID -parameter), will be processed. ProcessEvery -parameter can be used to skip passing components. If parameters value is 1, each and every product will be processed. If value is 2, every second product will be processed, if it is 5, every fifth is processed etc. UpdateRoute -parameter is used if products route should be updated (product starts to seek the next ID in the route). UpdateColor -parameter will change the color of the product if the product is processed. MTBF and MTTR (MeanTime Before Failure and MeanTime To Repair) can be used to simulate errors and production stops in workstation. Time defined in MTBF (seconds) will be spend in simulation (with some variation) until the workstation will broke down for time defined in MTTR (seconds). Again MTBF time is spent and the station will broke down etc.

Function -Initialization works in a same way than the workstation, but instead of processing the component, new route is initialized into the product, as described in Creator -function. Function -Statistics is for collecting infromation from the product flow. It will collect the count of products passed the point and how many products have passed per minute in whole production, or among 100 or 10 last products.

Component library -RemoteProcess, WS and output

RemoteProcess, RemoteWS and Remote Output are components that work together to simulate Remote or offline process. RemoteProcess simulates the trasfer time to actual workstation (RemoteWS) and also makes the decision, if routing is done. Process time is spend in the RemoteWS and after that the component is feeded into output point. Remote -components are connected to each other with abstract -interface. To connect, select a component, select PnP from the toolbar and change the Plug and Play selection from the Interactive PnP to abstract PnP. After this, select other component. White line indicates successfull connection.

Component library -RemoteProcess, WS and output

RemoteProcess -component is similar to normal workstation, but if the component is processed, it is transferred to RemoteWS after the components ProcessTime. Parameter -WaitRemoteWS is used to control, should coming component wait or pass the RemoteProcess -component, if there is no capacity in RemoteWS. RemoteWS -component has same parameters than normal Process -Function. ProcessTime is spend in the component, and it is defined, should color be changes or route updated. After process time, component is transferred to RemoteOutput -component, which is normal conveyor segment. From the RemoteWS, component can be forced to RemoteOuput -component with ForceOutput -parameter (even it has no capacity at that time).

Common Tasks
Simulating a stopper. All conveyors and components have a Capacity -parameter, which defines how many components there can on a components are at a time. In real life this behaviour is done with sensors and stoppers. If you like to create e.g. a bend into a conveyor, but you like to prevent products to be buffered over the bend, Bend -element can be used with Capacity -value set to 1.

Bend with 1 in Capacity -parameter .

Function with 1 in Capacity -parameter .

Common Tasks
Creating batches. Batches can be created with a function -BatchCreator but also with behaviour of crossings and processes. With BatchCreator, you can define the e.g. the length of the batch (as explaned on previous page). You can use crossings to create batches also by changing the Priority to BatchLength and BatchLength to desired value. Same values should be also in Track -parameters in order to route products from track to track in batches.

Crossing with 5 in BatchLength-, Track1toTrack2- and Track1toTrack1 -parameters. .

Function-Process with longer ProcessTime -value and 5 in the ProcessEvery -parameter. Now the process segment processes (delays) only every fifth component, so one is processes and four components are passed through.

Common Tasks
Creating parallel workstations. Function -Process component is used to simulate any workstation, robot or process in the system. If we like to create three parallel workstations (with same processtimes), we need to work with the ProcessEvery value. If value is e.g. 3, every third component is processed, if route is pointing to components. If we have three workstations, first should process only every third, second every second and last should process all products that are not processed yet.

Common Tasks
Creating crossing into bend. Crossing component is created (in simulation) from two parallel conveyors. If we like to simulate crossing, like pusher, that is connected to bend, we have to build the bend manually into correct radius. Crossing should be as small as possible (but not smaller that products length). Then connect two Bend-elements to both sides with desired radius minus the length of the crossing divided by two. (if the crossings length is 100mm and desired radius is 200mm, radius of the Bend -element should be 150mm)

Common Tasks
Measuring missing conveyor. In many cases, specially if you are creating a loop, you have to fit the last conveyor component between the start and the end of other components. To achieve this, you have to measure the distance components between the start and end. Measuring tool expects you to select two points anywhere from your layout, and it will display the total distance between points, but also the distance components. For accurate measurement, you may have to change the start of one conveyor and the end of another none, because the measurement tool snaps into surfaces and corners in conveyor geometry.

In this example same points are selected from the start and from the end of the conveyors. X -distance (red) is 2000mm and y-distance is 680mm. If we like to create a conveyor with two bends between these conveyors, we have to use math to calculate good angle and dimensions of the conveyor. If we select 45 degrees to be the angle, angled section (L2) should be (680 / sin(45)) 962mm long. From the x-distance the angled section will take 680 mm and if we select L1 = 500mm, then the L3 should be 2000 - 500 - 680 = 820.00 mm.

Common Tasks