An Open and Shut Case for Flexible Components

1. An Open and Shut Case for Flexible Components Michael Mongilio JHU Applied Physics Lab, Laurel, MD Swales Aerospace, Beltsville, MD

2. What Are Flexible Components? • In the Physical World: • An item whose shape is non-rigid. It’s shape can be changed as it is used in an assembly by bending, twisting, stretching, hinged movement, etc. • In the Pro/ENGINEER World: • A component in an assembly whose representation has been changed compared to its stand alone configuration without creating a new model name or instance. The variation only exists in the context of the assembly in which it has been changed.

3. The Need for Flexible Components • There are many occasions when a component needs to be added to an assembly but it won’t look like its standalone representation. • A spring – In the assembly, it may be extended, compressed, or twisted • An electronic component – In the assembly, its leads may be bent or trimmed • A Hinge Sub-assembly – In the assembly, the hinge may be in any position from opened to closed.

4. Other Examples • Compression of a Rivet • Compression of a Gasket or Other Elastomers • Ropes, Straps, Hoist Cables • Covers, Safe Pins Removed at Assembly • Flex Circuits – Printed Wiring

5. Family Table Instance Method • Each Variation could be created as a new instance on a family table • Instance Shows Correct Configuration of Design • Can be Automatically Substituted for Generic in Assembly • Variation restricted to discrete dimensional values • Each variation (instance) is a new part number, giving incorrect Bill of Materials information • Variation can only be created at the sub-assembly in which the component is a direct member.

6. Flexible Component Method • Define Component Flexibility • Variation is Created Only at the Assembly Where it is Needed. • Variation can be discrete values or measurement of assembly condition • Variation does not create a new part number. Bill of Materials reports correctly • Variation can transcend the assembly hierarchy. Flexibility can be defined on a component multiple levels deep with out affecting the in-between sub-assemblies.

7. Part Flexibility • Defining Flexibility “On the Fly” • Select the component to be made flexible (model tree or graphics window) • Right click > Make Flexible

8. Part Flexibility – Dimensional Variation • Select Dimension to Vary and New Value

9. Part Flexibility – Dimensional Variation • Model regenerates to new dimension • Name in Model Tree is Unaffected

10. Part Flexibility – Dimensional Variation • Name and Quantity on Parts List is Correct

11. Dimensional Variation - Measured • The Dimensional Variation Desired May Not be a Fixed Value • When Establishing Variability, the Dimensional Variation May Be Determined by a Measurement • Distance • Curve Length • Angle • Area • Diameter

12. Dimensional Variation - Measured • Spring Adjusts to Measured Distance

13. Dimensional Variation - Measured • Spring Height Adjusts Automatically When Gap Height Increases

14. (Make the Original Model Correctly) • As a Spring Elongates, the Coils Should Stretch.

15. Associated Parameter • Allows Varied Item Dimension to be Controlled by a Relation or a Family Table • Add Column for Assoc Param

16. Associated Parameter • Specify a Name for the Associated Parameter • The Parameter is Accessed from the Relations Menu or the Family Table Menu as a Component Parameter

17. Part Flexibility – Feature Variation • Example: Capacitors with different lead configurations

18. Part Flexibility – Feature Variation • All Lead Configurations are Modeled in Part

19. Part Flexibility – Feature Variation • Select Features Tab • Suppress or Resume Appropriate Features

20. Part Flexibility – All Options • Dimensions • Features • Geom. Tols • Parameters • Surf Finish

21. Assembly Flexibility • In Addition to the Varied Items of Part Flexibility, Assembly Flexibility Can Suppress or Resume Components • Varied Items can be Selected from the Assembly Itself or from any Sub-Assembly Component at any Sub-Assembly Level

22. Assembly Flexibility • Dimensional Modification to Sub-Assembly

23. Assembly Flexibility • Dimensional Modification This Hinge Angle Set to 45º Original Hinge Assembly This Hinge Remains Unchanged

24. Assembly Flexibility • Set Second Hinge to Measure First Hinge Angle

25. Where to Establish Flexibility • ARRAY-HINGE Flexible in SOLAR-ARRAY Sub-assembly • Both Arrays are Deployed at SPACECRAFT Assembly

26. Multi-Assembly Level Flexibility • SOLAR-ARRAY Sub-Assembly Flexible at SPACECRAFT Assembly

27. Multi-Assembly Level Flexibility • Select Dimensions from Lower Level Sub-Assembly ARRAY-HINGE

28. Multi-Assembly Level Flexibility • One SOLAR-ARRAY Deploys while Other Can be Shown Stowed This Sub-Assembly and Components are Flexible This Sub-Assembly is Not

29. (How Would It be Done with a Family Table?) • Create a Family Table of the HINGE-ASSEM with Three Instances for 0°, 45° and 180° • Create a Family Table of the SOLAR-ARRAY Sub-Assembly with an Open and Closed Instance. Add Each HINGE-ASSEM and Substitute with the Appropriate Instance • Create a Family Table of the SPACECRAFT Assembly with an Open and Closed Instance. Add Each SOLAR-ARRAY and Substitute with the Appropriate Instance • But what if I want to show partial deployment with other angles?

30. Setting Up Flexibility • Flexibility Can be Pre-Defined in a Model • By Pre-Defining the Flexibility, the Variable Items are Stored in a Dialog Box for Easy Access • Other Users Will Not Have to “Hunt” Through the Model to Establish its Flexibility • When Making the Component Flexible, the Same Dialog Box Appears, but the Varied Items are Already Populated • Additional Items that Weren’t Pre-Defined Can Still be Added

31. Setting Up Flexibility • With the Model Active – Edit > Setup > Flexibility Add the items (dimensions, features, etc.) which can be varied.