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.