I created this aluminum extrusion frame as a Weldment. To reduce contamination in manufacturing, our assembly lines require plastic cover strips in all the t-slots. That's 16 extrusions x 4 plastic strips each = 64 parts I'll have to configure to the correct lengths, and mate in 3 axes each (192 mates!).
I'll be creating a number of frame assemblies in the future. Is there a way to automate or semi-automate this process?
Hi Kevin,
What you can do is reuse the same sketch line as you used for the profile.
You know the distance from the center
change the sketch of the cover profile (.SLDLFP file) accordingly:
use the same distance, by making a construction line
EDIT : Put only one cover for each profile, and make circular pattern (Tip form Krzysztof Szpakowski )
Now when you place the covers, they will be linked to the center line and it's length. You just have to change the angle to get one of the other 3 orientations.
You don't need the locate profile anymore, because we used the origin before.
You can use patterning and mirrors to get to the other profiles/
Eddy
That's 16 extrusions x 4 plastic strips each = 64 parts
I think there will be more than 64 covers
Hi Krzysztof ,
I think there will be more than 64 covers
Yes, that was what I was thinking first, but the OP specifically asked for 64 covers.
Probably he just wants a cut list for ordering profiles and do the handwork manually.
But in that case you don't have to draw them, just get the same quantities and lengths * 4.
Eddy
Eddy Alleman wrote:
Hi Krzysztof ,
I think there will be more than 64 coversYes, that was what I was thinking first, but the OP specifically asked for 64 covers.
Probably he just wants a cut list for ordering profiles and do the handwork manually.
But in that case you don't have to draw them, just get the same quantities and lengths * 4.
Eddy
Hi Eddy
For this case is better way. Create three profile configurations: Profile, profile with covers and only cover. Depending on what drawing you need, you choose the configuration.
Or make cowers list "by hand" used profile list and add "x4"
profile with covers
Can you elaborate on that please.
The last time I tried (several years ago) it was not possible to use separate regions for the weldment profile.
With the approach of using separate weldment profiles for the 4 covers, you could use a trim where needed and get the exact length. But many trims can slow things down in larger structures.
Eddy Alleman wrote:
Hi Krzysztof ,
I think there will be more than 64 coversYes, that was what I was thinking first, but the OP specifically asked for 64 covers.
Probably he just wants a cut list for ordering profiles and do the handwork manually.
But in that case you don't have to draw them, just get the same quantities and lengths * 4.
Eddy
I count only 10 unique covers. Doesn't seem like all that big a deal.
8 for each vertical leg and one each for the end and side extrusions.
Thanks for all the tips. As Krzysztof assumed, there would actually be much more than 64 individual cover strips, if you Add up all the short cut pieces. But that's too much work for the CAD designer. The assembly tech knows what to do. My main goal for the strips is to show the total amount that needs to be ordered. It's not difficult to add up all the cut lengths for the aluminum extrusion & multiply by 4. It would be cool to have this number generated automatically, but that's a little beyond my capability, and/or the benefit to time invested might not be worth it.
Hi Kevin,
I'll have to configure to the correct lengths, and mate in 3 axes each (192 mates!).
This kind of frames, I make them mostly using the weldment environment. That's where my approach can be used.
Obviously I missed the fact you are mating = working in an assembly.
The weldment environment makes it possible to just use Sketch lines and populate them with weldment profiles. When you change the dimensions of the sketch lines, all profiles will follow. It is possible to mirror and pattern bodies, which is surely much less work in you example.
Eddy
Hi,
I haven't tried yet, but maybe the structure system will help here because of it's automatic trim function...?!
Sorry Eddy but my mistake. I overlooked that it is a welded construction.
No worries mate,
I´m not sure it is weldments, because the OP talked about mates....
Mates are also possible in a multi-body environment...
The frame extrusions were created as a weldment. Then I created an assembly and added the other components (not shown in the screen grab). Casters, shelving, t-slot covers, sheet metal, etc.
Eddy AllemanIn your method I'll change one things:
Put only one cover for each profile, and make circular pattern (I think that is faster)
Put only one cover for each profile, and make circular pattern (I think that is faster)
And then mirroring the legs to the other 4 corners and patterning the horizontal ones
I was always reluctant to using patterns if I don't really have to in automation projects like this. But since Solidworks does the patterning on another thread I should more follow that approach. good point! (changed the overview for others)
Eddy
Hi Heiko,
Mates are also possible in a multi-body environment...
You got me there... "Deutsche gruntlichkeit" ?
Eddy
I would recommend taking a step back and asking yourself if adding the strips in the drawing/model is really necessary or beneficial. Of course, it all depends on your workflow, ordering, etc. However, if you have folks out in the assembly shop putting these together, and if they're just cutting the plastic strips on-site with snips or a utility knife or something, then the effort in CAD to make a pretty model and a nice cutlist probably doesn't save as much time on the shop floor as it takes you to create it.
You're right. It's a time/benefit equation. I don't want to spend 10-20 hours developing an automated CAD solution that will save 1 or 2 minutes of math for each assembly. Our purchasing agent just needs to know how much t-slot cover material to order. It looks like the easiest solution would be for me to manually add up all the aluminum extrusion lengths in the cut list then multiply by 4. The assembly techs know how to measure/install the t-slot covers. They probably wouldn't bother referencing the drawing for that, even if I included a perfect cut list.
Or go another step back and ask yourself why you are willing to build this up in SWX?!
Bosch or item have large libraries combined with CAD-like configurator tools. With these you should be able to build up something like this in much shorter time, an automatic BOM included, ready to order!
Maybe you could export the modell to SWX? (don't know...)
Heiko Sohnholz wrote:
Or go another step back and ask yourself why you are willing to build this up in SWX?!
Bosch or item have large libraries combined with CAD-like configurator tools. With these you should be able to build up something like this in much shorter time, an automatic BOM included, ready to order!
Maybe you could export the modell to SWX? (don't know...)
I have not drawn an extruded frame in any CAD system I've used for years. My current favorite system is May-CAD by Maytec. They have an entire system set up so you you can drop in any size extrusion, add in any type of connector, hinges, slot covers and on and on.
If you absolutely have to have these individual parts inside a SW assy you can export the entire thing as native Solidworks files. Those files will have everything on them including necessary machining for connectors, hinges, brackets etc etc.
You can also create a "Vendor package" that will create drawings in PDF, BOM for the vendor and give you a price to boot. You can then send this to the vendor who can then, if you want them to, manufacture all the parts to specification. Since they are set up to do this they have been, in my experience, less expensive, by far, then what it would cost to purchase the sticks and do all the machining internally.
What used to take me hours, even days for large enclosures, combined with many other additional hours of purchasing, machining etc now takes minutes to hours on large enclosures.
The biggest hassle is in the case where you have to have the individual parts in the assembly. Then every time you change the enclosure you have to go thru the export, renaming all the components etc process.
Just an example, I did this in probably 5 minutes or less in May-CAD. Pretty much what you're showing, has all the connectors, covers etc. Also attached is the PDF file you would send to the distributor.
Again, a whole lot depends on your workflow. If you really want to minimize effort... My pref is to model the whole thing as a weldment, using plain ol' squares for the profile, no slots. I don't really use the slots in the model, and when you have a large frame the extra lines just kinda blur into one another. No hardware (except sometimes handles and hinges). Dimension a single ISO view for reference, add any notes (like "all exterior surfaces clear lexan, slot mounted" etc) and send that along with a SW or parasolid file to the distributor. Let them (many are happy to do it for no extra charge) make the whole thing up with all the fasteners, connectors, adjuster feet, etc into a kit that I can order with one part number. Kit comes with everything precut and drawings with BOMs etc. Best of both worlds! :-D
We do this a lot here(frames as weldments). Since all your extrusions are the same profile look at your cut list properties for the different lengths. At the bottom of the properties list for any of them should be a total length of that profile used in the model for all the pieces. Use that x 4 to get for cover length needed.
Josh Brady wrote:
Again, a whole lot depends on your workflow. If you really want to minimize effort... My pref is to model the whole thing as a weldment, using plain ol' squares for the profile, no slots. I don't really use the slots in the model, and when you have a large frame the extra lines just kinda blur into one another. No hardware (except sometimes handles and hinges). Dimension a single ISO view for reference, add any notes (like "all exterior surfaces clear lexan, slot mounted" etc) and send that along with a SW or parasolid file to the distributor. Let them (many are happy to do it for no extra charge) make the whole thing up with all the fasteners, connectors, adjuster feet, etc into a kit that I can order with one part number. Kit comes with everything precut and drawings with BOMs etc. Best of both worlds! :-D
Yes, I agree. If all you want is something that looks like something you can send most extrusion MFG'rs a napkin sketch and get what you want. The more specific you want the design the more info you have to give them.
This is yet another reason I like the May-tec software. Everything is automated. If you just want a general shape you can just plop in the sticks you want and you're done, quite literally in seconds. You still get all the connectors in the right place and have the ability to get SW, Step etc files if you want/Need them. You can then just send the package off and get the entire thing sent to you in a kit.
To the other extent the May-Tec software lets you make the design as complex as you want as well and or have the vendor do as much or as little design as you want them to.
Our distributor offers the design service as well.
In short, doing this sort of thing in SW today is, in my humble opinion, not really the most efficient way to approach it. However if you're absolutely forced to do it in SW, do as little as you can in order to get the idea across to the company that will recreate what took you hours to do in SW in a couple minutes :-)
I use May-tec and have for years but I know Bosch has a similar program. Not sure if 80/20 ever came out with one or not but I suspect most major players have one these days.
I would think you could create a weldment profile for the cover and make it part of your frame weldment. I'd be interested to hear if this works well. I do this same sort of work often.