Winter 2006

The start of a new year always presents fresh challenges and tasks. Our winter issue reflects this speedy pace with news on the latest acquisition by PTC as well as continuing efforts on software quality. You can read about the 2006 edition of PTC Awards, which has just kicked off and is an awesome opportunity for talented designers to gain recognition. On the technical side, we have four great articles in Tips and Tricks, including one based on Mike Mongilio's award-winning presentation at the PTC/USER World Event in 2005. Feel free to share your praise or criticisms about the magazine with us. You can write me at [email protected].

Rendering with Realism by Jason Clark, Jase Design

Setting the Standard by Evan Caille, PTC/USER President

Best Regards,

Rick Snider

CADTRAIN Goes to PTC University with Dennis Stajic and Matt Cohen, PTC Prove Your Mettle in the 2006 PTC Awards Competition with Alex Lorman, British School of Washington

PTC Executive Meeting Summary: Progress Continues

Regional User Group Calendar Download a PDF of this issue Copyright 2006 PTC/USER, Inc. All rights reserved.

Generating a 3D PCB in Pro/ENGINEER by Keith Richman, Simplified Solutions Inc. Creating Flexible Components in Pro/ENGINEER Wildfire by Mike Mongilio, Swales Aerospace Planning Your Upgrade from Pro/INTRALINK 3.x to 8.0 by Scott Carmichael, NxRev, Inc. Logging System for Developing in Windchill 8.0 by Dmitry Tkach, isLaNd Inc.

Rendering with Realism By Jason Clark, Jase Design [Editor's Note: Jason is making tutorial files available for this article through his web site, www.jase.ca. You can go there to download the files and see additional information.] With all the effort that goes into creating your CAD models, it is a shame not to render them to visualize the finished product in your proposals and presentations. This article is meant to help you do just this, first explaining how to export your data and then providing a short tutorial on how to render your models realistically. Hopefully, this information will either encourage you to learn more about rendering yourself or provide basic understanding about what happens behind the scenes if you contract out this service. There are many rendering packages available, ranging in cost from $300 to $10,000. For purposes here, I have chosen to use LightWave 8.5 from NewTek. LightWave is quite reasonably priced at $795 and is currently undergoing a major upgrade. Other products I suggest looking into are Maxon's Cinema4D, Autodesk's 3D Studio Max, and Caligari's trueSpace. All of these products offer reasonable import/export options and have capable rendering platforms. I have purposely left PTC's Pro/PHOTORENDER off this list. In my opinion, the product is not mature enough and does not provide the typical tools to deal with alpha masks, multiple textures, global illumination, and the like. In addition, the material functionality is a bit weak and the software cannot maintain your model display in OpenGL.

Preparing Your Models One of the biggest tasks in the rendering process is exporting your models from Pro/ ENGINEER to your rendering application. For small parts or even small assemblies (say a 10-part assembly), you can just use the .slp, .stl, .obj (wavefront) export. But these formats do not support hierarchies. Since most rendering applications support the .obj and .stl formats and recognize distinct parts, however, you can recreate the hierarchy in the renderer. For the options that deal best with Pro/ENGINEER files, I recommend either PolyTrans from Okino (www.okino.com) or Deep Exploration from Right Hemisphere (www. righthemisphere.com). Both products allow you buy modules to support Granite so that you can natively open and convert Pro/E files.

Assembly Organization (Reps and Datums)

Rendering with Realism Setting the Standard CADTRAIN Goes to PTC University Prove Your Mettle in the 2006 PTC Awards Competition PTC Executive Meeting Summary: Progress Continues Generating a 3D PCB in Pro/ ENGINEER Creating Flexible Components in Pro/ ENGINEER Wildfire Planning Your Upgrade from Pro/ INTRALINK 3.x to 8.0 Logging System for Developing in Windchill 8.0

Assemblies are generally what you'll want to render. But assemblies contain a tremendous amount of information, not all of which is necessary. The following list presents the minimum set of simplified reps that your assemblies should contain. From here you can build on your requirements. · All parts. You can, however, skip seals, fasteners, labels, and unimportant hardware (like crimps, and other small items). · Piping only. If your assembly has piping, create a rep that contains all the piping, including fittings within the piping run. · Fasteners only. In most shots, the fasteners are barely visible so you can treat them separately and possibly even omit them. If you need detail to represent fasteners, you can export this rep and reduce the polygon count by increasing the chord height or within your translation software. You want to group assemblies of components by either function or material, or some mix of the two. 1. Function. This grouping is typically shared assemblies that work together. For example, the front suspension of a car would likely include both front wheels and the rack system so you can easily link them together. 2. Material. This grouping is for ease of applying a specific material to more generic types of parts such as piping, fittings and fasteners. I use this grouping to deal with lowdetail items. Grouping is a grey area, but here are some useful guidelines to bear in mind. · Keep your subassemblies manageable so you can work on a specific subset and keep the render application responsive. You should be able to turn everything off from display but still work on a specific subset of models. · Make groupings easy to replace so that they are quick to update when CAD models change. · Simplified reps are a good way to group assembly items across different levels of a BOM structure.

Part Organization (More Reps) Following the example of assemblies, we can use simplified reps for parts as well. The ideal candidates for simplified reps are fastener parts and parts utilizing hole, rounds (fillet), or chamfer features. The idea is to limit the number of features shown at the assembly level. For example, our bolt fastener models need a rep to exclude the shaft because all we see in many instances is the head. For parts using many rounds, holes or chamfers, you can exclude these features as well if they won’t be visible. It is far easier to implement this methodology using start parts or company standard practices. Formats for Exporting from Pro/ENGINEER · Native Format (Using a third-party translator). Using native geometry is preferable, BUT! Yes, there is a but. The downside is that you will be dealing with

unprocessed data. If you have a large assembly, importing and exporting the data is very time-consuming. I therefore recommend using the native format only for smaller assemblies. · STEP Format (Using a third-party translator). If the translator supports the Granite kernel, you will have access to STEP. I prefer STEP because it handles geometry the best and maintains the hierarchy within one file. STEP retains models as solid geometry. Ideally, you can break your assembly into logical groups using simplified reps and then export the groups with a consistent coordinate system. · IGES Format (Using a third-party translator). While most translators support IGES, you need to ensure that the one you choose supports the latest version and can handle trimmed as well as untrimmed surfaces. Like STEP, IGES is useful because you can export and retain hierarchy and utilize simplified reps. · Native Triangulated Formats (Pro/ENGINEER direct). Exporting triangulated formats is the last resort reserved for small parts or assemblies of very limited size. But if you need to do part replacement, this can be a quick fix. If you want to do an individual part export with the .stl or obj format, there are a couple of things to consider. Use a consistent coordinate system. This will allow easy reassembly in the rendering application. Experiment using the chord height and chord angle options. These options control your mesh (triangle) density. · VRML. You can experiment with VRML, but be prepared for some oddities and frustration. In my experience, I have not seen any applications that properly support Pro/ENGINEER Wildfire's VRML 2.0 export. In addition, the VRML export creates extra objects.

The Export Process Prior to exporting, you should give some thought to what your requirements are. Although you will inevitably need to do some organization and cleanup in the rendering application, organizing your data beforehand can eliminate a lot of problems. First off, if you don't have a third-party translator, you are very much restricted to the native import types of your render engine—typically IGES, .stl, .obj, 3ds, and a few others. The native IGES implementation in most rendering software cannot deal with large assemblies and is often problematic, so do not count on it. Since the 3ds format is not available from Pro/ENGINEER, that leaves .stl and .obj. Almost every rendering application supports these formats and will have a free script to allow those types if they aren't natively supported. In general, I export my Pro/ENGINEER data to a neutral format such as IGES, STEP, or Pro/E Neutral. This lets you quickly modify an assembly without fear of conflicting with parent/child relationships. To do this, you can reuse Pro/ENGINEER (or your native CAD tool) to import the file back into session. Then you may edit the assembly. I then export the file to the rendering application.

Now on to Some Rendering! In our example, we're going to use LightWave rendering software (discovery edition available by contacting NewTek sales www.NewTek.com). Although undergoing major

updating for release 9, this is still one of nicest renderers around. It is extremely cost-effective and yields good results quickly. At the end of this article are a few of the many resources available on the web to get you going with LightWave.

A Primer of Rendering Terms and Techniques For those who are new to rendering, this section describes some basic terms and techniques. (Click here to view...)

Open the file torch.asm in Pro/ENGINEER. You will see that each major portion of the model has a part. When we convert our assembly for use in LightWave, we want to maintain this hierarchy. You may want to export from Pro/ ENGINEER in the wavefront format and open these files within LightWave directly to fully understand the export process and mesh details. In this case, however, I chose to import the native assembly file into Nugraf (PolyTrans is the same without the renderer) to convert to the LightWave scene file. I have included the .bdf file for you to open within PolyTrans (demo available at www.okino.com).

Mesh versus speed. At this point, we need to assess what end result is required of our render. The part files have chamfers and small details. To maintain those details in the rendering, we need to ensure we are bringing a highly defined polygon model, which means more polygons. Basically, we can output the models for one of two purposes: 1. Up-close product shots. This output has a high polygon count. For these types of renderings, we want to maintain edge detail. 2. General rendering or ”set” pieces. This output has a low to medium polygon count and is suitable for use in a large assembly rendering that won't be close to the camera. In this case, if you add auxiliary models to the scene to help break up the dead space, keep poly counts minimal. Scene lighting and setup. For the most part, you can use area lights to mimic studio lighting. Spotlights are another choice because they allow you to create soft shadows. Area lights do this as well, but I find the glow property of area lights more pleasing. Experiment to discover what your own preferences are The most famous (or infamous) scenario is called three-point lighting, which illuminates the object with: 1.

Key light. Provides the main illumination and typically the shadow caster.

2.

Fill light. Adds a gentle amount of light to break up dark areas or shadows.

3. Rim light. Used behind the object to illuminate its silhouette, helping to separate the object from the background. Three-point lighting can be a starting point and you can add your own variation. In this sample scene, I want to use soft lighting and shadows.

As for setting up the scene, I encourage you to do some research on composition. One basic principle is to avoid placing your object dead center, but instead follow the “rule of thirds.” This means dividing your picture into three columns and rows, and then placing the object a little above, below, or to the side to keep the focus where the three rows and columns intersect. In this scene, I placed the object slightly above the horizon to bring attention to the light shining through the flashlight. This also leaves a little space to add specifications or logos for a branding shot.

Scene setup requires careful thought. In reality, you will have set gear, people and such around a photography shoot, so you need to compensate for this. In our example, we are dealing with reflective materials so they need something to reflect. We could, for instance, add abstract shapes with color to simulate drapes, or set gear like posts, chairs, and the like.

In this case, I added two “bounce” cards, which are commonly used in product shots. Bounce cards not only act like fill lights, but also give the object something to reflect.

To get our scene set up in LightWave, 1.

Select File->Load Scene to load the torch_orig.lws.

2. Click Shift +c to select the camera. Then, using the coordinate manager on the bottom left, set its position. -

Hit t for translate and enter the coordinates as x=-71.68m, y=43.82m, z=-82.25m.

-

Hit y for rotate and enter heading=-0.6, pitch=76.9, bank=0.

This sets up the scene for our camera. If you want to experiment, I recommend you save here first. Lighting is extremely view-dependent, so revert to your saved scene before continuing. 3. To set up the lighting, we'll convert the existing light to an area light. Remember: the larger area lights are, the softer their shadows but their output level must also increase. Select the light either by using Shift+l or by selecting the light button at the bottom of the screen and then using the drop box. Once the light is selected, Hit t to translate and enter the coordinates in the bottom left input boxes as x=15.5, y=134.25, and z=-21.55. -

Hit y and enter h=15.5, p=134.25, b=-21.55.

-

To size the light, hit h and enter x=52, y=48.67, z=1.

-

Hit p for properties and enter the values shown.

4. To adjust the flashlight, select the objects button at the bottom and, with the selection tab above, select torch.asm.6. Hit t to translate and enter 6.9m in the coordinate box. 5.

To add the floor, use File->Load Object and select floor.lwo.

6. We can set up the fill light, rim light, and bounce cards. First clone the area light by selecting it and the hitting Ctrl+c. -

In the clone item dialog box, enter 2.

Select one of the clones and enter the coordinates for its position as x=-7.9, y=-3.4, z=-90.7 and then its rotation as h=10.4, p=6.6 and b=0. -

With the light still selected, hit p for properties and enter the values you see below.

-

Change to the shadow tab and make sure shadows are off.

Now select one of the other clones and enter the coordinates as x=-41.7, y=90, z=123.6, and a rotation of h=-203, p=23.6, b=0. Modify the properties (hotkey p) and then enter the properties below. Be sure to note this light becomes a spotlight. -

Change to the shadow tab and ensure shadows are off.

7. The last lights we’ll set up are for the flashlight. Activate the Items tab and from the lights tab, select a point light. -

Set the point light position as x=-5.75, y=7.05 and z=0.

-

Enter the light properties page and input the settings below.

-

Open the objects tab and tick the same items shown below.

8.

The next light is for the beam itself. Create a spotlight now and

-

Enter its position as x=-5.75, y=7.05 and z=0.

-

Enter the rotation as h=-90, p=0, b=0.

-

Enter the properties page and enter the properties below.

After enabling the volumetric lighting option, click the volumetric light options and enter the values below.

The idea of the point light is to illuminate inner components locally and to allow the glow to penetrate through the holes because the stud part is translucent. 9. Save your work now before creating the materials for the components. (Although I've created the materials for this example, we will tour through the settings to create the final render.) 10. Open the surface editor, using the F5 key, and set up the view to use scene materials. LightWave allows you to adjust all like-named materials in one interface.

Aluminum_powder material: For this material, I wanted to do a glossed speckled material with a high reflected specular. Some key areas of note are the blurry reflection and reflection falloff due to the fresnel effect. The gradient texture is very powerful, and I like the way NewTek has put this feature in LightWave. The bump adds to the texture and assists in breaking the reflection.

Aluminum basic properties

Color is a basic setting, which you then modify based on the values in diffuse, reflection and such. What you will notice is that the diffuse, specularity, reflection, and bump values are driven by a texture (highlighted T box). Click these boxes to modify them. When the textures are activated, the values in the named boxes usually have no effect.

Aluminum advanced properties

Under the advanced tab are two properties of note. First is “Alpha Channel,” which is set to “Surface Opacity.” This is important since LightWave will render an alpha channel that shows this material as white, so we can use it to block out the object in an image editor. Second is “Color Highlights,” which allows the material’s highlights to take on the color of the material.

Aluminum environment properties

Here is where we set the reflection blurring. The “Reflection Options” is noteworthy because we could instead use an image map to produce reflections rather than the time-consuming ray tracing.

Aluminum shader properties

The shader tab allows you to add rendering enhanced features like fresnel, brdf, and celshading effects. Here I've added a quick fresnel effect to the material.

11. Using the above panels you can explore other materials. In particular, pay attention to the stud, which has a translucent value. Turn this off and render the scene. The fact that it allows light to pass through it explains why the little holes glow.

Advanced Features To whet your appetite for further experimentation with rendering, let’s add some radiosity to our scene.

1.

Hit Ctrl+F5 to open the backdrop options.

2.

Select Add Environment and then the image world option.

3.

Double-click this option and browse for uffizi_probe.hdr.

4.

Select lights from the bottom buttons and then open the properties page.

5.

Select global illumination and then enable radiosity. Set the options as shown.

6. Hit F9 and take a break because rendering takes a while. What you will notice is the backdrop actually lights the scene. If you had used the monte carlo option, the light would instead bounce from other objects. The two images below show the alpha channel produced by the rendering and then the modified alpha so we can adjust the flashlight.

Unmodified rendered alpha

Modified rendered alpha

Rendered image

Modified rendered image

Notice the color shift in the rendered images. The image was edited in Adobe Photoshop without having to render the image over again.

LightWave Layout Shortcuts p

Item properties

F5

Surface editor

m

Motion properties

Shift+o

Objects

Shift+c

Camera

Shift+l

Lights

Ctrl+F8

Image processing

Ctrl+F5

Backdrop options

LightWave Resources Here are just a few of the many online resources geared toward LightWavers. http://www.NewTek.com/LightWave/—main page for LightWave http://www.NewTek.com/forums/—NewTek-sponsored forums http://www.NewTek.com/LightWave/tutorials/—extensive list of NewTek-hosted tutorials http://members.shaw.ca/LightWavetutorials/Main_Menu.htm—mega list of learning material for LightWavers, managed by a LightWave user http://www.spinquad.com—online forum http://www.simplyLightWave.com/—online forum and training resource

Other Resources Jeremy Birn's Lighting: http://www.3drender.com/light/index.html HDRI making tutorial: http://www.luminous-landscape.com/tutorials/hdr.shtml Paul Debevec (a defacto in HDRI): http://www.debevec.org/

Jason Clark is an engineering visualization consultant with his company Jase Design. In addition Jason is a senior designer and PTC applications administrator at OceanWorks International, Inc. Jason can be reached by email at [email protected] or [email protected].

CADTRAIN Goes to PTC University Q&A with Matt Cohen, Vice President of Customer Education, and Dennis Stajic, Vice President of Education Services, PTC

Rendering with Realism Setting the Standard

In early 2005, the PTC/USER Board met with PTC executives to discuss the future of education services and offerings. One of the issues raised was the role of CADTRAIN in serving the user community. For over a decade, CADTRAIN has been a great supporter of PTC/USER and its training products are in wide use among our members. We encouraged PTC to work cooperatively with CADTRAIN to ensure that it could continue to create top-quality learning materials for PTC customers. PTC really took this message to heart. The seeds planted in this discussion sprouted into a relationship that culminated in the December acquisition of CADTRAIN. By integrating the CADTRAIN offering within PTC University, PTC will be able to capitalize on the best of both solutions and expand its training offering early in 2006. Importantly, PTC acquired not only CADTRAIN technology but also the entire development and customer service staff, ensuring continuity for current CADTRAIN customers. In addition, CADTRAIN and PTC will continue to work with the PTC/USER Usability and Training Technical Committee to validate future training strategy and help determine product priorities. Given the importance of CADTRAIN services to PTC/USER members, Rick Snider recently posed a number of questions to the company’s principals who were involved in the acquisition, Dennis Stajic and Matt Cohen. Dennis is the founder of CADTRAIN while Matt, Vice President of Customer Education at PTC, was instrumental in initiating and completing the transaction. RS: Dennis and Matt, thank you for taking the time to talk with us. First of all, can you tell us if PTC is retaining the CADTRAIN development and technical support staff after the acquisition? DS: Rick, we appreciate the opportunity to talk with you. We want to assure our customers that every member of CADTRAIN’s development staff has been retained to continue the development of COACH/LMS and the COACH curriculum. CADTRAIN will also provide direct technical support. RS: Do current CADTRAIN customers face any change in pricing? MC: No. CADTRAIN customers will continue to pay the same maintenance fee for their current COACH and COACH/LMS installations.

CADTRAIN Goes to PTC University Prove Your Mettle in the 2006 PTC Awards Competition PTC Executive Meeting Summary: Progress Continues Generating a 3D PCB in Pro/ ENGINEER Creating Flexible Components in Pro/ ENGINEER Wildfire Planning Your Upgrade from Pro/ INTRALINK 3.x to 8.0 Logging System for Developing in Windchill 8.0

RS: With this acquisition, will PTC University's offerings be available in COACH/LMS so that we can get down to one LMS environment? DS: PTC University will provide the “hosted” solution, and COACH/LMS the client site solution. The same content will be available in either delivery mode. RS: Will the CADTRAIN content be available both as a PTC University subscription and installable on a company’s intranet? MC: CADTRAIN’s COACH content will be supported for intranet installations for current CADTRAIN customers. The COACH curriculum will also be embedded into PTC University as an optional training library. RS: CADTRAIN focused solely on PTC's MCAD-related products. Will the curriculum expand to Windchill and other PTC products? MC: Yes. Incentives will be available to help upgrade CADTRAIN customers to PTC’s Windchill and PLM offerings. RS: Will the structure of the CADTRAIN content become more like the Windchill training available on PTC University? DS: The CADTRAIN COACH content will keep to its current format. There are no plans to alter the instructional design but rather to use the multiple formats now available to complement each other for different learning styles. RS: When new versions of PTC software are released, will the training material be available simultaneously? DS: CADTRAIN will maintain its current release schedule for new versions of Pro/ ENGINEER. RS: Are there any plans to provide tighter integration with ModelCHECK? DS: Now that CADTRAIN is part of PTC, integration discussions are scheduled as part of the COACH and COACH/LMS product roadmap. RS: What about offering CADTRAIN courses in other languages? MC: Seven CADTRAIN courses are currently available in French and German for WF1 and WF2. We are developing a localization roadmap for additional languages for WF3 and beyond. RS: Will PTC University customers with a CREATE subscription automatically receive all CADTRAIN content? MC: Special incentives will be available to help CREATE subscribers access the CADTRAIN COACH library within PTC University. RS: Thanks again, guys. It sounds like PTC/USER members are sure to benefit from the innovative learning products that will come out of the new relationship between PTC and CADTRAIN. If you have questions about the acquisition or education, feel free to contact Dennis at [email protected] or Matt at [email protected].

Prove Your Mettle in the 2006 PTC Awards Competition with Alex Lorman, British School of Washington The PTC/USER community boasts an incredible depth of design talent in every industry and region around the globe. The annual PTC Awards competition is a showcase for these exceptional designers and their creations. This contest, now open for submissions, represents an awesome opportunity to prove your mettle against the best in the world. Past winners hail from organizations such as Motorola, John Deere, Lotus, Bombardier and others known for innovative products. All designs will be judged by a panel of industry experts, who will select the finalists within each of the categories of Heavy Equipment, Transportation, Life Sciences, Consumer Products, High-Tech Electronics and Education (with two subcategories, K12 and College & University). Judges will evaluate each entry against the contest criteria of product innovation, benefits, complexity and aesthetics. Category winners will be selected through an online vote, and an overall champion will be selected via online voting and voting at the PTC/USER World Event in June. Winners will be announced at the World Event and have their entries prominently published on the PTC website. You can get more details on contest rules at www.ptc.com/go/awards. The deadline is March 13, 2006, so be sure to enter right away. Images of winning designs from past competitions—including the Open60 Class Trimaran shown here—can also be found at ptc.com. Alex Lorman, a student at the British School of Washington and winner in the K-12 Education category in 2005, provided the following account about developing his award-winning concept in Pro/DESKTOP. A team from the University of Oklahoma also won in the College & University division in 2005, marking the first time ever that American students have taken top honors at the PTC Awards.

Sailing to Victory The original idea for the Open60 Trimaran came when I read about the disastrous Route de Rhum transatlantic sailing race in 2002 where 8 of 18 trimarans were forced to retire. I looked at the photos of the boats and was fascinated with the incredibly complex curves and multiple hulls of the craft. Although I was still learning the basics of Pro/DESKTOP at that point, I decided to challenge myself and attempt the design of one of the craft. The first iteration of the design was not at all successful because of the techniques I was employing in Pro/

Rendering with Realism Setting the Standard CADTRAIN Goes to PTC University Prove Your Mettle in the 2006 PTC Awards Competition PTC Executive Meeting Summary: Progress Continues Generating a 3D PCB in Pro/ ENGINEER Creating Flexible Components in Pro/ ENGINEER Wildfire Planning Your Upgrade from Pro/ INTRALINK 3.x to 8.0 Logging System for Developing in Windchill 8.0

DESKTOP, namely the wrong ones. On the whole, the failure of the first “draft” of the design was due to lack of experience in Pro/DESKTOP and lack of knowledge about what tools to use where. At that point, the project was put on a back burner and forgotten for many months. After I had designed several other boats, including an offshore rescue lifeboat [nominated in the Education K-12 category of the PTC design awards in 2004], I thought about continuing the Open60 Trimaran project. Continuing was something of a misnomer since it involved starting the whole project afresh. With my much-improved knowledge of the program, I was able to better envision the final design while still drawing initial ideas for the design on paper. As soon as I started to put my pen and ink sketches into Pro/DESKTOP as vector lines and curves, my newfound knowledge of the program was immediately useful. I was able to properly utilize the full potential of the program. Although Pro/DESKTOP is marketed as the little sister to Pro/ENGINEER, it is by no means the black sheep of the family. While lacking the physics suite and some of the extremely advanced features of Pro/ENGINEER, it is still a very capable program. The interface is slightly different and there are far fewer tools to use, but Pro/DESKTOP is easy to use and has the functions most needed by the typical user. The design began to take shape in Pro/DESKTOP thanks to the “loft profiles” tool, which interprets multiple closed chains of lines, on different planes, and creates a threedimensional, often curved, shape. Another tool I discovered in making this particular model was the “mirror solids” tool. The problem I faced was that the two outer hulls are not identical, but rather mirror images of each other. This design aids the boat in cutting rather than pushing its way through the water. I solved this problem by creating one hull as per the specification and then mirrored it in the final assembly to create the complete model. This tool saved significant amounts of time and effort and made the hulls identical rather than factoring human error into the design.

3D model half completed. When all the individual pieces were created as separate files, I began to combine them in a new file, which consisted solely of all the separate components and their positional restraints. This method of combining all the other parts into one design is the most reliable way I found for keeping restraint errors between components to a minimum. Some of the components were subassemblies, in the sense that the one file being added as a part to the main assembly file consisted of a couple of smaller files that were constrained in a particular manner.

Completed 3D model awaiting decals and rendering. By far the most difficult and time-consuming part of this design project was the rendering in three dimensions and addition of decals, giving the boat its lifelike appearance. When the final assembly file was complete and exactly as desired, I imported the whole file into an album view. This is Pro/DESKTOP’s visual rendering suite. The one file added to the display model that is not true to life was a large oval symbolizing the water that the catamaran was slicing through. This was for realism purposes in the final three-dimensional rendering. During three-dimensional rendering, a whole different skill set is used, namely proficiency with Adobe Photoshop and other graphics suites. These programs then output BMP files to be applied as a decal to the three-dimensional model in Pro/ DESKTOP. Getting the decals and the various textures to correspond to each other correctly and look realistic is very much a trial-and-error process that requires many redrawings of the images to ensure accuracy and consistency throughout the design. The decal system in Pro/DESKTOP is analogous to attaching two-dimensional sticky decals onto a plastic model, so that the two-dimensional image becomes “wrapped” around the three-dimensional surface.

Applying the surface decals to the hulls. When I had completed defining the material properties of the entire model and all the decals were applied and positioned properly (not a quick task, and not helped by the fact that I lacked a powerful workstation), I started to “pose” the model. The point of posing the model when all the surface finishes were in place was to get the best view of the model rendered and also to create several different JPG images that could easily be sent by email to a potential client. This process is rather like “working the angles” in a photography shoot.

Final image of the completed design. Like Pro/ENGINEER, Pro/DESKTOP is only as powerful as its operator. Pro/DESKTOP simply provides an easy and accessible way to visualize ideas without trying to do too many tasks in one operation, instead taking smaller steps that are more easily accomplished. Although I think I pushed Pro/DESKTOP to its limits in terms of the number of functions used and different processes completed, I still think that more creative things can be achieved with it, given enough time. As with any system, it is not perfect and improvements could be made, but thanks to PTC it is continually updated and a work in progress. Alex Lorman currently attends St. John’s College in Annapolis, Maryland. He freelances as a photographer and continues to develop designs in his (limited) spare time. Alex can be reached by email at lormanalex@msn. com or through his website www.alexlorman.com.

Progress Continues in 2006 Quality Remains Prime Focus at PTC November’s annual PTC/USER Board of Directors meeting with PTC executives brought few surprises and seemed more of a continuation of the previous year’s discussions. In reviewing the highlights of 2005, it is clear that PTC has been making steady progress in many key areas of greatest concern to the PTC/USER community—most notably software quality and training. In addition, PTC’s run of acquisitions last year addressed unfilled needs and also added important complementary technology to the company’s portfolio of solutions.

Assuring Quality As always, software quality remains a top concern. In the years since beginning its quality assurance initiative, PTC has methodically improved its process for building quality into its software, ensuring end-to-end coverage within the organization. Through the deployment of the Quality Management System, the company has implemented comprehensive automated and manual testing procedures. In the last year alone, PTC nearly doubled the number of quality assurance engineers, bringing the ratio of developers to test staff to approximately 1.6 to 1. This change ensures a far more thorough examination of software than previously possible. PTC has also reached a significant milestone in achieving CMMI level 2.0. As progress is made, PTC is systematically tightening its release criteria. Wildfire 3.0 is on track for its scheduled release in early Spring 2006 and is expected to meet increased quality requirements. The company is also raising its investment in research and development for the coming year. Aggressive action on multiple fronts should eliminate more defects before product is shipped to customers.

Rendering with Realism Setting the Standard CADTRAIN Goes to PTC University Prove Your Mettle in the 2006 PTC Awards Competition PTC Executive Meeting Summary: Progress Continues Generating a 3D PCB in Pro/ ENGINEER Creating Flexible Components in Pro/ ENGINEER Wildfire Planning Your Upgrade from Pro/ INTRALINK 3.x to 8.0

Taking on Training Reversing a recent trend, PTC is now taking a more active role in the production of training materials and services. Global Services is refocusing and redoubling efforts to improve quality and customer satisfaction with education. This includes training provided through PTC University Learning Management System and all direct and certified training centers. As part of this strategy, PTC has recently acquired CADTRAIN, the leading third-party provider of training solutions for Pro/ENGINEER. [See accompanying article in this issue for details.] The overall education experience is the first priority for enhancements. Among its commitments, Global Services is charged with: ●

Strengthening standards for instructor certification to guarantee that the content is valuable and delivered in a professional manner. Student evaluations will play a

Logging System for Developing in Windchill 8.0

●

●

●

major role in driving improvements. Developing new course content that addresses issues of best practices and business processes, particularly in growth areas such as Windchill and Arbortext. Adapting the scheduling and availability of courses to better meet customer needs and avoid overbooking or canceling sessions. Streamlining order and payment procedures to make it easier for customers to do business.

Business and Acquisitions PTC was in an acquisitive mood in 2005, snapping up technology outfits Aptavis and Polyplan along with Arbortext, a leader in the dynamic enterprise publishing industry. PTC expects to make further acquisitions as business conditions and technology needs warrant. PTC’s revenues and profits are up significantly with growth attributable to existing business as well as Arbortext. The company has rebuilt its cash reserves to around $200 million. PTC is forecasting 12% growth in the coming year, with further upside potential in that number. Clearly, PTC has made great strides in solidifying the gains it has made through financial discipline, and is now well positioned to better serve its customers and take advantage of future opportunities.

Generating a 3D PCB in Pro/ENGINEER By Keith Richman, Simplified Solutions Inc.

Rendering with Realism Setting the Standard

Integrating a printed circuit board into product design is vital when developing electronic devices. Although bundled with each license of Pro/ENGINEER, the Pro/ ECAD interface remains vastly underutilized within the PTC product user community. Instead, many companies continue to struggle with the interface between their 2D electrical ECAD tools and Pro/ENGINEER. Others continue to pass “paper sketches” back and forth. In reality, the basic IDF (Intermediate Data Format) interface is extremely simple to use. Circuit board data typically originates in the 2D electrical world. A simple IDF export of EMN and EMP files from your company’s 2D ECAD tool provides the basic information required to generate a simplified version of your PCB. Specifically, the EMN file contains information about the physical PCB shape, keep-out areas, keep-in areas, and drilled holes, along with the location and orientation of each component. The EMP file, in contrast, contains information describing each component’s 2D size, height and shape. In Pro/ENGINEER, all you have to do to import your PCB is 1.

Use the FILE–OPEN command and select the correct EMN file.

2. Choose Assembly as the type. The PCB outline and component locations are then imported. 3.

When prompted, choose the EMP file that contains the component profiles.

4.

A PCB similar to the one below will appear (Fig. 1)

CADTRAIN Goes to PTC University Prove Your Mettle in the 2006 PTC Awards Competition PTC Executive Meeting Summary: Progress Continues Generating a 3D PCB in Pro/ ENGINEER Creating Flexible Components in Pro/ ENGINEER Wildfire Planning Your Upgrade from Pro/ INTRALINK 3.x to 8.0 Logging System for Developing in Windchill 8.0

Figure 1.

Adding 3D Information But mechanical engineers need a lot more information to do their job right the first time. To create a 100% geometrically accurate PCB, the “block” components must be replaced with 3D models. The mechanism Pro/E provides to accomplish this task is a text file called the ecad_hint.map. When you import an IDF (EMN) file, Pro/ENGINEER searches the ecad_hint.map file for a matching component called out in the EMN file. Pro/ENGINEER then replaces block geometry with a real 3D Pro/ENGINEER part. Here’s a sample component entry in an EMN file: SOT-23 A-32788545 15.0

21.0

Q12 0.0

90.0

TOP

PLACED

·

SOT-23 represents the ecad_name (typically a geometry package name)

·

A-32788545 represents the ecad_alt_name (often a company part number)

·

Q12 is the reference designator

· 15.0, 21.0, and 0.0 represent the component location with respect to the circuit board’s (0,0) point in the X, Y and Z directions. ·

The 90.0 represents the orientation of the component

·

TOP is the side of the PCB on which the component resides.

· PLACED (as opposed to unplaced) means this component will be populated upon import.

The entry in the ecad_hint.map file has the following format:

map_objects_by_name -> ecad_name "SOT-23" ecad_alt_name "A-32788545" ecad_type "" mcad_name "sot-3p290x130ll237h100" mcad_type part end

In this example, Pro/ENGINEER searches the ecad_hint.map for unique combinations of the ecad_name (SOT-23) and ecad_alt_name (A-32788545). Since a match was found, Pro/ENGINEER replaces the block geometry with a 3D part called sot3p290x130ll237h100. Pro/ENGINEER assemblies can also be imported to a PCB by changing the mcad_type from part to assembly.

Orienting the Component The next step in the process is to insure that the orientation of the ECAD geometry and Pro/ENGINEER geometry matches. If the coordinate systems do not match, the 3D component will be rotated with respect to the ECAD geometry when imported into Pro/ ENGINEER. The center image in Figure 2 shows an overlay of the Pro/E 3D model and the ECAD geometry.

The coordinate systems for the ECAD and Pro/ENGINEER data must also be in the same location with respect to the component outline. The physical center of the part is often the best location for surface-mount components, while the center of Pin 1 often works best for through-hole components.

Importing a 3D Component After connecting the EMN file entries to your 3D part using the ecad_hint.map file and verifying that the ECAD and MCAD components have the same orientation, you can import a component. To import a fully populated 3D PCB, all items in the EMN file should have: ·

A matching entry in the ecad_hint.map file containing the proper mcad_name.

· A matching 3D model for the mcad_name that Pro/ENGINEER can locate during your PCB import. This model must have the proper coordinate system orientation and location.

The following configuration settings need to be added to your config.pro prior when importing your PCB: ecad_mapping_file ecad_comp_csys_def_name

“Location of your ecad_hint.map” “ECAD component coordinate system name”

Once you have updated your configuration settings, use the same step for importing your improved PCB as for importing the PCB with the block components. 1.

Use the FILE–OPEN command and select the correct EMN File.

2.

Choose Assembly as the type.

3.

The PCB outline and component locations are imported. This time, the 3D models

called out by the ecad_hint.map appear, as shown in Figure 3.

Figure 3.

Generating Component Outlines One of the most common issues mechanical engineers run into when importing a PCB is lack of quality information from the ECAD side. For this reason, IDF allows the transfer of data to, as well as from, the electrical world. From the top view of a 3D PCB, the geometric data should be identical to the 2D information in the ECAD tool. With this in mind, it often makes sense for mechanical engineers to define the PCB and component outlines in Pro/ENGINEER. ECAD drafting tools are not as sophisticated as Pro/E, and PCB designers often take much longer to produce less detailed outlines. This outline data can be exported through IDF and imported into ECAD by following these steps.

1. Create a protrusion using the surface that contacts the PCB as the sketching plane (Fig. 4a). 2.

Choose all external edges of the component as seen from a top view.

3.

Extrude the protrusion to the top surface of the component (Fig. 4b).

4.

Choose File, Save A Copy, select ECAD IDF (*.emn), and save the file (Fig. 4c).

5.

Import the EMN file into your ECAD software.

Note: The EMN file will not export if there is not a consistent cross section at every Z height.

Design Process for PCB Development With mechanical engineers and PCB designers transferring data back and forth, it’s important to have a standard procedure for information exchange. Here is a good starting point for establishing your company’s own process for developing circuit board designs. 1. The mechanical engineer creates the PCB board outline in Pro/ENGINEER and exports the file as an IDF EMN file. 2. The PCB designer imports the PCB outline EMN file into the electrical design tool, places critical mechanical parts outside the PCB profile, and exports an EMN file. 3. The mechanical engineer imports the EMN file back into Pro/ENGINEER, moves incorrectly placed components to the proper locations, and exports an EMN file. 4. The PCB designer imports the EMN file, completes circuit layouts, etc., and exports an EMN file. 5. The mechanical team imports the EMN file and performs analyses, including interference checks. 6.

The mechanical team and PCB designer go through an iterative process, checking

and moving components until the PCB is ready for release.

Building a Library of 3D Components Building 3D circuit boards in Pro/ENGINEER requires an organized library of components. Since most companies do not have dedicated resources for accomplishing this task, here are some resources for streamlining the creation of a 3D component library. · Many connector vendors provide IGES files and/or Pro/ENGINEER .prt files on their websites, which can be integrated into your library to save time and money. For example, Molex Inc. (www.molex.com) has thousands of connectors modeled in Pro/E. Other manufacturers such as Amp (www.amp.com) and Samtec (www.samtec.com) have IGES files available for a large percentage of their connector products. · Mechanical PCB components created in Pro/ENGINEER through the normal design process can also be added to your library. Components such as shields and contacts typically are designed and tooled based upon 3D models created by mechanical engineers. These same models can be integrated into a corporate library of components. · Electrical packages are typically used over and over. A one-time investment in modeling or acquiring these 3D models will pay dividends over the long haul. A library of 3D electrical packages modeled in Pro/ENGINEER can be found at www. simplifiedsolutionsinc.com.

Benefits of Using Pro/ECAD With handheld products shrinking in size and product development cycles getting shorter, mechanical engineers need more detailed PCB information to get their designs right the first time. Pro/ECAD provides an easy-to-use interface for importing 3D Pro/ ENGINEER components to improve the accuracy and speed of PCB design. Using more realistic 3D components makes the process more efficient in several ways: · Mechanical engineers work with the exact PCB geometry before the first circuit board is manufactured, minimizing costly tooling errors. · Interference checks reflect reality. Using more realistic geometric information often enhances shock and thermal analysis. · Product housings can be designed more accurately with the improved PCB information. · The detailed and accurate PCB information allows design of smaller, sleeker products. ·

ECAD design errors can often be caught before circuit boards are ordered.

· Communication among PCB designers, mechanical engineers, industrial designers, engineering management, and marketing is vastly improved.

In sum, the upfront resources needed to generate 3D PCB geometric information more than pay for themselves over time.

Keith Richman is a mechanical engineer and chair of PTC/USER’s ECAD Technical Committee. He is also founder of Simplified Solutions Inc., which offers an extensive 3D electrical component library modeled in Pro/ ENGINEER, along with time-saving tools for integrating components into PCB designs. This article is based on his presentation at the 2005 PTC/ USER World Event. Keith can be reached at keith@simplifiedsolutionsinc. com.

Creating Flexible Components in Pro/ENGINEER Wildfire By Michael Mongilio, Swales Aerospace The ability to create flexible components was a popular enhancement request for many years. PTC has now implemented this functionality beginning with Pro/ENGINEER Wildfire. A flexible component is defined as a part that is represented differently in the assembly than in its stand-alone configuration. The alternate representation is controlled entirely at the assembly in which the flexibility is established. As a result, creating or changing the flexibility state in assembly does not modify the component or change its name. A spring is the most obvious example of a flexible component since it can exist at any extension or compression length. But flexible components can vary by more than just their dimensions. Say a part has a tab that’s used to hold it during assembly and is then cut off. Rather than use an assembly cut to achieve this, Wildfire lets you make the component flexible and then simply suppress the feature that represents the tab. In addition, a sub-assembly can be made flexible. Several types of sub-assemblies contain components that are removed when the sub-assembly is added to the nexthigher assembly. For example, a sub-assembly that has a flex circuit includes a bracket to secure the flex-circuit connector until it is installed at the next assembly. That bracket can be removed by making the installed assembly flexible. The same is true for dust covers, safe pins, or temporary fasteners that are removed or replaced at a higher-level assembly.

Significance of Flexible Components Pro/ENGINEER has always been able to accomplish these same tasks without the need for flexible components, but with one major drawback. Until Wildfire, It was impossible to create a part variation within the assembly without creating a new model name. In many organizations, a new model name represents a new part number. As more and more companies use the bill of material generated by the Pro/ENGINEER model in their data management applications, it is important for components in the assembly to correspond one-to-one to the final bill of material. Creating a second model to represent a part in an alternate state not only added an extra part number, but also caused the correct part number to show an incorrect quantity. With the new flexible component functionality, you can create a variation of a model to accommodate its assembly state without modifying it. Part number and quantity in the bill of material remain correct. This also means that no new version of the model needs be checked into

Rendering with Realism Setting the Standard CADTRAIN Goes to PTC University Prove Your Mettle in the 2006 PTC Awards Competition PTC Executive Meeting Summary: Progress Continues Generating a 3D PCB in Pro/ ENGINEER Creating Flexible Components in Pro/ ENGINEER Wildfire Planning Your Upgrade from Pro/ INTRALINK 3.x to 8.0 Logging System for Developing in Windchill 8.0

the data management system.

Creating Part Flexibility Making a component flexible in Wildfire takes just a few steps. In this case, we use the example of a spring. 1. Highlight the component in the graphics window or model tree. Click the right mouse button and choose Make Flexible from the pop-up menu. A tabbed dialog box will open (Fig. 1).

Figure 1. 2. Select the Dimension to vary (pick on features to display dimensions) and select OK. The dimension will be added to the dialog box. 3. Enter a New Value for the dimension and select OK. The model will regenerate and the icon for the component in the model tree will change to reflect its flexible status (Fig. 2). A bill of material will still show only one component with no change to its quantity.

Figure 2. Computing measurements. There are many times when the exact value of the desired variation is unknown. Going back to the spring example, the extension or compression length is determined by the components to which it is attached. In such a situation, a fixed value for the variation will not do. In this case, go the Method column of the flexible components dialog box, change the field from By value to Distance. The Measure dialog box will open so that a distance measurement can be computed. This computed value will become the new value for the flexible dimension. The measurement will be re-computed each time the assembly is regenerated, keeping the component dimension up to date. Feature variations. The flexible components dialog box also lets you create feature variations. Feature variations provide the means to model variations that can’t be expressed by simple dimensional changes. As an example, say a capacitor is used in two different locations in an assembly. The leads are not only bent but also trimmed differently in each installation. Since dimensions alone cannot capture this variability, the answer is to create two sets of lead configurations in the part model. After assembling the component, it is made flexible. The particular set of leads is resumed for the appropriate installation while the other set is suppressed. In the other installation, the feature states are reversed (Fig. 3).

Figure 3.

Creating Assembly Variation When working with sub-assemblies, it is important to note that flexibility can be established at different levels with different results. Fig. 4 shows a simplified spacecraft assembly with two representative solar array assemblies. The solar arrays have hinge sub-assemblies that allow the solar arrays to be stowed, deployed, or something in between. If the hinge assemblies are made flexible in the context of the solar-array assembly, both solar arrays will modify together (Fig. 5).

Figure 4.

Figure 5. But what if you want to deploy only one solar array assembly? The dimension that controls deployment exists within the lower-level hinge assembly rather than in the solar array assembly itself. With flexible components, you can select a dimension from the lower-level assembly to vary at the higher assembly level. As Fig. 6 shows, the dimension that is made flexible comes from the lower-level array_hinge assembly, even though it was the solar-array assembly that was made flexible. As a result, one solar array is deployed while the other remains stowed. In the model tree, a smaller flexible component icon denotes which sub-components of the flexible assembly have been varied.

Figure 6.

Figure 7.

Setting Up Flexibility In a similar fashion to component interfaces, flexibility can be predefined in any model to better communicate how it should be varied when used in an assembly. All you have to do is choose Edit, Setup, Flexibility. A dialog box similar to the one for assembly flexible components opens. You can add variable items to this dialog box. When the model is made flexible in an assembly, these predefined variable items will already be populated in the dialog box. All you have to do is specify the new values. Michael Mongilio is a senior CAE applications engineer at Swales Aerospace in Beltsville, Maryland, USA. This article is based on his presentation at the 2005 PTC/USER World Event. Mike can be reached by email at [email protected].

Planning Your Upgrade from Pro/ INTRALINK 3.x to 8.0 By Scott Carmichael, NxRev, Inc. Pro/INTRALINK 8.0 is built on PTC’s Windchill architecture. Windchill provides many administrative and user benefits, including a complete web-based design and collaboration environment, integrated visualization, dramatically better WAN performance, improved user interface, and extensive review and red-lining capabilities. In addition, the internal structure and access control functionality provides a much more robust method of managing access to your design environment. To successfully migrate your current environment to Pro/INTRALINK 8.0, it is important to review, test, and configure this new functionality to maximize its utility within your own company. Once you fully understand the new usage of Pro/ INTRALINK 8.0 for your environment, you can plan and complete your migration. Note: The migration to PDMLink is identical to that for Pro/INTRALINK 8.0, with one additional step (explained below).

Data Migrator The Pro/INTRALINK Data Migrator is a command line-based utility that allows you to integrate one or more Pro/INTRALINK 3.x databases into one Pro/INTRALINK 8.0 database. The process requires several “mock” or test migrations of your database to uncover and resolve potential conflicts before a final migration to the Pro/INTRALINK 8.0 schema. During this process, your users, folders, release levels, attributes and revision scheme can be mapped to the same and/or new values. The major tasks/ milestones in the migration process are: 1. Migration analysis and planning. Includes review of your existing Pro/ INTRALINK 3.x source system and product development process, a review of the requirements of Pro/INTRALINK 8.0, and a plan for mapping metadata between the two different schemas. 2. Metadata-only migration. Uncovers any and all conflicts within your metadata. Conflicts can then be resolved in your existing production Pro/INTRALINK 3. x system, your mapping files or Pro/INTRALINK 8.0. 3. Test migration. Allows detailed planning of your final migration. After this phase, you will have a fully functioning copy of your Pro/INTRALINK 8.0 database for testing of the ACL and document control processes.

Rendering with Realism Setting the Standard CADTRAIN Goes to PTC University Prove Your Mettle in the 2006 PTC Awards Competition PTC Executive Meeting Summary: Progress Continues Generating a 3D PCB in Pro/ ENGINEER Creating Flexible Components in Pro/ ENGINEER Wildfire Planning Your Upgrade from Pro/ INTRALINK 3.x to 8.0 Logging System for Developing in Windchill 8.0

4. Final migration. Entails a final run of the Data Migrator software. Once completed, you can apply the ACL and process control rules created and validated in the test migration. 5. Post-migration steps. Includes using several scripts and queues to complete the migration. Each milestone must be completed in turn to ensure success throughout the implementation. Details of each step are outlined in the below.

1.

Migration Analysis and Planning

Preliminary analysis and planning is the most critical phase in your data migration. In addition to reviewing your existing product development process for adherence in Pro/ INTRALINK 3.x and its future adoption in Pro/INTRALINK 8.0, you need to test differences between 3.x and 8.0 to ensure a clean adaptation to your specific enterprise needs. Validation plans and data sets should be developed and recorded, and a migration timeline should be created. As a first step, you need to determine what data to migrate to the new system. Here are some basic guidelines.

What is migrated

Versioned data (PTC and non-PTC data types), revision and version history, named baselines, “as-stored” configuration, folder structure, users, attributes and their values and RTP/ check-in forms

What is not migrated

Roles, folder authorizations, release procedures, preferences, table displays, locate searches, and replication settings

What can be mapped

Folder structure, usernames, release levels and revisions

Data that is migrated will be copied from the source Pro/INTRALINK 3.x system into the new 8.0 system. That data will be migrated according to its structure in Pro/ INTRALINK 3.x, with the exception of information that is mapped. Folder structure, usernames, release levels and revisions can be mapped between the two systems (see options below). There are also several areas in Pro/INTRALINK 3.x that do not have a realistic method of mapping to the 8.0 system. These areas need to be reviewed and corresponding functionality in Pro/INTRALINK 8.0 will need to be configured and tested to ensure a successful migration and adaptation to your specific process. You should also review several areas within Pro/INTRALINK 8.0’s functionality to understand how they will affect current processes. Here are just a few areas where there are notable differences with Pro/INTRALINK 3.x.

· Revision sequence. In Pro/INTRALINK 8.0, Revision becomes Version, and Version becomes iteration. In addition, -

Multiple versions can be worked on simultaneously.

-

Revising increments your version by one increment.

· Lifecycle states. Lifecycle states (formerly known as release level) can be integrated into your revision sequence and change workflow. Revising can also be controlled by the design’s lifecycle state. This allows multiple versioning schemes within your product lifecycle (e.g., numeric for engineering design and alpha once it’s in production). Upon revising or updating a Pro/INTRALINK 8.0 document, you can set an automatic change of lifecycle state (e.g., on the revision of production items, the lifecycle can be automatically set to “In Work”). Promoting/approving your design is far simpler and more applicable to the design process. During the promote workflow, the end user is allowed to set “approvers and/or reviewers” on the fly. · Access control. The primary mechanism for controlling access is through usage of product containers and not folders. The use of folders in Pro/INTRALINK 8.0 is less critical thanks to a far more powerful and integrated search tool, decreasing your dependency on browsing through the folder structure. Moving files is also easier, so you should review your usage of folders before data migration begins. Several migration decisions thus require a basic understanding of Pro/INTRALINK 8.0 usage and a more detailed understanding of your customized usage of the solution. For example, how you want to use versioning, lifecycle, product/library containers and folders helps determine how the mappings are configured to control your migration. Once your Pro/INTRALINK 8.0 process is fully understood, you need to develop a test and validation plan. This should include bill of material and relationship reports run in Pro/INTRALINK 3.x that show attribute values and are set with “as-stored” configurations. It is recommended that you choose several (or all if it’s feasible) of your top-level products to verify and validate your migration. You also need to consider functional usage as it pertains to your document control process. All user roles and activities from initial concept design or new product introduction through release should be tested to ensure your process is configured adequately. 2. Metadata-only Migration This is the first phase that involves using the Data Migrator tool. In the metadata-only migration phase, you want to uncover all conflicts between the 3.x source systems metadata and the planned usage of Pro/INTRALINK 8.0 and any of its metadata. Your first step should be to “clone” your existing production Pro/INTRALINK 3.x server. By duplicating this environment, you can more easily replicate a migration while ensuring minimal production downtime. After cloning your 3.x system, it’s time to install Pro/INTRALINK 8.0. The Data Migrator can then be installed on your Pro/INTRALINK 8.0 machine. A folder of scripts

from this install will be used by the 3.x system and needs to be copied to the 3.x install loadpoint. These scripts allow you to “lock” the system so that the Data Migrator can extract the information it needs. The metadata-only migration involves several steps: · Load admin data. Pro/INTRALINK 3.x data is exported to text-editable property files (release levels, users, folders and attribute mappings). · Configure mappings. Mappings files may be edited to establish a method of converting or mapping your Pro/INTRALINK 3.x metadata to the 8.0 schema. · Load mappings. Mappings files are uploaded into the target system and compared to ensure compatibility. · Review and resolve conflicts. Conflicts are available in detailed HTML reports and can usually be resolved by either editing the source or the target system. Conflicts typically involve user, folder, release level, and revision sequence mapping. · Initiate the migration in discrete phases. The Data Migrator tool was created to allow you to migrate your data in stages, e.g., documents, family tables, and links. This allows for a better understanding of failures and an easier way to troubleshoot any potential conflicts/errors. · Test system to ensure the metadata-only migration is valid. Apply complete validation requirements, but omit any task that requires a check-out or retrieval of file content. At this point, you can log into Pro/INTRALINK 8.0 and all of your metadata will be loaded. You can perform any action that does not require access to the file content, such as reports, searches, browsing and form review. You should focus on testing your results to ensure Pro/INTRALINK 8.0 performs as expected. 3–4. Test and Production Migrations After completing the metadata-only migration, all log files and results from your validation testing should be recorded. The purpose of the next phase is to build a more complete test environment for validation and to confirm the time and resource requirements for the final production migration. The test migration is performed the same as the metadata-only migration, except that you will also complete the file transfer phase. Once this is done, you will have a full copy of your Pro/INTRALINK 3.x environment to test in Pro/INTRALINK 8.0. This environment will be what you use in production and should be used to test, document, and validate your planned process and usage of Pro/ INTRALINK 8.0. Any configuration can be exported and stored for usage once the final migration is completed. The production migration should run identical to the test migration. The main difference here is that your production Pro/INTRALINK 3.x environment must be shut down to end-users. Many companies complete this migration during off-hours to minimize the impact on operations. Completing a successful test migration helps immensely when planning for your final migration and rollout to production. Furthermore, it minimizes any unforeseen issues that may affect the migration and ultimately user productivity.

Once the final migration is completed, any exported configurations from testing can be implemented and the new production Pro/INTRALINK 8.0 system is fully migrated. 5. Post-Migration Tasks After completing your production migration, there are still a few tasks to complete. The first is to ensure the proper vaulting of any new data or documentation. All existing data must be migrated into an external vault, but new data (by default) will be configured for storage within Oracle as BLOBS (Binary Large OBjectS). This is generally not preferred because it can affect performance. Resetting your vaulting rules will quickly address this issue. Second, if you are upgrading to Windchill PDMLink, there is a final step in the Data Migrator that is used to create WTParts for each CAD document. And third, you will want to schedule the queue manager to publish viewables and thumbnails for your recently migrated data and Index the database where appropriate. At this point, the system should be ready for full-production usage.

Final Considerations Now that you have successfully migrated to Pro/INTRALINK 8.0, what do you do next? Well, there are many places to go to enhance your environment. One might be to upgrade it to PDMLink and incorporate your ECO/ECN control processes with Windchill. Another might be to integrate your PDM release into an ERP/MRP system. Yet another might be to just get more people in your enterprise to review and/or redline the design data. With Pro/INTRALINK 8.0 installed, these are many more options and possibilities out there. Good luck and best wishes with all your migration challenges! Scott Carmichael is CTO of NxRev, Inc. in Santa Clara, CA. He can be reached by email at [email protected].

Logging System for Developing in Windchill 8.0 By Dmitry Tkach, isLaNd Inc. In software development, logging is the process of inserting statements into the program that provide some kind of output information that is useful to the developer. Examples of logging are trace statements, dumping of structures and the familiar System.out. println or printf debug statements. Log4j is a popular logging package written in Java. One of its distinctive features is the notion of inheritance. Using a logger hierarchy, it is possible to control which log statements are output at what granularity. This helps reduce the volume of logged output and minimize the cost of logging. One of the advantages of the log4j API is its manageability. Once the log statements are inserted into the code, you can control them with configuration files. They can be selectively enabled or disabled, and sent to multiple output targets in different formats. The log4j package is designed so that log statements can remain in shipped code without reducing performance. In the following example, we use log4j in Windchill to eliminate the headache of maintaining thousands of System.out.println statements. But first we need to do some customization.

Setup To use the tools we are about to install, you must set up the operating environment so that the tools know where to find what they need and the operating system knows where to find the tools. 1. Download the log4j distribution from http://jakarta.apache.org/log4j/docs/download. html. (During installation, Windchill 8.0 loj4j.jar is already there.) 2. Extract the archived files to some suitable directory.

The Logger The Logger is the core component of the logging process. In log4j, there are five normal levels of logger available (not including custom levels). The following descriptions are borrowed from the log4j API (http://jakarta.apache.org/log4j/docs/api/index.html). · Static Level DEBUG. Designates fine-grained informational events that are most useful to debug an application.

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· Static Level INFO. Designates informational messages that highlight the progress of the application at coarse-grained level. ·

Static Level WARN. Designates potentially harmful situations.

· Static Level ERROR. Designates error events that might still allow the application to continue running. · Static Level FATAL. Designates very severe error events that will presumably lead the application to abort. In addition, there are two special levels of logging available. (Descriptions borrowed from the log4j API http://jakarta.apache.org/log4j/docs/api/index.html.) ·

Static Level ALL. Has the lowest possible rank and is intended to turn on all logging.

·

Static Level OFF. Has the highest possible rank and is intended to turn off logging.

You can use any of seven levels: Level.DEBUG, Level.INFO, Level.WARN, Level. ERROR, Level.FATAL, Level.ALL and Level.OFF. For our example here, we created the package in src/ext folder and called – logging. src/ext/logging/LoggingService.java src/ext/logging/LoggingServiceFwd.java src/ext/logging/LogginServiceHelper.java src/ext/loggin/StandardLoggingService.java src/ext/logging/LoggingUtils.java To check the loading process using log files, we need to configure Log4j for Windchill Server. Log4j is initialized via a property file. Two configuration files exists. The primary one is PDM.lsf in the codebase directory of the Windchill server. For development purposes, a developer may create a PDMdev.lcf exists. PDM. lsf will not be used.

The Appender The Appender controls how the logging is output. The available appenders are as follows. (Descriptions borrowed from the log4j API http://jakarta.apache.org/log4j/ docs/api/index.html.) · ConsoleAppender: Appends log events to System.out or System.err using a layout specified by the user. The default target is System.out. ·

FileAppender. Appends log events to a file.

· DailyRollingFileAppender. Extends FileAppender so that the underlying file is rolled over at a user chosen frequency.

· RollingFileAppender. Extends FileAppender to back up the log files when they reach a certain size. · WriterAppender. Appends log events to a Writer or an OutputStream depending on the user's choice. · SMTPAppender. Sends an email when a specific logging event occurs, typically on errors or fatal errors. · SocketAppender. Sends LoggingEvent objects to a remote a log server, usually a SocketNode. · SocketHubAppender. Sends LoggingEvent objects to a set of remote log servers, usually SocketNodes. ·

SyslogAppender Sends messages to a remote syslog daemon.

·

TelnetAppender. Specializes in writing to a read-only socket.

You can also implement the Appender interface to create your own ways of outputting log statements.

PDM-Wide Log4j Configuration Here is a sample PDM.lsf configuration file that would go in the Windchill logs folder. Appenders Stdout is set to be a ConsoleAppender that outputs to System.out. log4j.appender.stdout=org.apache.log4j.ConsoleAppender log4j.appender.stdout.layout=org.apache.log4j.PatternLayout log4j.appender.stdout.threshold=WARN

The method server adds a timestamp to every line, so don't do it via log4j too. log4j.appender.stdout.layout.ConversionPattern=%-5p %c{1} - %m%n

Send Deere messages to $WT_HOME/logs/test.log log4j.appender.test=org.apache.log4j.RollingFileAppender log4j.appender.test.File=${deere.logs.dir}/test.log log4j.appender.test.MaxFileSize=6MB

log4j.appender.test.MaxBackupIndex=0 log4j.appender.test.layout=org.apache.log4j.PatternLayout log4j.appender.test.layout.ConversionPattern=%d{DATE} %-5p %c{1} - %m%n

Loggers By default, everything goes to the stdout appender. log4j.rooLogger=WARN, stdout

For third-party packages, we only want priority WARN or above. Some of these packages use Jakarta Commons Logging wrapper which, when log4j is found on the classpath, routes the logs through log4. log4j.logger.org.apache=WARN log4j.logger.org.apache.commons.httpclient=WARN log4j.logger.httpclient.wire=WARN

log4j.logger.ext.cf.loaders.Test=DEBUG, deere log4j.additivity.ext.cf.loaders.Test=false

Setup for Windchill So now, to configure several log files at once for each module, you need to set up log4j for Windchill Server. 1. Copy the log4j.jar archive to the Windchill codebase directory. 2. Create the PDM.lcf (production servers) or PDMDev.lcf (development servers) 3. Initialize the log4j in the new sources code files if you need. 4. Restart the Tomcat and Method Server.

Dmitry Tkach is software architect at isLaNd Inc.(www.ittechstar.com). He can be reached by email at [email protected].

Setting the Standard

Rendering with Realism Setting the Standard CADTRAIN Goes to PTC University

by Evan Caille, President of PTC/USER “The beauty of standards is there are so many to choose from, you can just pick the one you like.” How many times have you heard someone say this—only partly in jest? As engineers, we benefit from standards that ensure part commonality and help us meet safety, environmental, and ergonomic regulations. For example, fastener standards make it easier to specify parts and have confidence that any manufacturer meeting those standards will produce something that conforms to our needs. As a case of standards being used to improve the health and safety of people, take the development of boiler standards by the American Society of Mechanical Engineers in 1914–15. During the prior 35 years, over 10,000 boiler explosions were recorded—many resulting in loss of life. The boiler standard was a voluntary guideline that many state and foreign governments adopted and incorporated it into law. (See http://anniversary. asme.org/history.shtml for more details.) On the other hand, standards can be a detriment if they are issued before a specific technology matures. The effect can be unrealistic constraints that inhibit innovation or widespread adoption by the marketplace. We see instances throughout history where innovative approaches supplanted the so-called standard at the time. This is often because the new approach is a simpler and less costly solution that leads to widespread adoption—eventually becoming the de-facto standard. The success of TCP/IP as a network protocol is a clear example of this. Another interesting example involves railway track gauges. One would think that a single-track gauge would be used to enable the free flow of goods across the rail network. In actuality, early railroad companies adopted one of several rail gauges for various economic and practical reasons. This meant that goods often had to be offloaded from one railcar onto another in order to traverse the US. It wasn’t until after the 1860s that there was a common gauge across the Northern and Southern states. This brings to mind the efforts we sometimes go through to exchange data between two different CAD systems. It can also take years for everyone to adopt a particular standard. Time zones are a case

Prove Your Mettle in the 2006 PTC Awards Competition PTC Executive Meeting Summary: Progress Continues Generating a 3D PCB in Pro/ ENGINEER Creating Flexible Components in Pro/ ENGINEER Wildfire Planning Your Upgrade from Pro/ INTRALINK 3.x to 8.0 Logging System for Developing in Windchill 8.0

in point. Before they existed, each community adjusted its clock to solar time. This is a classic case of everyone setting their own “standard.” This meant the people living in the same community could agree on the exact time. But if you visited a neighboring community, your watch could be off by several minutes or more. Because of the distances involved, train travel exacerbated the problem. As trains moved between terminuses, they would either be running ahead of or behind time depending on whether they were going east or west. This made it very difficult to schedule arrivals and departures. To remedy the situation, the railroads adopted standard time by dividing the US into four zones so that clocks could be synchronized across the country and timetables would be accurate. It should be noted that the railroad companies adopted standard time several years before the general population did so. (For more info, see http://webexhibits.org/daylightsaving/d.html.) What does all this have to do with PTC/USER? As users, we are often looking for the best, or standard, practice when it comes to using PTC tools. I firmly believe a healthy dialog within the PTC/USER community can help us assess these practices. And I believe evolution and variety are key watchwords. As technology evolves, these practices must also adapt to the changing environment. In addition, each company must consider the pros and cons of each best practice, adopting those that apply and avoiding those that hinder. It is safe to say that across industries, there is a wide range of suitable best practices. So I encourage everyone to share their experience with fellow users, whether on the PTC/ USER mail exploder or at our conferences. One forum that we found to be particularly effective at the 2005 World Event in Orlando was a panel session devoted to companies’ experiences of adopting Pro/ENGINEER Wildfire. Audience members were able to ask numerous questions about how they might achieve the same success at their own companies. Out of this followup Q&A session came numerous tips on how to conduct user training and how to configure the system environment. As attendees have attested, the value of this information exchange was immense. As the new year begins, we at PTC/USER reaffirm our commitment to setting the standard for providing valuable information, sharing opportunities with our membership, and serving as the voice of the customer to PTC. Evan Caille works at HP in Houston, TX. He can be reached via e-mail at [email protected].