Cool Toys… I mean Tools… for SolidWorks Users.

We had an excellent turnout at the Columbus SWUGN Summit, 105 attendees according to Richard Doyle. Jeff Sweeney, from 3DVision Technologies also gave it a thumbs up! I agree with both of them, the Columbus Summit was a hit and those that missed it lost an opportunity to learn from some of the best. My favorite presentations were Weldments by Richard Wand of MJ Engineering and COSUG, and Sheet Metal by Bill Hall of Fisher/Unitech. Thanks to everyone that presented and attended!

I did a Hands On session about External Input Devices at the end of the day, and that is the topic of this post. There are several types of devices that work in harmony with a mouse to create an efficient modeling environment. Some of these include:

3DConnexion Devices

Custom Mouse

Keypads

There are many reasons for adding an input device for your non-mouse hand when using SolidWorks:

1. It balances your desktop interface… mouse in one hand, 6-axis controller in the other, keyboard in the middle.
2. Most are programmable and reduce keystrokes.
3. It looks really cool…
4. A motion controller enables easy model manipulation during feature creation & editing.
5. All your friends want one…

Seriously, an additional input device can really increase your productivity. Whether your reducing keystrokes with a programmed keypad like the Logitech G13 or flying your model with a 3DConnexion device, you WILL increase your modeling speed and efficiency.

My favorite layout is a 6-axis controller, with a couple of programmed buttons, and a 5-button optical mouse with buttons specifically programmed for SolidWorks functions.

I can’t stress enough the importance of using the proper driver with each device. Using the correct mouse drive will enable application specific button programming. If you use the basic 2-button mouse driver with a 5 button mouse, you’re wasting time and money!

Mouse Button Setup

Space Traveler Button Setup

Whatever device you’re considering, try to get a test drive before you buy. Form-Fit-Function are extremely important when choosing tools as these. Function is the only aspect that can be considered without trying one.

Choose your device with caution! Once you get started, you’ll be hooked, and will be toting your SpacePilot PRO along with your laptop!!

Congratulations SolidWorks!

I’m sure many of you received the same email I did from Jeff Ray announcing one million licenses sold. Hopefully, it brings back great memories for you and your career since you’ve been a SolidWorks user. I’m sure many of you fondly remember the old SolidWorks logo. The red square, simply stating ‘SolidWorks’. I still have my first SolidWorks hat with that logo!

Well, as I was reading Jeff’s email, an image popped into my head and just wouldn’t go away. So, with his permission, I’m sharing it with everyone! Sorry I didn’t take the time to actually put it on a sign post in front of the SolidWorks corporate building. But, I think you get the idea, and hopefully a good chuckle with it.

Don’t forget to visit the SolidWorks website page celebrating this great milestone!

Getting Started… and Grounded.

This is for the gear heads out there. As some of you may know, I really enjoy riding my recumbent trike. I was happy when it was chosen as my ride for the local MS150 Pedal to the Point by my sponsors. Unfortunately, a recumbent trike has its own set of requirements for hauling. I know many people just place their trikes sideways on a regular rack… but that’s a bit too simple for me. So, I crafted a custom rack from a receiver mounted cargo rack that can carry the trike flat, as it would be ridden.

This rack works very well with my Suzuki x90 car… well, 4×4… sort of SUV… OK, let’s just call it the x90. But, the x90 developed a starting issue, more specifically, a lack-of-starting issue. Resulting in several push starts and clutch pops. Those were much more fun as a youngster with several friends to help push!

I finally had some time to address the issue this weekend. I had previously tested the battery, bypassed the clutch safety switch, and checked the solenoid & started motor with a remote start switch. These were fairly easy to access. With no success, I was reviewing my game plan for starter R&R when I realized I’d have easy access to the solenoid ground strap from below. It was the only item not checked, mainly because I couldn’t reach it! The connection looked a little rusty, but not what I’d consider excessive, or non-conductive.

Then I remembered the battery gremlin that visited this car a few years ago, and disrupted service by producing a bad ground connection at the battery terminal. The terminal was clean, and looked fine, with none of that wonderful white fuzzy growth that often occurs on battery terminals. I removed, cleaned, and returned the ground cable connector, solving the issue. Why not try the solenoid ground strap before I remove the starter? What have I got to lose, except $125 for a new starter?!

Well… after a short period of time in the man-cave, under the x90 with a small wire brush, a headlight, a wrench, some anti-corrosion electrical grease, and loud classic rock, I emerged victorious! With 20+ strong, successful starts (fingers crossed), I considered the problem solved. Always check your ground connections… if I would have replaced the starter, I would have cleaned this connection anyway, and not known the real issue.

With the trike loaded, and a sunny, 80 degree day, I’m very much looking forward to a ride after work today! My apologies for such a long delay between posts, but a death in the family took priority, and I appreciate your understanding. Thanks for coming back to visit, I’ll try to get things ramped up again!

Richard Doyle is honored by The CAD Society

Those of you that missed the crowning of Sir King Richard by his merry followers (or jesters) at SolidWorks World can now join in the celebration of his award from The CAD Society. Richard is the recipient of the 2009 CAD Society Joe Greco Community Award, for his achievements in building the SolidWorks community.

Richard’s enthusiasm has energized the SolidWorks User Group Network into the great community it is today. Please join the SolidWorks Community in congratulating Richard in a job well done! Don’t forget to read the SolidWorks Blog.

Great work, Richard!

Recycling broken spokes… into small files.

Arriving home last night, I was greeted with a big hug from my 4 year old (aren’t they great?!) and quickly escorted into the living room to see two ‘new’ toy cranes. These experienced toys were donated to our construction collection by a family member. Like most hand-me-down toys, they weren’t perfect.

After the structural issues were resolved, I moved on the electronics. I wanted to give the battery contacts a good filing since they had a bit of corrosion. Looking around the workbench, a file wasn’t handy….but, the broken spoke from my recent wheel repair was lying there. I know, most people would have tossed it, right?

Well, the threaded end of the spoke, with its sharp edged threads, made an EXCELLENT small, round file! It quickly removed the corrosion, and the contact was again shiny. If you do any repair or hobby work that requires small file use in tight areas, try an old, broken spoke.

They can be cut to any length, and bent to any configuration to access that ‘impossible to reach’ area. You don’t have any old broken bicycle wheels around as a source for broken spokes? Just stop by your local bicycle shop and ask…they’ll most likely enjoy your conversation and give you a fistful of them if they haven’t emptied the trash yet!

Test Patterns… Pattern Tests… OK, Testing Feature Patterns

Test patterns won’t do much for us in SolidWorks, but they are fun to look up online!

A Familiar BBC Television Test Pattern

Many of us use patterns & mirrors to save time…but, are we really saving time?

This post describes Feature Pattern behavior that I observed while working on a sheet metal tray full of holes. I tried a variety of modeling methods to create the main pan of the tray. Two of the patterns were mirrors of each other, so I thought it was a good time to experiment with patterns.

The findings are significant enough to note, but not an endorsement to freely pattern every hole found in your products. If these patterns are used for visual purposes only, then other methods may work better. If they are needed for weight calculations, structural analysis, etc., then the findings here may save some modeling time.

The model used for testing was a 10’ x 10’ plate, 1” thick. The seed hole is 1” diameter, using an Extruded Cut (Through All) with a 2” spacing pattern. The linear pattern only was used to fill the entire plate. The mirror pattern was used to create four quadrants as shown below. The initial quadrant was filled with a linear pattern, and the first mirror filled a second quadrant. The second mirror filled the remaining two quadrants. The fill pattern was also tested, with the seed hole in the center of the plate, using 2” spacing at 60 degrees to fill the entire plate.

While the fill pattern seems like a great idea at first, note that it patterns the holes with respect to hole center distance, not specified row & column spacing. It’s easy to create different results unintentionally. Be certain your finished pattern is what you desire regarding x & y dimensions, angles, and ligaments (distances between hole edges).

Plate part with Linear and Mirror Patterns

The following rebuild times are based on the model described above, and conducted on a computer operating in a consistent state. The computer is a Lenovo T61P, but this is not significant to the observations. The specific times are not as important as the relationships between them, the different features used, and the options checked. The options are described in SolidWorks Help. Please review the Help files, they contain good visual explanations, especially of the Geometry Pattern functionality.

My condensed description is as follows:

Geometry Pattern – the exact size and shape of the seed feature will be repeated, regardless of references to surfaces, planes, and other driving references in the model.

Propagate Visual Properties – If you have changed the color, texture, etc. on the seed feature, it will be copied in the pattern.

I tested these combinations using the same part. I created the desired combination, did a Forced Rebuild, Saved the part, exited the part, an exited SW. Next, I started SW, opened the part fully resolved and ran Feature Statistics. I conducted the tests in SW2008 SP5.0 and SW2009 SP2.0.

Rebuild times using different Feature Pattern Options

My apologies for the chart appearance, I’ll take any advice regarding posting graphics!

1. The Fill Pattern was faster with the Geometry Pattern option OFF.
2. The Linear Pattern was significantly faster with the Geometry Pattern option OFF.
3. The Mirror Pattern was significantly faster with the Geometry Pattern option ON.

I’m not sure why the Linear & Mirror Patterns react oppositely to the Geometry Pattern option, but they do. The key is to understand this difference and how it can affect your model rebuild times. Waiting 30 more seconds for single part isn’t too bad, but if you have multiple parts with large patterns, the wait time could increase quickly. If you use Circular, Sketch/Curve Driven, or Table Driven Feature Patterns, I encourage you to investigate the effects of the Geometry Pattern & Propagate Visual Properties options.

I’ll exit with another famous television test pattern from the United States.

Indian Head Test Pattern

Flippin’ Hub

I got hooked on fixed gear cycling several years ago, and that’s when I built my first set of wheels. I bought a Sovos flip-flop hub, sprocket and lockring from Sheldon Brown at Harris Cyclery. I decided to convert my beloved Schwinn tourer to a fixie, and I used an old 5 speed freewheel on the other side to provide a couple possible ratios. I studied wheelbuilding, and decided to keep it simple with a 3-cross pattern, using some nice Araya 27″ rims. The solid axle and track nuts that came with Sovos were fine and worked well for a few years. When I wanted to flip it, I grabbed a wrench…and, well, you know what to do here. At the end of last season, I noticed a broken spoke…bummer!

I was tired of carrying & using a wrench everytime I wanted to flip the hub. I always figured a Flip-Flop hub should have a Quick-Release (QR) axle. Since I had to repair the wheel anyway, it was a good time to convert it to QR. I still had the original QR hub with axle & skewer. I measured the bearing dust covers and they seemed close enough. One hub had seals press fit to the hub, and the other had seals pressed onto the bearing cone. Of course, they were not interchangable…so, I made a set from some plastic (polypro) caps I had lying around and pressed them into the hub.

The next step was to true the wheel, which is a task I truly enjoy. It’s relaxing, and takes me to the state of Zen …which is better than my ususal state of confusion! It’s interesting to note the enso is a circle…hmmm.

With the tire mounted, I was ready for a ride. I tested it in the driveway, and all was well. When I want to change from fixed-gear to freewheel, all I need to do is flip the QR lever! Another advantage to this… I can pack the bike in my Beetle much easier with both wheels removed. For the gearheads, I’m running 39/16 fixed and 39/17 free. This is a nice combo for flats & rolling hills which I encounter here in Ohio.

Pics are posted on the Cycling Projects page.
If you’ve never ridden fixed…it’s GREAT for training!
Check out the Fixed Gear Gallery for ideas.

Don’t forget your pre-season cycle safety check…as I did!
-A story for another day-

Happy Trails!

Sheet Metal Studs… no… not Gerald & Wayne!

Weld stud on conic plate.

I know most of you sheet metal guys work with thinner (<.25″) material, but I’m trying to make use of SolidWorks sheet metal tools for our plate work. Occasionally, we weld studs (threaded rod) in holes for equipment & door mounts. I was challenged with a conical part, and asked how to mate the studs to the part in an assembly. Here’s what I discovered…

I was hoping to create an axis in the hole. Then simply mate the axis of the stud to the axis of the hole, and the end of the stud to the inner surface of the conic. Sounds simple enough, right? Well, if the holes are created in the flattened form, then an axis cannot be created once the part is rolled. The holes must be created in the conic shape, and axis added before it is unfolded. When I added fold/unfold features, I could only add an axis during the process stage the hole is created. This behavior is consistent and also applies to cylinders.

The drawback with this behavior is that if the holes are added in the flat, then mating is affected at the assembly level when the part is rolled. If the holes are added in the rolled state, then dimensioning is more difficult. I’m sure that everything can be handled in each state with workarounds, and I’ve already discovered a few. Such as sketching a 3-point circle over the edge of a flattened hole to provide diameter & center locations for flat pattern dimensions.

The priority of these features is up to you. If the assembly mates are more important, then apply the holes in the rolled state to enable axis to included. If the flat pattern is more important, possibly for automated cutting in manufacturing, then apply the holes in the flat. Keep in mind the reality of using the axis to mate. When going around a conic/cylinder, the axis lead away from each other, not parallel. In our case, a hingeless door that’s bolted onto the conic, the studs need to be installed parallel so the door can be removed.

Got Mud?

It’s last Thursday afternoon, warm, the sky is mostly clear, and it hasn’t rained in a couple days. I’ve got the x90 (trike hauler) back on the road after cleaning a starter solenoid connection that left it lifeless during the winter. I’ve made the effort to load my trike and bring it to work with high hopes of riding the towpath after work.

I wrapped things up a little early and was very excited about my first trike ride this season. Riding a trike is a bit different than other cycles. It is a recumbent and has a comfortable, yet firm seat. If you saw the red Catrike at Solidworks World in the Product Showcase, my trike is very similar. The most challenging part is watching the trail for 3 tracks (all 3 wheels) rather than one track (normal bicycle w/ wheels in tandem). The fun part is riding very close to the ground, and going fast!

The bike trails in NE Ohio are either crushed limestone, or asphalt, with most of them being the former. Usually this isn’t a problem and they ride fairly well, even with semi-slick road tires. My normal setup on the trike is Primo Comets at 85-90psi for the trail. At 1 1/8″ wide, these are without a doubt, road tires.  They work fine on dry, hard pack trails. Let’s just say looks can be deceiving on a limestone trail.

The trail appeared wet, but generally smooth and other tracks were visible. Which meant others had been through with no problem, right? I ventured off, pedalling down the trail, avoiding the small puddles and ’soft spots’. Everything was going fine until I encountered the first bridge, which included a downhill approached on both ends.

It went something like this, down the slope to the bridge, bumpety-bump over the wooden bridge, squish, (uh-oh) pedal-pedal, sinking (dang-it), downshift-pedal…spin, spin, spin (&%^!). I couldn’t believe it… I was stuck in the mud!! Yes, I could have gotten off the trike, and pulled it up the rest of the slope. But, then I would have not only a muddy bike to clean, but muddy bike shoes. I really didn’t want mud in my shoe cleats & pedals. Since I don’t have fenders on the trike (yet!), I was able to use the front tires “wheelchair” style to add a little traction. I’m sure it would have made a great youtube video, but luckily, no one was watching.

Once I was out, I rode a little more. Realizing I would face the same fate at each small hill, I decided to make it a short ride and turn around. I went back across the same bridge a bit faster on the return trip and didn’t get stuck…but, I did spin the back wheel quite a bit! If you’ve ever ridden in wet sand, then you understand. I’m glad I got an early start this season, but I will stick to asphalt until I get the knobbies on the trike!

Winter Cycling…or “Why do I need more than one helmet?!”

This weekend I took delivery of the birthday present I purchased with funds from my wonderful parents. It is a stylish (a la Hot Wheels), lightweight, ski helmetwhich I intend to wear during cold Ohio months of winter riding. It ran a little smaller than I expected, so I’m still fitting it, via assorted pads I had left over from other helmets. It should work great, according to the many mtn. bikers that use ski helmets in cold weather. I figured it was time to replace my bright yellow helmet that has served me well. I’ve read something about a 2-3 yr. life span for helmets, but I really had a good ROI on that one! I can’t remember exactly how old it is, and it’s too cold to go out to the barn & check! I think it’s more than 10 yrs. old, watch for an update.

I bought a Bell Metro in white, hoping it would be just as visible as my old safety yellow one (yes, I painted it myself).  I was attracted to the Metros by all the great reviews and the optional rain cover & winter kit. I got a great deal on the helmet, but finding the accessories at 60-70% off is impossible! So, for less than the price of the little foam inserts and rain cover, I got another entire helmet with its own removable plugs, ear covers, and really cool orange flames. I’ll post a review after I’ve ridden a few times with it.

I did get to test some $2 neoprene gloves (Purchased at Marc’s), some new tights, and an Illuminite jacket. It was 44 deg, and I only rode 4 miles around downtown, but I wasn’t cold. I could probably use some toe covers, but it wasn’t unbearable. I’ll have to be careful with the Illuminite jacket, however. Apparently, it attracts cars full of hungry, hollerin’, rednecks from Barbertucky on the way to the golden arches! How did I know their destination? I didn’t, but I couldn’t resist following them to ask if they needed anything when they whooped at me. I normally ignore these mild infractions, but I was in a friendly mood. I wished them a good day, and left them a bit speechless.

So, get out there and ride…even if it’s a bit chilly where you live!! Happy Trails!