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THE HONG KONG POLYTECHNIC UNIVERSITY DEPARTEMENT OF BUILDING ESTATE BSc (Hons) in Building Engineering and Management BRE 488 Dissertation Construction Virtual Prototyping – Case Study of Ho Tung Lau Development Author: CHAN KANG YUEN (03510381D) Year of submission: 2006

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  • THE HONG KONG POLYTECHNIC UNIVERSITY

    DEPARTEMENT OF BUILDING ESTATE

    BSc (Hons) in Building Engineering and Management

    BRE 488 Dissertation

    Construction Virtual Prototyping

    Case Study of Ho Tung Lau Development

    Author: CHAN KANG YUEN (03510381D)

    Year of submission: 2006

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development DECLARTAION

    i

    DECLARTAION

    I declare that this dissertation, entitled Construction Virtual Prototyping

    Case Study of Ho Tung Lau Development represents my own work, expect

    where due acknowledgement is made, and that it has not been previously

    included in a thesis, dissertation or report submitted to this University or other

    institution for a degree, diploma or other qualification.

    ________________

    CHAN KANG YUEN

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development ACKNOWLEDGEMENT

    ii

    Acknowledgement

    I would like to express my gratitude to everyone who has offered me valuable

    information and advice in this dissertation.

    First, I would like to take this opportunity to express my sincere thanks to my

    supervisor, Prof. Heng Li, Professor at the Department of Building and Real

    Estate in the Hong Kong Polytechnic University, for his advice and guidance.

    I would like to devote my special thanks to Mr. Stephen Kong, Mr. Michael

    Chan and Mr Ting Huang, the Project Associate, the Research Assistant and PhD Candidate respectively who teach the application of CATIA V5 in

    Department of Building and Real Estate in The Hong Kong Polytechnic

    University, provide precious opportunities for me to participate in various

    virtual prototyping projects and share their valuable experiences.

    Besides, I would like to thank Mr. Shu Xian Wang, the project manager at the China State Construction Engrg. (Hong Kong) Ltd., who attend my interviews

    in this construction virtual prototyping project with his tight schedule.

    At last, I would also like to express my thanks to my family members and

    friends for their generous support and efforts.

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development ABSTRACT

    iii

    Abstract

    Construction Information Technology (IT) is a hot and new topic in local

    construction industry in recent years as Information Technology makes a great

    impact on construction industry all over the world, specially Virtual

    Prototyping.

    Virtual Prototyping can provide a capacity to construct in the computer.

    After the information is input, it creates a three-dimensional model and

    simulation environment that is capable to simulate the production, fabrication

    and assembly of construction components, including the associated operational

    processes in the computer.

    The case study of Virtual Prototyping comes from The China State

    Construction Engrg. (Hong Kong), Foundations and Railway Depot Works for

    Ho Tung Lau (Site A) Development project. The CATIA system is applied in this project as it equips the functions of 3D model and simulation process to allow the team to have a whole picture of the work.

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development TABLE OF CONTENT

    iv

    Table of content DECLARTAION ......................................................................................... i

    Acknowledgement .................................................................................. ii

    Abstract .................................................................................................. iii

    Table of content ..................................................................................... iv

    List of Figures .......................................................................................viii

    List of Tables ......................................................................................... xii

    CHATPER 1 - Introduction......................................................................2

    1.1 Introduction......................................................................2

    1.2 Problem Statement ............................................................2

    1.3 Research Objective ...........................................................3 1.4 Research Methodology .....................................................4

    1.4.1 Literature review ..............................................................4

    1.4.2 Use of CATIA V5 Mechanical Design..............................4

    1.4.3 Use of DEMLIA V5............................................................4

    1.4.4 Interview ...........................................................................5

    1.5 Dissertation Organization ...............................................6

    CHATPER 2 - Literature Review .............................................................8

    2.1 Information Technology (IT) .............................................8 2.2 Construction and Computers .........................................10

    2.3 Overview of Construction Applications......................... 11

    2.4 Computer Aided Design..................................................14

    2.5 Virtual Prototyping ..........................................................14

    2.6 The Background of CATIA ..............................................15

    2.6.1 Boeing 777 .....................................................................15

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development LIST OF CONTENT

    v

    2.6.2 Walt Disney Concert Hall ..............................................16

    CHATPER 3 - CATIA V5 Environment ..................................................18

    3.1 Introduction......................................................................18

    3.2 Workbench .......................................................................18

    3.2.1 Product Structure ...................................................18

    3.2.2 Part Design ............................................................18

    3.2.3 Assembly Design ..................................................19

    3.2.4 Sketcher .................................................................19

    3.3 CATIA V5 Document Types .............................................19

    3.4 The CATIA V5 Standard Screen Layout .........................20

    3.4.1 Start Menu ......................................................................20

    3.4.2 The Standard Windows Tool bar ..................................21

    3.4.3 The Specification Tree...................................................26

    3.4.4 Plane representation .....................................................27

    3.4.5 3D Compass ...................................................................27

    3.4.6 Current Workbench .......................................................27

    3.4.7 The Tools Toolbars ........................................................27

    3.4.8 Power Input Mode..........................................................27

    3.4.9 Mouse Control (Viewing tools) .....................................28 3.5 Conclusion .......................................................................28

    CHATPER 4 - Case Study of Ho Tung Lau Development ...................30

    4.1 Introduction......................................................................30

    4.2 The background information of the site ......................30

    4.3 The location of the site..................................................31

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development LIST OF CONTENT

    vi

    4.4 Using CATIA system on this project ............................32 4.5 The production of the site layout .................................33

    4.6 The production of 3D Virtual Resources .....................42

    4.6.1 Gantry .............................................................................42

    4.6.2 LTM1500 mobile crane ..................................................44

    4.7 The production of the part elements ............................47

    4.7.1 The sample of creating the Column (Assembly File) 51

    4.7.2 Ho Tung Laul Model .................................................76

    4.8 The production of the process simulation ..................77

    4.8.1 Creating process simulation.........................................78

    4.8.2 Editing process simulation ...........................................83

    4.8.3 Viewing a Simulation .....................................................85

    4.9 Conclusion .......................................................................86

    CHAPTER 5 - Analysis using virtual prototyping on Ho Tung Lau

    Development .........................................................................................94

    5.1 Benefits of using virtual prototyping in the building

    industry 94

    5.1.1 Identification of possible planning error .....................94

    5.1.2 Evaluation of innovative construction method in a

    virtually real environment ......................................................94

    5.1.3 Identification of idle time and resources .....................95

    5.1.4 Good communication between project staff from top management to worker level .................................................95

    5.1.5 Better understanding on the design ............................95

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development LIST OF CONTENT

    vii

    5.2 Limitation of using virtual prototyping in the building

    industry 96

    5.2.1 High hardware configuration ........................................96

    5.2.2 High price and license Fee............................................96

    5.2.3 High training cost and labour cost...............................97

    CHAPTER 6 - Conclusion .....................................................................99

    6.1 Conclusion .....................................................................99

    6.2 Recommendation...........................................................99

    Reference ............................................................................................102

    Bibliography ........................................................................................103

    Appendix .............................................................................................105

    Appendix I Interview Letter................................................106

    Appendix II Interview Question ..........................................107

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development LIST OF FIGURES

    viii

    List of Figures Figure Title Page

    No.

    Figure 2.1 Boeings 777 airliner digital model by CATIA 16

    Figure 2.2 Walt Disney Concert Hall in Los Angeles 16

    Figure 3.1 CATIAV5 Standard Screen 20

    Figure 3.2 Start Menu 21

    Figure 3.3 File menu options 22

    Figure 3.4 Edit menu options 22

    Figure 3.5 View menu option 23

    Figure 3.6 Insert menu options 24

    Figure 3.7 Tools menu option 25

    Figure 3.8 Window menu option 26

    Figure 3.9 Help menu option 26

    Figure 4.1 The map of the site 1 31

    Figure 4.2 The map of the site 2 31

    Figure 4.3 Master Layout 35

    Figure 4.4 Site Layout 35

    Figure 4.5 Road & Building Layout 35

    Figure 4.6 Rail Layout 36

    Figure 4.7 Existing Pad 36

    Figure 4.8 Railway 37

    Figure 4.9 Tai Po Road Layout 37

    Figure 4.10 Beam and Girder Layout 38

    Figure 4.11 Minipiles Layout 39

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development LIST OF FIGURES

    ix

    Figure 4.12 Wall Layout 39

    Figure 4.13 Tracks 39

    Figure 4.14 Concrete Platform Layout 40

    Figure 4.15 Ground Layout 40

    Figure 4.16 Train and Podium 41

    Figure 4.17 Gantry machine 42

    Figure 4.18 Detail of gantry machine 43

    Figure 4.19 Control of gantry 43

    Figure 4.20 LTM1500 mobile crane 44

    Figure 4.21 The detail of LTM1500 mobile crane 45

    Figure 4.22 Control of LTM1500 mobile crane 46

    Figure 4.23 The typical sample of columns which is Structural Steel

    Column SC33A 49

    Figure 4.24 The inside view of columns 50

    Figure 4.25 The wireframe view of columns 50

    Figure 4.26 Part Design Workench 52

    Figure 4.27 Contextual Menu 53

    Figure 4.28 Properties 53

    Figure 4.29 Using Profile tool 54

    Figure 4.30 Using Rectangle tool 54

    Figure 4.31 Using Constraint 54

    Figure 4.32 Constraint Definition 54

    Figure 4.33 After editing on constraint 55

    Figure 4.35 Structural Steel Column SC53A Steel 56

    Figure 4.36 Structural Steel Column SC53A Grout 56

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development LIST OF FIGURES

    x

    Figure 4.37 Steel Column Top Plate TP53A 57

    Figure 4.38 Steel Column Base Plate BP53A 57

    Figure 4.39 Proporties 58

    Figure 4.40 Steel Column Base Plate BP53A 60

    Figure 4.41 Inserted all components all one product 60

    Figure 4.42 Dragged element 62

    Figure 4.43 Dragged all elements 62

    Figure 4.44 Snapped element 1 63

    Figure 4.45 Snapedp element 2 63

    Figure 4.46 Inserted the element 64

    Figure 4.47 Finished the insert 64

    Figure 4.48 Open Column Layout 66

    Figure 4.49 Placed One Structural Steel Column 66

    Figure 4.50 Placed All Structural Steel Columns 67

    Figure 4.51 Save as CGR 69

    Figure 4.52 Replace Component 69

    Figure 4.53 Macros 71

    Figure 4.54 Create a new macro 71

    Figure 4.55 Marco Editor 1 71

    Figure 4.56 Marco Editor 2 71

    Figure 4.57 Ho Tung Lau Model 76

    Figure 4.58 Ho Tung Lau Model in DELMIA 77

    Figure 4.59 Activity Creation Options 79

    Figure 4.60 Jog window 79

    Figure 4.61 Delay Window 80

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development LIST OF FIGURES

    xi

    Figure 4.62 Edit Visibility Operation 1 81

    Figure 4.63 Edit Visibility Operation 2 81

    Figure 4.64 The tree of the simulation activities 82

    Figure 4.65 PERT Chart 83

    Figure 4.66 Gantt chart 84

    Figure 4.67 Ho Tung Lau Model in DELMIA 86

    Figure 4.68 Process Simulation 1 87

    Figure 4.69 Process Simulation 2 87

    Figure 4.70 Process Simulation 3 88

    Figure 4.71 Process Simulation 4 88

    Figure 4.72 Process Simulation 5 89

    Figure 4.73 Process Simulation 6 89

    Figure 4.74 Process Simulation 7 90

    Figure 4.75 Process Simulation 8 90

    Figure 4.76 Process Simulation 9 91

    Figure 4.77 Process Simulation 10 91

    Figure 4.78 Process Simulation 11 92

    Figure 4.79 Process Simulation 12 92

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development LIST OF TABLES

    xii

    List of Tables Table Title Page

    No.

    Table 3.1 Document Type 19

    Table 3.2 Table of mouse control 28

    Table 4.1 Table of background information of site 30

    Table 4.2 Table of Command in Gantry 43

    Table 4.3 Table of Command in LTM1500 mobile crane 46

    Table 4.4 The structure of all CATIA file in Ho Tung Tau Model 49

    Table 5.1 Software price list 97

  • CHAPTER 1 INTRODUCTION

    1.1 Introduction

    1.2 Problem Statement

    1.3 Research Objective

    1.4 Research Methodology

    1.5 Dissertation Organization

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 1

    2

    CHATPER 1 - Introduction

    1.1 Introduction

    Nowadays, Construction IT is a hot and new topic in construction industry in

    recently years in Hong Kong as Information Technology has made a great

    impact on construction industry, specially Virtual Prototyping. It is one of the

    computer system which is newly applied in local industry.

    1.2 Problem Statement

    As the development of the computer, the construction virtual prototyping is

    become more important. The construction virtual prototyping is an essential

    ingredient in the conceptualization and realization of a design. Virtual Object and the simulation have now shown as an intermediary between architects, engineers

    and clients.

    At present, most of building construction drawings is drawn by Computer Aided

    Design (CAD) for example, AutoCAD, Mircostation. Although CAD is a very

    powerful software to illustrate the details of layout of building construction, it is

    not user-friendly. It is found that some of construction workers still confuse with

    drawing and misunderstand during the construction process. Besides, some of

    undergraduate students also find difficulties in applying this software. Because of

    these, it might be concluded that AutoCAD and Mircostation are insufficient to

    assist in the process of building construction. Therefore, a better CAD is need for

    construction industry.

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 1

    3

    1.3 Research Objective

    The CAD technology is very useful for building construction as it allows design

    work to be more efficient and effective to share ideas with others. The French

    programmer developed a user-friendly and powerful drawing which is CATIA.

    Virtual prototyping (CATIA) will be applied in 3-D building design and

    simulation process. In order to illustrate the application of the software, a

    building would be constructed as a 3D model and the construction process of the

    building such as the process of the column construction, beam construction, etc

    will be simulated.

    The objectives of this research are as follows: 1. To outline benefits and limitations of the application of Information

    technology in local construction industry specially in Computer Aided

    Design and Visualization

    2. To study on the function of CATIA V5 system

    3. To study on the model design and simulation process through case study on

    Ho Tung Lau Development project at the Construction Virtual Prototyping Laboratory in The Hon Kong Polytechnic University

    4. To find out the benefits and drawbacks of applying CATIA V5 to the local

    construction industry

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 1

    4

    1.4 Research Methodology

    According to the problem statement of the research, the dissertation is based on

    data collection from two parts, namely literature review and desk study by

    CATIA V5 and DELMIA V5 on Ho Tung Lau Development project.

    1.4.1 Literature review

    The literature review of the dissertation is obtained from professional

    journals, articles, books and internet which is related to the IT construction specially Computer Aided Design.

    1.4.2 Use of CATIA V5 Mechanical Design

    CATIA V5 (Computer-Aided Three-dimensional Interactive Applications

    Verson 5) is a mechanical design which provides a special tool to illustrate

    the generation of production drawings and three-dimensional part. It can

    provide integrated real-time rendering capabilities and support different

    types of drawing formats. Therefore, CATIA Mechanical Designs tools

    provide advanced three-dimensional oriented productivity features, such as

    advanced specification graph display.

    1.4.3 Use of DEMLIA V5

    DELMIA V5 (Digital Enterprise Lean Manufacturing Intergrated

    Application Version 5) is a brand for digital manufacturing and simulation

    solutions from Dassault Systemes. It provides entire digital solutions for

    manufacturing process such as aircraft manufacture, car manufacture and

    building construction.

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 1

    5

    DELMIA has three main functions such as Process Planning, Process and

    Resource Plan Definaiton and Resource Modelling and simulation.

    Process Planning provides a obvious overview of the working

    sequences and links which is related to time and resources.

    Process and Resource Plan Definaiton provide tools to verfiy or

    redefine 3D process.

    Resource Modelling and simulation provide tools to model and

    simulate the building and buidling process by using robotic work.

    1.4.4 Interview

    In the interview, Mr. Wang the project manager of the China State Construction Engrg. (Hong Kong) Ltd shared his ideas and experiences on

    construction virtual prototyping project on Foundations and Railway Depot Works for Ho Tung Lau Development.

    .

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 1

    6

    1.5 Dissertation Organization

    Chapter 1 identify the problem statement of this dissertation. Research

    objectives and reseach methodology of this dissertation are also included in this Chapter.

    Chapter 2 reviews the literature of the IT construction specially Computer

    Aided Design and the history of CATIA

    Chapter 3 describes the CATIA V5 environment

    Chapter 4 demonstrates desk study on Foundaitons and Railway Depot

    Works for Ho Tung Lau Development project by CATIA V5 and DELMIA V5

    Chapter 5 analyses and discusses the application of CATIA V5 on

    construction industry

    Chapter 6 concludes this dissertation and recommends for further research

  • CHAPTER 2 Literature Review

    2.1 Information Technology

    2.2 Construction and Computers

    2.3 Overview of Construction

    Applications

    2.4 Computer Aided Design

    2.5 Virtual Prototyping

    2.6 The Background of CATIA

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 2

    8

    CHATPER 2 - Literature Review

    2.1 Information Technology (IT)

    Information Technology is the applications of a wide variety of electronic

    technologies on the information-handling activities. It is an integration of computing

    technology and information processing which builds up new systems and products to

    assist people to work, to learn as well as live.

    Information Technology (IT) is defined as The use of electronic machines and

    progames for the programs for the processing, storage, transfer and presentation of

    information. IT encompasses many technologies such as computers, software,

    networks and even telephones and fax machines. Bjork, (1999)

    Lucas (2000) defined IT as all form of technology applied to processing, storing and

    transmitting information in electronic form.

    Besides, according to Laudon, Kenneth C (1995) claims that IT can be grouped into

    four categories: Sensing, Communication, Analyzing and Display.

    Sensing Technologies

    Devices assist to gather data (raw unprocessed facts) from the environment and

    translate them into a form that can be understood by a computer fall within the

    category of sensing technologies.

    Communication Technologies

    Technologies which tie together and transmit information between sensing,

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 2

    9

    analyzing, and display technologies are communication technologies.

    Analyzing Technologies

    Computer hardware (a physical equipment) and software (programs or

    instructions that tell the computer what to do) come with the category of

    analyzing technologies. Computers take in the data from sensing and

    communicating devices and then store and process the data, transform them into

    useful information.

    Display Technologies

    Devices and related software that make processed data available to human users,

    either through sight or sound, make up our last category of information

    technologies. Display technologies from the interface, or connection, between

    sensing, communicating, and analyzing technologies and the human user.

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 2

    10

    2.2 Construction and Computers

    Since the rapidly developed computer is launched, some programmers have started to

    develop software for construction industry such as Computer Aided Deign to assist

    the complex drawing.

    A Graphical User Interface feature, together with those fairly large and expensive

    computers, formed the prime platform on which the idea of Computer Aided Design

    (CAD) was invented (Li 1995).

    From Laudon, Kenneth C (1995) explained the relationship between construction and

    computers. The construction process usually results in a unique product, a specific

    building for a specific context of site conditions and client requirements. On one hand,

    this requires a detailed evaluation and appraisal of building performance during the

    design stages where IT applications can be of great help. On the other hand, design

    consultants are reluctant to invest in learning the skills required for IT systems and

    collecting data for operating the systems, when the benefits are perceived as limited.

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 2

    11

    2.3 Overview of Construction Applications

    IT applications are used for a wide range of construction industry such as initial

    design, estimating and job costing, through to detailed design and project management.

    According to Ming Sun and Rob Howard (2004) claims that construction applications

    can be categorized into six parts:

    Business and Information Management

    The construction process is an information intensive one which a huge amount of

    information is generated and consumed and all the professionals involved. The

    common type of information includes site survey, cost analysis. design drawings,

    specifications, regulations, bill of quantities, project planning, job costing and estimates, etc. The information is presented in a range of paper drawings,

    documents, correspondence, fax, computer files or e-mails. An Electronic

    Document Management (EDM) system, such as TDOC or OpenDoc, can create

    an environment which links disparate forms of information together, in the

    context of a project or organization, to achieve easy access and control.

    Computer Aided Design and Visualization

    Computer Aided Design (CAD) software is widely adopted by design

    professionals. The initial drawing alone does not show the clear advantages of

    CAD, since experienced designers can draw on the drawing board equally fast.

    The real strength of CAD lies on its ability to allow editing. Once a graphic is

    drawn, functions such as delete, move, copy, rotate, scale, mirror, etc., can be

    applied. AutoCAD has the largest share of the CAD market. Other popular CAD

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 2

    12

    packages include Microstation, ArchiCAD, MiniCAD, FastCAD, etc.

    Building Engineering Applications

    Clients of construction industry have ever-higher expectations. They want their

    buildings to look good visually, to be safe structurally, to provide comfortable

    living environments to their occupants, and to consume less energy in operations,

    etc. The ever more complex demands on the buildings design process have urged

    to the need to a new approach to building engineering design based on computer

    software. For example, CADLink from Cymap and the HEVACOMP package

    both offer a comprehensive range of software options for energy, lighting, and

    building services design.

    Computer Aided Cost Estimating

    Controlling costs is one of the most important missions in a construction project. To achieve the control, contractors and sub-contractors must first carry out an

    accurate cost estimation and establish budget. Rigorous project accounting must then be employed to ensure the actual expenditure will not exceed its budget.

    Project managers or estimators may also use different methods to prepare the cost estimation for construction projects. At present, there are sophisticated computer software packages such as Esti-Mate, Manifest and FBS-Estimator.

    Planning, Scheduling, Site Management

    Construction work requires careful planning and skillful management for human

    and physical resources. Computer systems can assist on site managers to plan

    ahead, evaluate different options, adopt and execute the most efficient

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 2

    13

    construction operations. Apart from a widely application of planning packages

    such as Microsoft Project, Primavera, Power Project, etc., to program and schedule the detailed construction activities, some applications, like JobMaster

    and ICON are also adopted.

    Computer Aided Facilities Management

    Facilities Management (FM) is a relatively new discipline that emerged in the

    early 1980s. It gets a wide recognition of the importance of the building

    operation and maintenance and their impacts on the life cycle cost of a building.

    The software available for facility management has been developed from a

    combination of CAD and database management systems.

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 2

    14

    2.4 Computer Aided Design

    Computer Aided Design such as AutoCAD and MicroStation is widely utilized in the

    construction industry as it can create and demonstrate an imaginary building to satisfy

    the needs of clients. Clients and designers need to share the ideas while using virtual

    prototyping CAD.

    According to G. Aound, A. Lee and S. Wu (2005), Computer Aided Design is an

    essential tool of the production of drawings in construction industry. The upstream

    CAD data mainly remains in the form of 2D geometry data, compiled by

    entity based CAD software such as AutoCAD and MicroStation.

    According to Ming Sun and Rob Howard (2004), there is a great need of the

    advancement of more powerful computer workstations as users are now demanding

    methods to view these 3D models as shaded, photo-realistic images. Visualization is

    the production of such images using computer systems.

    2.5 Virtual Prototyping

    Virtual Prototyping provides a large capacity to construct in the computer. It can

    provide a creating 3D model and simulation environment that allows the production,

    fabrication and assembly of construction components, including the associated project operational processes, to be simulated in computer and demonstrated to the users.

    CATIA V5 is one of the Virtual Prototyping application.

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 2

    15

    2.6 The Background of CATIA

    CATIA (Computer-Aided Three-dimensional Interactive Applications) is the Product

    Life Cycle Management / Computer-Aided-design / computer aided manufacturing /

    computer aided engineering (PLM/ CAD/CAM/CAE) commercial software suite for

    digital product definition and simulation developed by Dassault Systemes. In 1981,

    Dassault Systemes formed a strategic partnership with IBM to distribute the

    development of CATIA all over the world. As CATIA is a powerful tool for drawing,

    it has a built-in capacity to capture and reuse the implementation of the design

    practices. Nowadays, CATIA becomes one of the popular product development

    system in the world as it is widely used in the digital mockup process.

    2.6.1 Boeing 777

    Boeing Commercial Airplanes has used CATIA V4 to develop and create the

    Boeing 777, which is the first airplane to be 100 percentage digitally designed

    and preassembled on computer. According to the virtual prototyping, Boeing 777

    Airplane Group won the top award in the Manufacturing category of the 1995

    Computerworld Smithsonian Awards program. Afterwards, the Boeing 787 or

    Dreamliner series aircraft also adopt the system of CATIA V5 in their

    construction.

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 2

    16

    Figure 2.1 Boeings 777 airliner digital model by CATIA (Source: Boeing Commercial Airplane Group)

    2.6.2 Walt Disney Concert Hall

    Disney Concert Hall is very complex. It has many curve structure which can be

    drawn and demonstrated by CATIA. Besides, CATIA can make precise

    documentation. The CATIA mechanical design system has revolutionized what

    had primarily been an engineering application. (James Steele, 2002).

    Figure 2.2 Walt Disney Concert Hall in Los Angeles (Source: http://www.gehrytechnologies.com/)

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 3

    CHAPTER 3 CATIA V5 Environment

    3.1 Introduction

    3.2 Workbench

    3.3 CATIA V5 Document Types

    3.4 Overview of Construction

    Applications

    3.5 The Specification Tree

    3.6 Conclusion

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 3

    18

    CHATPER 3 - CATIA V5 Environment

    3.1 Introduction

    This Chapter is intended to introduce to the CATIA V5 environment.

    3.2 Workbench

    In CATIA V5, workbench is a characteristic feature. Workbench means a working

    environment which allows users with unique functionality to create and manipulate

    geometry.

    3.2.1 Product Structure

    The performance of this CATIA V5 is a product structure. In this program, the

    structure of product is organized as a logical structure comprising a large number

    of assemblies, sub-assemblies and parts. For example, assemblies consist of

    levels of building, sub-assemblies consist of each room and parts consist of

    reinforcement and wall in a building. Numerous tools are similar or duplicates of

    tools found in the Assembly Design Workbench.

    3.2.2 Part Design

    This workbench allows the design of precise 3D mechanical parts with an

    intuitive and flexible user interface. It is core mechanical solid modeling

    capability.

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 3

    19

    3.2.3 Assembly Design

    This workbench allows the design of assemblies with an intuitive and flexible

    user interface. Also, it can be cooperatively applied with other current

    companion products such as Part Design.

    3.2.4 Sketcher

    This workbench allows the design of sketch precise and rapid 2D profiles. Also,

    it is tied closely to Part Design workbench.

    3.3 CATIA V5 Document Types

    Different CATIA V5 workbenches generate different types of document files.

    Table 3.1 Document Type (Source: Kang Yuen Chan,2006)

    Document Types WorkBench

    Sketcher

    Part Design

    .CATPart

    Product Structure

    .CATProduct Assembly Design

    Process and Resource Definition CATProcess

    Workcell Squencing

  • Construction Virtual Prototyping Case Study of Ho Tung Lau Development CHATPER 3

    20

    3.4 The CATIA V5 Standard Screen Layout

    This section describes the main components of the CATIA V5 user inferface. The

    following standard screen layout shows you where different tools bars and icons.

    Figure 3.1 CATIAV5 Standard Screen (Source: Kang Yuen Chan,2006)

    3.4.1 Start Menu

    The Start menu bar is the main menu for opening the different environments. You

    can access to various CATIA V5 workbenches and product portfolios. The option

    of the workbenches depends on the licenses configuration. The Start menu will

    keep track of the last models used in session in order to provide quick retrieval.

    3.4.1 3.4.2

    3.4.5 3.4.3

    3.4.4

    3.4.7

    3.4.8

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    21

    Figure 3.2 Start Menu (Source: Kang Yuen Chan,2006)

    3.4.2 The Standard Windows Tool bar

    The Standard Windows tool bar is consistent with the Microsoft Windows

    environment. There are different CATIA V5 tools found in the different pull

    down menus. There are various shortcuts into the user inferface.

    File Menu

    This Menu is similar to the most MS Windows applications. Opening and closing

    documents are the primary functions of this section.

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    Edit Menu

    This Menu is similar to the most MS Windows applications. There are common

    functions such as cut, copy and paste. Also this menu allows for the manipulation

    of objects within the CATIA V5 environment.

    Figure 3.4 Edit menu options (Source: Kang Yuen Chan,2006)

    Figure 3.3 File menu options (Source: Kang Yuen Chan,2006)

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    View Menu

    This Menu provides a many of the tools that can be accessed from bottom

    toolbar, quick keys and contextually for different model geometry. Toolbar

    menus allows user to toggle on and off within this menu option for

    customizing the user environment.

    Figure 3.5 View menu option (Source: Kang Yuen Chan,2006)

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    Insert

    This Menu provides the creation, manipulation and insertion of geometry

    elements with the object. Most of the Insert tools are alternative tools which are depending on the active workbench.

    Figure 3.6 Insert menu options (Source: Kang Yuen Chan,2006)

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    Tools

    This Menu provides utilities for customizing the user environment, capturing

    images, macro application for Visual Basic Language, and quickly showing or

    hiding common geometry element types.

    Figure 3.7 Tools menu option (Source: Kang Yuen Chan,2006)

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    26

    Windows

    This Menu is similar to the most MS Windows applications. The first section can

    display the different documents to be vertically, horizontally, or in cascading

    fashion. It is useful for user to coordinate the display. The bottom section shows

    how many documents are open.

    Help

    The Help menu provides access to CATIA V5 Complete Content, Index and

    search screen as well as find out License and Release information.

    Figure 3.8 Window menu option Figure 3.9 Help menu option (Source: Kang Yuen Chan,2006) (Source: Kang Yuen Chan,2006)

    3.4.3 The Specification Tree

    CATIA V5 provides a particular history of tools and processes, which captures and

    reuses process specification in order to accelerate the design process. You can click

    the and + sign located on each branch to expand and contract the specification tree.

    Also, you can Zoom In, Zoom Out and Pan the Specification Tree the same way you

    would a part.

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    3.4.4 Plane representation

    XY, YZ and ZX planes are represented in the workspace and Specification Tree. If

    you select any one plane from Specification Tree, you will highlight its plane for

    using.

    3.4.5 3D Compass

    Viewpoint representations which are used to capture viewpoints can be manipulated

    by using compass. The object can be manipulated by dragging and dropping the compass on a surface of object. Non-constrained objects can also be manipulated by using compass. However, groups of objects in assemblies which are linked to each other by constraints can be manipulated.

    3.4.6 Current Workbench

    This icon displays the active workbench. In different workbenchs such as part design,

    assembly design and Sketcher, different tool bars and tools can be provided to use.

    3.4.7 The Tools Toolbars

    The toolbar changes depending on which workbench you are in.

    3.4.8 Power Input Mode Its mode is for advanced user. It allows user to directly enter commands or queries.

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    3.4.9 Mouse Control (Viewing tools)

    Control the mouse Function

    Click the middle mouse button Center the display at a specific location

    Press and hold down the middle mouse button

    and then drag

    Pan the view

    Press and hold down both the middle mouse

    button and the left (or right) mouse button and then drag

    Rotate the view

    Press and hold down the middle mouse

    button, then click the left (or right) mouse button once and drag

    Zoom In or Out

    Table 3.2 Table of mouse control (Source: Kang Yuen Chan,2006)

    3.5 Conclusion

    This Chapter has introduced to the CATIA V5 environment and basic function of

    CATIA V5.

  • CHAPTER 4 Case Study of Ho Tung Lau Development

    4.1 Introduction

    4.2 The background information of

    the site

    4.3 The location of the site

    4.4 Using CATIA system on this

    project

    4.5 The production of the site

    layout

    4.6 The production of 3D Virtual

    Resources

    4.7 The production of the part

    elements

    4.8 The production of process

    simulation

    4.9 Conclusio

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    CHATPER 4 - Case Study of Ho Tung Lau

    Development

    4.1 Introduction

    The China State Construction Engrg. (Hong Kong) Ltd. has invited Professor

    Heng Li, Department of Building & Real Estate of The Hong Kong

    Polytechnic University to draw the 3D drawing and make the simulation in the

    construction process of one of their project, Foundations and Railway Depot Works for Ho Tung Lau (Site A) Development.

    4.2 The background information of the site

    Information

    Address of Site Ho Tung Lau (Site A) Fo Tan East of Fo Tan

    Station Area bounded by Tai Po Road Shatin,

    Lok King Street, Jubilee Garden & Nullah

    Shatin Town Lot No 470

    GFA Domestic --

    GFA Non-Domestic 2073.5

    Authorized Person Ronald Lu

    Registered Structural Engineer Kwan Kin Kei

    Applicant Full Fair Ltd

    Project Period 2004.04-2007.05 Table 4.1 Table of background information of sitel

    (Source: Kang Yuen Chan,2006)

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    4.3 The location of the site

    The red colour area is the location of the site

    Figure 4.1 The map of the site 1

    (Source: http://www.centamap.com)

    Figure 4.2 The map of the site 2

    (Source: http://www.centamap.com)

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    4.4 Using CATIA system on this project

    The CATIA system is applied in this project as it is capable to draw a whole picture to meet the requirements of different parties. Its application can be

    divided into three parts. They are as follows.

    First, it is the production of 3D models. Site environment (Site environment

    (including site layout, on site buildings, surrounding buildings, roads inside and

    surrounding the site), precast beams and slabs (including concrete and

    reinforcement), temporary supports (including formworks, scaffoldings, struts

    and working platforms) and in- situ concrete elements (including concrete and

    reinforcement).are drawn.

    Second, the production of 3D Virtual Resources is LTM1500 mobile crane (3D

    models production, setting of speeds and loading capacity properties) and

    Workers of all types of trade (3D models production and setting of

    productivities).

    At last, the process simulation sets up site environment, events sequence and

    duration, and resources usage, as well as builds up virtual processes in 3D

    environment (including plants movement, workers movement, erection of precast

    elements, visualization of temporary support works and concreting works) and

    produces PERT chart, program Gantt chart and resources Gantt chart.

    There are four main processes to produce this project 1. the production of the site layout

    2. the production of the part elements

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    3. the production of 3D Virtual Resources

    4. the production of process simulation

    4.5 The production of the site layout

    Site layout is an essential element of drawing 3D models as it points out the

    exactly location of the models. For this development, as the site consists of Fo

    Tan Station and its surrounding buildings, its site layout will be more complex.

    Master Layout (Fig.4.3) Plan includes

    1. Site Layout (Site Layout.CATPart) (Fig.4.4)

    2. Road & Building Layout (Road & Bldg Layout.CATPart) (Fig.4.5)

    3. Rail Layout (Rail Layout.CATPart) (Fig.4.6)

    4. Existing Pad (Existing Pad.CATPart) (Fig.4.7)

    5. Railway (Railway.CATPart) (Fig.4.8)

    6. Tai Po Road Layout (Tai Po Road.CATPart) (Fig.4.9)

    7. Beam and Girder Layout (Beam and Girder Layout.CATPart) (Fig.4.10)

    8. Minipiles Layout (Minipiles Layout.CATPart) (Fig.4.11)

    9. Wall Layout (Wall Layout.CATPart) (Fig.4.12)

    10. Tracks (Track.CATPart) (Fig.4.13)

    11. Concrete Platform layout (Concrete Platform.CATPart) (Fig.4.14)

    12. Ground foundation (Ground.CATPart) (Fig.4.15)

    13. Train Station and Podium(Train_Station_and_Podium.CATPart) (Fig.4.16)

    (.) is the file name in CATIA V5.

    Layout drawing is very complicated part in CATIA V5 and time consuming. As

    all existing layout plans of this site are AutoCAD file (dwg), this AutoCAD type

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    34

    file (dwg) cannot be used in CATIA V5. However, the other AutoCAD type file

    (dxf) can be opened and applied by CATIA V5.

    Therefore, the file type of these layouts is translated from dwg to dxf by

    AutoCAD 2004. All layouts (dxf) then can be opened on the CATIA V5

    environment but it cannot be edited by CATIA V5. To deal with this problem, all

    files are saved as the format of CATIA type file (CATPart) which can be edited in

    CATIA V5.

    Figure 4.3 Master Layout (Source: Kang Yuen Chan,2006)

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    Figure 4.4 Site Layout (Source: Kang Yuen Chan,2006)

    Figure 4.5 Road & Building Layout (Source: Kang Yuen Chan,2006)

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    36

    Figure 4.6 Rail Layout (Source: Kang Yuen Chan,2006)

    Figure 4.7 Existing Pad (Source: Kang Yuen Chan,2006)

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    37

    Figure 4.8 Railway (Source: Kang Yuen Chan,2006)

    Figure 4.9 Tai Po Road Layout (Source: Kang Yuen Chan,2006)

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    38

    Figure 4.10 Beam and Girder Layout (Source: Kang Yuen Chan,2006)

    Figure 4.11 Minipiles Layout (Source: Kang Yuen Chan,2006)

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    Figure 4.12 Wall Layout (Source: Kang Yuen Chan,2006)

    Figure 4.13 Tracks (Source: Kang Yuen Chan,2006)

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    40

    Figure 4.14 Concrete Platform Layout (Source: Kang Yuen Chan,2006)

    Figure 4.15 Ground Layout (Source: Kang Yuen Chan,2006)

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    41

    Figure 4.16 Train and Podium

    (Source: Kang Yuen Chan,2006)

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    42

    4.6 The production of 3D Virtual Resources

    The production of 3D Virtual Resources is Gantry and LTM1500 mobile crane.

    The functions of these two 3D Virtual Resources are to generate the

    transportation of the all types of elements in the simulation process. These two

    transportation machines are also created by CATIA V5 assembly design, part

    design and advanced command for control the action. They are applied in

    different stages of the production. The Gantry and LTM1500 mobile are applied

    in the first stage and second stage respective.

    4.6.1 Gantry

    The Gantry can generate the rail roads and does not affect the transportation of

    rail. There are four gantry cranes which connect one gantry hock on gantry as

    well as move along the rail.

    Figure 4.17 Gantry machine

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    43

    (Source: Kang Yuen Chan,2006)

    Figure 4.18 Detail of gantry machine

    (Source: Kang Yuen Chan,2006)

    By selecting the Create a Device Move Activity icon. , the Jog window will

    appear on the screen. The gantry, Gantry Car and Gantry Hook can be moved by

    the adjustment of value in the window.

    Table 4.2 Table of Command (Source: Kang Yuen Chan,2006)

    Figure 4.19 Control of gantry (Source: Kang Yuen Chan,2006)

    DOF Controls Function

    Command 1 Moving Gantry along the rail

    Command 2 Moving horizontal Gantry Car1

    Command 3 Moving horizontal Gantry Car2

    Command 4 Moving Vertical Gantry Hook1

    Command 5 Moving Vertical Gantry Hook2

    Command 6 Moving horizontal Gantry Car3

    Command 7 Moving horizontal Gantry Car4

    Command 8 Moving Vertical Gantry Hook3

    Command 9 Moving Vertical Gantry Hook4

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    4.6.2 LTM1500 mobile crane

    The LTM1500 mobile crane has better mobility and takes shorter time to set-up.

    It can be applied on the podium, pad. As Ho Tung Lau site is a very crowded site,

    it is more convenient for the worker to use the transportation machine with high

    mobility. Besides, there is one hook of this transportation machine to allow the

    worker to transport materials in all directions.

    Figure 4.20 LTM1500 mobile crane

    (Source: Kang Yuen Chan,2006)

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    Figure 4.21 The detail of LTM1500 mobile crane

    (Source: Kang Yuen Chan,2006)

    By selecting the Create a Device Move Activity icon. , the Jog window will

    appear on the screen. Adjusting the angle projection of the CraneArm, extending the length of CraneArm1-5, adjusting the angle projection of the RopeHolder, moving Vertical Hook and rotating the whole of CraneArm can be used on this

    window.

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    Figure 4.22 Control of LTM1500 mobile crane

    (Source: Kang Yuen Chan,2006)

    Table 4.3 Table of Command in LTM1500 mobile crane (Source: Kang Yuen Chan,2006)

    DOF Controls Function

    CraneBaseRev Adjusting the angle projection of the

    CraneArm

    CraneArm1 Extending the length of CraneArm1

    CraneArm2 Extending the length of CraneArm2

    CraneArm3 Extending the length of CraneArm3

    CraneArm4 Extending the length of CraneArm4

    CraneArm5 Extending the length of CraneArm5

    RopeHolderRev Adjusting the angle projection of the

    RopeHolder

    HookVerticalPosit

    ion

    Moving Vertical Hook

    Command 9 Rotating the whole of CraneArm

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    4.7 The production of the part elements

    In this site, there are numerous parts of elements (1957 files) to establish the Ho

    Tung Lau Model. You should remember the concept of the CATIA V5. The

    model has many assembly parts. In the Assembly workbench, it is easy for users

    to place component parts and sub-component together to form finished

    assemblies.

    There are all assembly files which include many components parts.

    No Assembly File Part File Sub-Part File

    Bracing Layout 1 Bracing

    Bracing-A-D34 to

    Bracing-A-D51

    Beam and Girder Layout

    Steel Beam Layout

    2 Girder

    SG-D33 to

    SG-D53

    Beam and Girder Layout

    Bracing Layout

    Steel Beam Layout

    3 Steel Beam

    SB-7 to

    SB-41-9

    Beam Layout

    Beam and Girder Layout

    4 T-Beam

    T-Beam-D33 T-Beam-D33-01 to T-Beam-D33-26,

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    T-Beam-D33-Joint

    T-Beam-D33-Part

    T-Beam-D33-Top

    T-Beam-D52-01 to T-Beam-D52-26,

    T-Beam-D52-Joint

    T-Beam-D52-Part

    to T-Beam-D52

    T-Beam-D52-Top

    Beam and Girder Layout

    Steel Beam Layout

    Truss-1-Grid truss-1

    ST-1-a to

    ST-1-e8

    Truss-4-Grid

    5 Trusses

    to truss-4

    ST-4-1 to

    ST-4-3

    Structural Steel Column SC33A Grout

    Structural Steel Column SC33A Steel

    Steel Column Top Plate TP33A

    Structural Steel Column

    SC33A

    Steel Column Base Plate BP33A

    Structural Steel Column SC53A Grout

    Structural Steel Column SC53A Steel

    Steel Column Top Plate TP53A

    6 Columns

    to Structural Steel Column

    SC53A

    Steel Column Base Plate BP53A

    Podium 7 Train Station

    and Podium Train_Station

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    Present D32

    8 Track Track

    9 Ground Ground

    10 Existing Pad Existing Pad

    Table 4.4 the structure of all CATIA file in Ho Tung Tau Model (Source: Kang Yuen Chan,2006)

    The Columns (Assembly) such as is typical sample for creating the assembly file

    as it includes many components part. For example, Structural Steel Column

    SC33A (Fig. 4.23) is a one part product contains four sub-part elements which is

    Structural Steel Column SC33A Steel, Structural Steel Column SC33A Grout,

    Steel Column Top Plate TP33A and Steel Column Base Plate BP33A. Next part

    will show the step of creating the whole Structural Steel Column SC33A.

    Figure 4.23 The typical sample of columns which is Structural Steel Column SC33A

    (Source: Kang Yuen Chan,2006)

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    Figure 4.24 The inside view of columns

    (Source: Kang Yuen Chan,2006)

    Figure 4.25 The wireframe view of columns

    (Source: Kang Yuen Chan,2006)

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    4.7.1 The sample of creating the Column (Assembly File)

    There are seven steps to create the Column Structural Steel Column SC33A

    A. Creating the Structural Steel Column SC53A Steel .etc using

    Sketcher & Part Design

    B. Changing the color of 3D model

    C. Inserting components into the Assembly Design Workbench

    D. Moving components in the Assembly Design Workbench using the Compass

    and Snap Tool

    E. Setting up Site Layout

    F. Changing CATProduct to CGR

    G. Automating the Modification Using a Marco

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    A. Creating the Structural Steel Column SC53A Steel .etc using

    Sketcher & Part Design

    1. Start CATIA V5

    2. By default CATIA V5 will bring up the Product Structure Workbench.

    Select the Part Design Workbench from Start pull down menu or the

    Welcome To CATIA V5 window.

    Figure 4.26 Part Design Workench (Source: Kang Yuen Chan,2006)

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    53

    3. With the Part1 branch highlighted use your Right mouse button to activate

    the Contextual Menu.

    4. Select Properties (Fig. 4.27).

    5. From the Properties window select the Product tab. This will show you

    the Part Number (Fig. 4.28).

    6. For the New Part box type in Structural Steel Column SC53A Steel.

    7. Select OK to change the name of part1.

    8. Notice that a Structural Steel Column SC53A Steel branch was just

    created in the Specification Tree. If you expand the Structural Steel

    Column SC53A Steel branch you will have a Specification Tree.

    9. Enter the Sketcher Workbench using the ZX Plane.

    10. Use the Profile tool.

    11. Create 12 lines in succession and click the End Point to the Start Point (Fig.

    4.29).

    Figure 4.27 Contextual Menu (Source: Kang Yuen Chan,2006) Figure 4.28 Properties

    (Source: Kang Yuen Chan,2006)

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    12. Use the Rectangle tool.

    13. Create the rectangle inside the previous drawing (Fig. 4.30).

    14. Select the Constraint

    tool.

    15. Select the all lines to be

    constrained (Fig. 4.31).

    16. Double click on the value box

    of the Dimensional Constraint

    you want to modify. The value

    box is the green dimension line with an attached with an attached value.

    17. The Constraint Definition

    window will pop up (Fig. 4.32).

    This window shows the existing

    value for the Sketcher element.

    18. Edit the value by typing over the

    existing value.

    19. Apply the new value by selecting the OK button or pushing the Enter key

    Figure 4.30 Using Rectangle tool (Source: Kang Yuen Chan,2006)

    Figure 4.29 Using Profile tool (Source: Kang Yuen Chan,2006)

    Figure 4.31 Using Constraint (Source: Kang Yuen Chan,2006)

    Figure 4.32 Constraint Definition (Source: Kang Yuen Chan,2006)

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    (Fig. 4.33).

    20. Exit the Sketcher Workbench. This will put you back into the Part Design

    Workbench.

    21. Select the Pad tool.

    22. The Pad Definition window appears.

    23. In the First Limit area, enter 11405mm for the Length box. Leave the

    Type box set at Dimension.

    24. In the Profile section, the Selection box should show Sketch.1.

    25. Select the OK button.

    26. Then, the Structural Steel Column SC53A Steel is finished (Fig. 4.35).

    Other three part components such as Structural Steel Column SC53A Grout,

    Steel Column Top Plate TP53A and Steel Column Base Plate BP53A are

    Figure 4.33 After editing on constraint (Source: Kang Yuen Chan,2006)

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    created by using previous Sketcher and Part Design. (Fig. 4.36 - 4.38 )

    Figure 4.35 Structural Steel Column SC53A Steel

    (Source: Kang Yuen Chan,2006)

    Figure 4.36 Structural Steel Column SC53A Grout

    (Source: Kang Yuen Chan,2006)

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    Figure 4.37 Steel Column Top Plate TP53A

    (Source: Kang Yuen Chan,2006)

    Figure 4.38 Steel Column Base Plate BP53A

    (Source: Kang Yuen Chan,2006)

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    B. Changing the color of 3D model

    However, the 3D model of Steel Column Top Plate TP53A and Steel Column

    Base Plate BP53A should be filled in orange color. This process should be added

    between part A in step 8 and 9.

    1. With the Part branch highlighted use your Right mouse button to activate

    the Contextual Menu.

    2. Select Properties (Fig. 4.39).

    3. From the Properties window select the Graphic tab.

    4. Select the suitable color in the fill color box.

    5. Select OK and then the color of all 3D models will be changed.

    Figure 4.39 Proporties (Source: Kang Yuen Chan,2006)

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    C. Inserting components into the Assembly Design Workbench

    There are four part components to insert the Assembly Product Design.

    1. Select the Assembly Design Workbench from Start pull down menu

    2. With the Product1 branch highlighted use your Right mouse button to

    activate the Contextual Menu.

    3. Select Properties to edit the name in Structural Steel Column SC53A.

    4. The top of the Specification Free must be selected before components can

    be inserted into the Assembly Design Workbench.

    5. Double click on the Structural Steel Column SC53A. There are two

    methods of selecting an Existing Component. Select the Existing Component

    tool or use your Right mouse button to activate the Contextual Menu

    and then select Components (Fig. 4.40), Existing Component. Then the

    File Selection window will appear on the screen.

    6. In the File Selection window, select the document that was saved earlier in

    named Structural Steel Column SC53A Steel. Select the Open button. The

    part should appear on the screen.

    7. Repeat the step 6 and 7 to open Structural Steel Column SC53A Grout,

    Steel Column Top Plate TP53A and Steel Column Base Plate BP53A.

    8. All the components will appear on the screen (Fig. 4.41).

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    Figure 4.40 Steel Column Base Plate BP53A

    (Source: Kang Yuen Chan,2006)

    Figure 4.41 Inserted all components all one product

    (Source: Kang Yuen Chan,2006)

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    D. Moving components in the Assembly Design Workbench using

    the Compass and Snap Tool

    The location and orientation of the assembly components can also be

    manipulated by using the Compass tool. The Compass tool was briefly illustrated

    below.

    1. From the Specification Tree, select the Structural Steel Column SC53A

    Steel branch.

    2. Place the Compass tool on the Structural Steel Column SC53A Steel

    Surface. The Compass tool will turn green indicating that the selected

    component can be manipulated. For detail instructions on how to

    manipulate the Compass tool refer back (Fig. 4.42).

    3. Select the Z-axis on the Compass tool and drag it to the approximate

    location to prevent the overlap other components. The Structural Steel

    Column SC53A Steel will move along with the Compass.

    4. By previous step, the components can be dragged to the approximate

    location (Fig. 4.43).

    5. With Structural Steel Column SC53A Steel highlighted, select the Snap

    tool.

    6. Select the first line of the Structural Steel Column SC53A Steel component

    and then select the second line of the Structural Steel Column SC53A Grout

    component. The first line of the Structural Steel Column SC53A Steel

    component will be moved to the position which projected onto the second line (Fig. 4.44).

    7. Select the first point which is angle of the Structural Steel Column SC53A

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    Steel component and then select the second point which is angle of the

    Structural Steel Column SC53A Grout component. The first point of will be

    moved to the position. The two points are coincident. Structural Steel

    Column SC53A Steel component will be moved inside Structural Steel

    Column SC53A Grout component (Fig. 4.45 - 4.46).

    By using compass and Snap Tool, all the components can be moved onto their

    exact locations (Fig. 4.47).

    Figure 4.42 Dragged element (Source: Kang Yuen Chan,2006)

    Figure 4.43 Dragged all elements

    (Source: Kang Yuen Chan,2006)

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    Figure 4.44 Snapped element 1

    (Source: Kang Yuen Chan,2006)

    Figure 4.45 Snapped element 2

    (Source: Kang Yuen Chan,2006)

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    Figure 4.46 Inserted the element

    (Source: Kang Yuen Chan,2006)

    Figure 4.47 Finished the insert

    (Source: Kang Yuen Chan,2006)

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    E. Inserting Column Layout and Structural Steel Column SC33A to

    SC53A

    1. Select the Assembly Design Workbench from Start pull down menu.

    2. Select Properties to edit the name in Columns.

    3. Select OK to change the name of product1.

    4. Double click on the Columns. There are two methods of selecting an

    Existing Component. Select the Existing Component tool and then

    select Components, Existing Component.

    5. In the File Selection window, select the document that was saved earlier in

    named Column Layout. Select the Open button. The part should appear on

    the screen (Fig. 4.48).

    6. Double click on the Columns. Select the Existing Component tool. Select

    Structural Steel Column SC33A to SC53A. Select the Open button. The part

    should appear on the screen.

    7. By using the Compass and Snap Tool, the Structural Steel Column SC33A to

    SC53A can be placed on the suitable position (Fig. 4.49 - 4.50).

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    Figure 4.48 Open Column Layout

    (Source: Kang Yuen Chan,2006)

    Figure 4.49 Placed One Structural Steel Column

    (Source: Kang Yuen Chan,2006)

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    Figure 4.50 Placed All Structural Steel Columns

    (Source: Kang Yuen Chan,2006)

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    F. Changing CATProduct to CGR

    CATIA V5 is powerful software. The requirement of this system is very high

    specially the simulation process. It is good for the users to adopt smaller files so

    as to run the program smoothly.

    In this Structural Steel Column SC53A.CATProduct, there are five files such as

    Steel Column Base Plate BP53A.CATPart, Steel Column Top Plate TP53A.CATPart,

    Structural Steel Column SC53A Grout.CATPart, Structural Steel Column SC53A

    Steel.CATPart and Structural Steel Column SC53A.CATProduct. As the total size of

    these five files is 365K and the overall size of the Structural Steel Column is

    16.3MB, the workload of the computer is very heavy. In order to ensure the

    smooth operation of the program, reducing file size is necessary.

    Changing the types (format) of file can be saved the memory. The file type

    changes from CATProduct to CGR. But, the drawback of CGR is that this file

    cannot edit the drawing.

    1. Open file Structural Steel Column SC53A.CATProduct

    2. Select File, Save As. This will bring up the Save as window (Fig. 4.51).

    3. Select file type to CGR and then OK. (The file name is Structural Steel

    Column SC53A.CGR)

    The new file size is 29.2KB that is reduced 92%. After the file sizes reduction,

    CATProduct is then replaced by CGR.

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    4. Open file Columns.CATProduct

    5. With Structural Steel Column SC53A highlighted, selecting the Replace

    Component tool and then Select Components, Replace Component.

    Then the File Selection window will appear on the screen (Fig. 4.52).

    6. Select file Structural Steel Column SC53A.CGR and then select the Open

    button or pushing the Enter key.

    Figure 4.51 Save as CGR (Source: Kang Yuen Chan,2006)

    Figure 4.52 Replace Component (Source: Kang Yuen Chan,2006)

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    G. Automating the Modification Using a Marco

    Reduction of file size is a good method to save the memory but this process

    should be repeated more times as many files should be edited. Fortunately,

    CATIA V5 has macro function. This function is a powerful tool when it comes to

    accomplishing a process that is repeated times and times. All the CATProduct can

    be saved and replaced automatically to the CGR by one button.

    1. Open file Columns.CATProduct

    2. Select Tools, Macro, Macros. This will bring up the Macros window (Fig.

    4.53).

    3. Select the Create button. This will bring up the Create a new macro window

    and then select the OK button or pushing the Enter key (Fig. 4.54).

    4. Select the Edit Button. This will bring up the Macros Editor window shown

    in Figure (Fig. 4.55).

    5. Type the below Language="VBSCRIPT" command in the blank of Macros

    Editor.

    6. Save the edits and then close the Macros Editor window (Fig. 4.56).

    7. The Macros window should still be on the screen. Select the Run button.

    The program runs that from Structural Steel Column SC33A.CATProduct to

    Structural Steel Column SC53A.CATProduct save as from Structural Steel

    Column SC33A.cgr to Structural Steel Column SC53A.cgr and then from

    Structural Steel Column SC33A.CATProduct to Structural Steel Column

    SC53A.CATProduct will replaced the position in the Columns file by from

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    Structural Steel Column SC33A.cgr to Structural Steel Column SC53A.cgr .

    Figure 4.55 Marco Editor 1 Figure 4.56 Marco Editor 2

    (Source: Kang Yuen Chan,2006) (Source: Kang Yuen Chan,2006)

    Figure 4.53 Macros (Source: Kang Yuen Chan,2006)

    Figure 4.54 Create a new macro (Source: Kang Yuen Chan,2006)

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    Language="VBSCRIPT" command

    Sub CATMain()

    Set productDocument1 = CATIA.ActiveDocument

    Set documents1 = CATIA.Documents

    Set product1 = productDocument1.Product

    Set products1 = product1.Products

    Set productDocument4 = documents1.Item("Structural Steel Column SC44A.CATProduct")

    productDocument4.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC44A.cgr", "cgr"

    Set product4 = products1.Item("Structural Steel Column SC44A.1")

    Set Nothing1 = products1.ReplaceComponent(product4, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC44A.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument5 = documents1.Item("Structural Steel Column SC44B.CATProduct")

    productDocument5.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC44B.cgr", "cgr"

    Set product5 = products1.Item("Structural Steel Column SC44B.1")

    Set Nothing1 = products1.ReplaceComponent(product5, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC44B.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument4 = documents1.Item("Structural Steel Column SC45A.CATProduct")

    productDocument4.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC45A.cgr", "cgr"

    Set product4 = products1.Item("Structural Steel Column SC45A.1")

    Set Nothing1 = products1.ReplaceComponent(product4, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC45A.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument5 = documents1.Item("Structural Steel Column SC45B.CATProduct")

    productDocument5.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC45B.cgr", "cgr"

    Set product5 = products1.Item("Structural Steel Column SC45B.1")

    Set Nothing1 = products1.ReplaceComponent(product5, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC45B.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument4 = documents1.Item("Structural Steel Column SC46A.CATProduct")

    productDocument4.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC46A.cgr", "cgr"

    Set product4 = products1.Item("Structural Steel Column SC46A.1")

    Set Nothing1 = products1.ReplaceComponent(product4, "E:\China

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    State\CATProduct\Columns\column cgr\Structural Steel Column SC46A.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument5 = documents1.Item("Structural Steel Column SC46B.CATProduct")

    productDocument5.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC46B.cgr", "cgr"

    Set product5 = products1.Item("Structural Steel Column SC46B.1")

    Set Nothing1 = products1.ReplaceComponent(product5, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC46B.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument4 = documents1.Item("Structural Steel Column SC47A.CATProduct")

    productDocument4.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC47A.cgr", "cgr"

    Set product4 = products1.Item("Structural Steel Column SC47A.1")

    Set Nothing1 = products1.ReplaceComponent(product4, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC47A.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument5 = documents1.Item("Structural Steel Column SC47B.CATProduct")

    productDocument5.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC47B.cgr", "cgr"

    Set product5 = products1.Item("Structural Steel Column SC47B.1")

    Set Nothing1 = products1.ReplaceComponent(product5, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC47B.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument4 = documents1.Item("Structural Steel Column SC48A.CATProduct")

    productDocument4.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC48A.cgr", "cgr"

    Set product4 = products1.Item("Structural Steel Column SC48A.1")

    Set Nothing1 = products1.ReplaceComponent(product4, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC48A.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument5 = documents1.Item("Structural Steel Column SC48B.CATProduct")

    productDocument5.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC48B.cgr", "cgr"

    Set product5 = products1.Item("Structural Steel Column SC48B.1")

    Set Nothing1 = products1.ReplaceComponent(product5, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC48B.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument4 = documents1.Item("Structural Steel Column SC49A.CATProduct")

    productDocument4.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC49A.cgr", "cgr"

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    Set product4 = products1.Item("Structural Steel Column SC49A.1")

    Set Nothing1 = products1.ReplaceComponent(product4, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC49A.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument5 = documents1.Item("Structural Steel Column SC49B.CATProduct")

    productDocument5.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC49B.cgr", "cgr"

    Set product5 = products1.Item("Structural Steel Column SC49B.1")

    Set Nothing1 = products1.ReplaceComponent(product5, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC49B.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument4 = documents1.Item("Structural Steel Column SC50A.CATProduct")

    productDocument4.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC50A.cgr", "cgr"

    Set product4 = products1.Item("Structural Steel Column SC50A.1")

    Set Nothing1 = products1.ReplaceComponent(product4, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC50A.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument5 = documents1.Item("Structural Steel Column SC50B.CATProduct")

    productDocument5.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC50B.cgr", "cgr"

    Set product5 = products1.Item("Structural Steel Column SC50B.1")

    Set Nothing1 = products1.ReplaceComponent(product5, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC50B.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument4 = documents1.Item("Structural Steel Column SC51A.CATProduct")

    productDocument4.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC51A.cgr", "cgr"

    Set product4 = products1.Item("Structural Steel Column SC51A.1")

    Set Nothing1 = products1.ReplaceComponent(product4, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC51A.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument5 = documents1.Item("Structural Steel Column SC51B.CATProduct")

    productDocument5.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC51B.cgr", "cgr"

    Set product5 = products1.Item("Structural Steel Column SC51B.1")

    Set Nothing1 = products1.ReplaceComponent(product5, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC51B.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument4 = documents1.Item("Structural Steel Column SC52A.CATProduct")

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    productDocument4.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC52A.cgr", "cgr"

    Set product4 = products1.Item("Structural Steel Column SC52A.1")

    Set Nothing1 = products1.ReplaceComponent(product4, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC52A.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument5 = documents1.Item("Structural Steel Column SC52B.CATProduct")

    productDocument5.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC52B.cgr", "cgr"

    Set product5 = products1.Item("Structural Steel Column SC52B.1")

    Set Nothing1 = products1.ReplaceComponent(product5, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC52B.cgr", True)

    Set productDocument1 = CATIA.ActiveDocument

    Set productDocument4 = documents1.Item("Structural Steel Column SC53A.CATProduct")

    productDocument4.ExportData "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC53A.cgr", "cgr"

    Set product4 = products1.Item("Structural Steel Column SC53A.1")

    Set Nothing1 = products1.ReplaceComponent(product4, "E:\China State\CATProduct\Columns\column cgr\Structural Steel Column SC53A.cgr", True)

    End Sub

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    4.7.2 Ho Tung Laul Model

    According to previous method, all type of assembly files can be created. By the

    Master Layout and all type of building elements, Ho Tung Lau 3D model can be

    created and save as Ho Tung Lau Model. CATProduct (Fig. 4.58).

    Figure 4.57 Ho Tung Lau Model

    (Source: Kang Yuen Chan,2006)

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    4.8 The production of the process simulation

    1. Start DELMIA V5

    2. Select the DPM - Process and Resource Definition from Start pull down

    menu

    3. With the Product branch highlighted and select Insert, Insert Product .

    This will bring up the File Selection window.

    4. Select Ho Tung Lau Model. CATProduct. The Ho Tung Lau Model should

    appear on the screen (Fig. 4.58).

    Figure 4.58 Ho Tung Lau Model in DELMIA

    (Source: Kang Yuen Chan,2006)

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    4.8.1 Creating process simulation

    There are sive main essential activities in process simulation below:

    A. Creating Activities to a Process

    B. Creating logical activities

    C. Creating a Device Move Activity

    D. Creating a Simulation Delay Activity

    E. Creating a Visibility Activity

    F. Combined using previous activities

    A. Creating Activities to a Process

    1. Select the Insert Activity icon in the Activity Management

    toolbar.

    2. The Activities to a Process appears in the PPR tree.

    B. Creating logical activities

    The function of logical activities ensures the action of

    activity. Start and Stop activities may be automatically

    created inside the activity.

    1. Select the logical activities icon on the logical activities toolbar.

    2. The logical activities appears in the PPR tree.

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    C. Creating a Device Move Activity

    According to the production of 3D Virtual Resources, Full set of robotic

    motion of a robot can be used. By creating a Device Move Activity, the

    machines such as Gantry and LTM1500 mobile crane can be moved.

    1. Select the Create a Device Move Activity icon. The Activity

    Creation window will appear on the screen (Fig. 4.59).

    2. Select the location for the activity and select the OK button.

    3. On the PPR tree e, select the device you want to move.

    4. Select the joint jogging tab and adjust the value of command (Fig. 4.60).

    5. Select the Modify Activity and then Close.

    6. The Device Move Activity appears in the PPR tree.

    Figure 4.59 Activity Creation Options Figure 4.60 Jog window

    (Source: Kang Yuen Chan,2006) (Source: Kang Yuen Chan,2006)

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    D. Creating a Simulation Delay Activity

    In the whole process, the delay is required to simulate the processing time for

    some non-motion activities

    1. Select the Create Simulation Delay Activity icon . The Activity

    Creation window will appear on the screen.

    2. Select the location for the activity and select the OK button. The Delay

    window appears in the bottom right corner.

    3. Enter the length of the delay (in seconds) in the Duration box and select

    the OK button. The delay activity appears in the PPR tree (Fig. 4.61).

    4. The duration of the delay can be modified by selecting the Delay Activity

    on the PPR tree with the right mouse button and using the context menu.

    Figure 4.61 Delay Window

    (Source: Kang Yuen Chan,2006)

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    E. Creating a Visibility Activity

    A function of visibility activity is to hide or show parts, provide a transparent

    view of a part and provide a different color for a part. .

    1. Select the Create a Visibility Activity icon. The Activity Creation

    window will appear on the screen.

    2. Select the location for the activity and select the OK button.

    3. The Visibility Activity appears in the PPR tree.

    4. The preview window appears and the Edit Visibility Operation window will

    appear on the screen.

    Case 1 - showing component part (represented under construction)

    In the Edit Visibility Operation window, select Show Selected and Set in color

    tab. Then select red color and select the OK button (Fig. 4.62