CATIA

Guidelines for CATIA - CAD

Prepared by Org. sign

KN 15
English translation

Dirk Sheets
Released by

ICT
Org. sign

KEIPER Standard
Released on Edition

KN
Version

A. Kurtuldu ICS 01.100.20, 35.240.10 Descriptors:

2005-02-14

2005-02-14

005

CAD, CATIA, project environment, name conventions, model structuring, modelling types, drawings, assemblies, model approval

Supersedes KN 15 : 2005-01-04

Contents
Foreword ................................................................. 3 1 2 3 4 Scope ............................................................... 3 Standard references ....................................... 3 Definitions of terms ........................................ 4 Project environment ....................................... 7 6.7 Kinematics ...................................................... 17 6.8 LAWs (not kinematics laws)............................ 17 6.9 AXIS................................................................ 17 7 Model structuring ......................................... 17 7.1 LAYER ............................................................ 17 7.1.1 Layer assignment..................................... 18 7.1.2 Amendment management........................ 19 7.2 SETs ............................................................... 19 7.3 SYMBOLs ....................................................... 19 7.4 DETAILs.......................................................... 19 7.5 Colour display of elements ............................. 19 7.6 Transformations .............................................. 20 7.7 DRAFTs .......................................................... 20 7.8 VIEWs ............................................................. 20 7.9 GROUPs ......................................................... 20 7.10 LAYER filter .................................................... 20 7.11 PICK - NO PICK.............................................. 20 7.12 Comment ........................................................ 20 7.13 SHOW - NO SHOW ........................................ 20 7.14 AXIS (axis systems)........................................ 21 7.15 Double elements ............................................. 21 8 3D modelling types ....................................... 22 8.1 Wire model...................................................... 22 Continued on pages 2 to 44

4.1 Project file ......................................................... 7 4.2 Start model........................................................ 7 4.3 STARTUP model .............................................. 8 4.4 Model size......................................................... 8 4.4.1 Index Size .................................................. 8 4.4.2 Data Size.................................................... 8 4.5 Libraries ............................................................ 9 4.5.1 KEI library................................................... 9 4.5.2 Customer libraries ...................................... 9 4.6 CATIA file........................................................ 10 5 6 Reference co-ordinate system .................... 11 Name conventions ........................................ 12

6.1 Model names .................................................. 12 6.2 SET names ..................................................... 14 6.3 LAYER filter names ........................................ 15 6.4 Window and screen names ............................ 15 6.5 View names .................................................... 15 6.6 Transformations .............................................. 16

Translation by SEIGNEURGENS & Partner. Klenzestrae 4, 45138 Essen In case of doubt, the German-language original should be consulted as the authoritative text.
No part of this translation may be reproduced without the prior permission of KEIPER GmbH & Co. Form KN 104:1997-08 Ref. No.: KN 15:2001-08 Created with Microsoft Word 97

Page 2 of 44 KN 15 : 2005-02-14 8.2 Edge model .....................................................22 8.3 Sectional model...............................................22 8.4 Face model......................................................22 8.4.1 Unrounded face model .............................22 8.4.2 Rounded face model ................................23 8.4.3 Hole image display ...................................23 8.4.4 Normal line alignment...............................23 8.4.5 Expansion / extension of surfaces............23 8.5 Solid models....................................................23 8.5.1 General information on SOLIDS...............23 8.5.2 Creation geometry: ...................................23 8.5.3 Selection of basic body:............................24 8.5.4 Geometry used repeatedly .......................24 8.5.5 Correct penetration of primitives ..............25 8.5.6 Split at a surface:......................................25 8.5.7 Avoidance of locally congruent surfaces: .26 8.5.8 Tangents between drill hole and outer side:27 8.5.9 Fillet ..........................................................28 8.5.10 Structure of the CSG tree .........................28 8.5.10.1 Fewer basic bodies:..................................29 8.5.11 Correct arrangement of operations in the CSG tree:.................................................................29 8.5.11.1 Combination of several primitives ............30 8.5.11.2 Grouping primitives...................................31 8.5.11.3 Deleting unneeded primitives ...................31 8.5.11.4 Execution of geometry modifications directly on the primitive ...........................................32 8.5.11.5 Structuring using the Solide/Transfor function 33 8.5.12 8.5.13 8.5.14 9 Update capability: .....................................33 Model size: ...............................................33 Approval or archiving of SOLID data........33 9.4 TAB drawing model .........................................36 9.5 Explosion drawing model ................................36 9.6 Package model................................................36 9.7 Law drawing (typing drawing) .........................36 9.8 Supplier or spare part drawing ........................36 9.9 Standard parts.................................................36 9.10 Drawing standards ..........................................36 9.10.1 Drafts ........................................................36 9.10.2 Line thickness...........................................37 9.10.3 Text creation / character set.....................37 9.10.4 Dimensions and tolerances ......................37 9.11 Material display ...............................................38 10 ZB models ......................................................39 10.1 Assembly.........................................................39 10.2 Overlay ............................................................39 10.3 MERGE ...........................................................39 11 Model release.................................................40 11.1 K.O. criteria .....................................................40 11.1.1 CATCLEAN ..............................................40 11.1.2 KEIPER start model..................................40 11.1.3 SOLIDs unsmart and updated..................40 11.1.4 Skin capability...........................................40 11.1.5 Mathematical technical data quality .........41 11.2 Model organisation ..........................................41 11.2.1 Layer assignment .....................................41 11.2.2 SHOW / NO SHOW ..................................41 11.2.3 PICK / NO PICK .......................................41 11.2.4 Element limits ...........................................41 11.2.5 Reorganisation of elements......................41 11.2.6 Display modes (NHR, HRD, HLR, SHD) ..41 11.2.7 Storage status ..........................................41 11.2.8 Comment ..................................................42 11.3 Release status.................................................43 12 Observance of CAD/CAM guidelines ..........44 12.1 KEIPER projects..............................................44 12.2 Customer projects ...........................................44

Drawing models.............................................34

9.1 Structure of a drawing .....................................34 9.1.1 Views ........................................................34 9.1.2 Dimensioning............................................34 9.1.3 Drawing frame ..........................................35 9.2 Developmental drawing...................................35 9.3 Series drawing.................................................35

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Foreword
This standard represents a collection of guidelines and information on dealing with CAD/CAM and EDM systems within KEIPER. This is a binding standard and serves users as a reference for daily work. This standard may be placed at the disposal of customers and suppliers via TQK. In the event of any questions the HOTLINE under 4444 is available to users at KEIPER. Changes In comparison with KRN 15: 2005-02 (version 4) the following changes were made: a) Page 13, Table 9: Comment (NOTE: Work Instruction KQ050G01 is to be observed) and text may be passed on to customer in ZBs. of special model VM deleted

Previous editions and drafts KN 15 : 2005-01-04; 2002-09; 2001-08 KN 15: 2001-08/A1 : 2001-10, 2001-06(E) KRN 15 : 1996-08, 1996-03, 1995-11, 1994-11, 1994-08, 1993-03 KRN 15 supplement: 1996-01

1 Scope
In addition to mathematical technical data quality, the organisational structure of CATIA models is an essential quality criterion for CAD. Good and clearly structured data sets make trouble-free co-operation possible, make many queries unnecessary and greatly contribute to good developmental results. CATIA provides many different possibilities to structure models. It is necessary to define agreements and rules to make use of these possibilities in order to preclude the need for unnecessary searching and questioning or even re-working. The KRN 15 is binding for all CAD models classified as technically audited (FK 1130 and subsequent). The designer is responsible for observing this. In the case of models directly and exclusively created for customers, then their regulations have precedence.

2 Standard references
KRN 11-1 Ausfhrung von technischen Unterlagen; Zeichnungen; Teil 1: Format und Gestaltung von KRC Zeichnungen Presentation of technical documents - Drawings - Part 1: Format and design of KRC drawings KRN 11-2 Ausfhrung von technischen Unterlagen; Zeichnungen; Teil 2: Ausfhrungsrichtlinie fr KRC Zeichnungen Presentation of technical documents - Drawings - Part 1: Execution guideline for KRC drawings KN 11-3 Ausfhrung von technischen Unterlagen - Zeichnungen - Teil 3: Checkliste fr Zeichnungsprfung Presentation of technical documents - Drawings - Part 3: Checklist for drawing audit KN 11-4 Ausfhrungen von Technischen Unterlagen Zeichnungen Teil 4: Form- und Lagetoleranzen Presentation of technical documents - Drawings - Part 4: Geometrical tolerancing

Page 4 of 44 KN 15 : 2005-02-14 KRN 110 Benennung Title KRN 111 Benennung Zusatz Title optional KN 127 Labor / Bro - Kennung Laboratory / Office - Designation KRN 138 Zeichnungsrichtlinie Tab-Zeichnung Guideline for table drawings KN 154 Technische Produktdokumentation von Normteilen Technical product documentation of standard parts KN 200 Nummerung - Zeichnungs, CAD-Modell- und Materialnummer Numbering - Drawing, CAD model and part number

3 Definitions of terms
CADIM/EDB
A database linked to the CAD system CATIA via an interface. At KEIPER, CAD models are administered and data exchange carried out via CADIM/EDB.

CATCLEAN
Auxiliary program for finding errors in the CATIA data structure. Call up is effected with /cln.

Detail
A group of CATIA elements which are addressed via a name. Details are administered in the model in so-called detail workspaces or externally in a library. They are referenced as Ditto within a CATIA model and can thus be used repeatedly. Details from a library are embedded in the CAD model as ditto using title and reference point. (e.g. the drawing frame).

Ditto
Reference of a detail in the master workspace.

Draft
Workspace in Draw to store further drawing sheets.

Draw
Environment in which the drawing in CATIA is created.

EDB Assembly
EDB functionality for creating and managing assemblies

Euro-Project-File
European agreements on the pre-setting of the standards of CATIA software.

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Face
CATIA element which describes a topologically limited area.

File
The CATIA models are in an index which is described as CATIA file.

Filter
Various layers are combined to form a filter. Geometry is switched to visible or invisible.

HLR (HIDDEN LINE REMOVAL)

Hidden body edges are removed.

HRD (HIDDEN LINE REMOVAL DYNAMIC)

Hidden body edges are removed and the image structure recalculated in a transformation.

LAW
Laws used to generate faces.

Layer
Representational level to which certain CATIA elements of a model are assigned according to the user's requirements. CATIA recognises 255 layers. Any element may only be assigned to one layer.

Macro
Auxiliary program in CATIA.

Merge
Function in CATIA which makes it possible to copy geometry from one model into another.

Model
File with 3D or 2D data from CATIA, is always in a CATIA file (index).

NHR (NON HIDDEN LINE REMOVAL)

Graphic default setting in CATIA. Geometries are visible with hidden edges.

Overlay
Possibility of creating assemblies with CATIA up to now. This is replaced by EDB-assembly.

PICK/NO PICK
Display type for CATIA elements (selectable / non-selectable).

Q-Checker
Program for checking models start with /m QCHECKER.

Screen
Shows the screen allocation for the model geometry.

SHD (SHADING DYNAMIC)

Possibility of shading and simultaneously moving CATIA models.

SHOW/NOSHOW
Visible or invisible switching of CATIA elements.

Solid
Complex bodies are constructed using Boolean operations.

Space
Area in which the 3D-geometry is created.

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Surface
Area element in CATIA.

VDA checker
Program to audit models. Program call up in CATIA: /m vdacs.

View
View of a drawing to which geometry elements have been assigned.

Window
Interactive selected partial view of a model display.

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4 Project environment
The CATIA project environment comprises: Project file Start model Start-up model Libraries

Work on Keiper projects must always be carried out in the Keiper environment. Deviations from this procedure can only be permitted in agreement (prior to project start) with ICT. In the case of customer projects (development projects for OEMs), the suppliers have to provide Keiper with their CAD data in the respective applicable customer standard for the customer project..

4.1 Project file

The project file EURO-PROJECT-2 is used at Keiper. It is administered with responsibility by ICT. In the project file, the PATTERN and DIMENS2 | TEXTD2 standards are defined as quantities. The patterns correspond to the ECUIA Standard.

4.2 Start model

The KEIPER start model is oriented to the DaimlerChrysler start model. This contains definitions of the standards beyond the project file. These are: In the permanent menu bar under the ST button, depending on the button setting DR / SP: Edit settings in draw Edit settings in space Via the function STANDARD: Display type Draw elements Display type Space elements Colour tables and colour assignments MODEL DIMENSION and the tolerances derived from this as well as: The settings for TEXTD2, DIMENS2 and AUXVIEW2 Furthermore, filter, view axes or AUXVIEW2 settings are pre-defined in the model. These pre-settings may not be altered in order to ensure smooth processing of models. The KEIPER start model as well as the customer start models are in the CATIA file

START_AKTUELL_EDBKL
It is named

82033348 +000+ +E+ F+08+HOF+STARTMODELL KEI-2000 +311000 ---------1---------2---------3---------4---------5---------6---------7

It is administered with responsibility by ICT. When creating new models, the KEIPER or customer start model valid for the project must be loaded from this file via EDB and given a valid model name. This ensures that the current status of the start model is always used. Models must be created via the function CATEDB5 | MODEL | CREATE directly within the EDB!

Multi-model sessions at KEIPER are generally to be created with multi-model techniques (e.g. Assembly). If elements are to be copied beyond model limits then generally the function MODEL | COPY | ELEMENT is preferred to the function MERGE.

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When merging geometries, the MODEL DIMENSION must be observed (see STANDARD | MODEL | Page 2). Face, skins, volume and solids from models with a MODEL DIMENSION greater than that of the KEIPER start models (>2000) may not be merged in KEIPER models. Otherwise, CATIA reports: MODEL MERGED, TOLERANCE MODIFIED after merging.

4.3 STARTUP model

Using the functions DIMENS2 | MANAGE | STARTUP or TEXTD2 | MANAGE | STARTUP, the settings for the KEIPER or customer start model with regard to settings for DIMENS2, TEXTD2 and AUXVIEW2 are loaded. These settings are to be used constantly to ensure a uniform drawing image. The STARTUP model applicable for Keiper is the KEIPER start model:

82033348 +000+ +E+ +08+HOF+STARTMODELL KEI-2000 +311000 ---------1---------2---------3---------4---------5---------6---------7

STARTUP models are in the CATIA FILE:

START_AKTUELL_EDBKL
In customer projects, the respective start model serves as STARTUP model.

4.4 Model size

The model size corresponds to the sum of the index size and the data size (ERASE | PACK). When starting CATIA in the KEIPER environment, the user can set an upper limit for this. This upper limit must have a reasonable proportion to the actual model size of the CATIA model to be edited, in order to achieve high editing speed. The actual model size should always be kept small. Possibilities of reducing model size: VDA-Checker resp. Q-Checker: delete double elements and mini elements. Delete unused details, unused views TANDEM | #YDEL) Link sets not required SETS | LINK Reorganise data structure ERASE | PACK Switch exact solids to UNSMART mode Delete boundaries of faces V-F-Tool | QDEL Delete unneeded auxiliary geometry

4.4.1 Index Size The index size describes the size of the data structure with the identifier and description (colour, line style etc.) of the CATIA elements. Deleted elements leave gaps in the data structure. These tables are re-organised using ERASE | PACK. This function is executed automatically when saving. 4.4.2 Data Size The data size describes the size of the data structure for the mathematical description of the elements.

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4.5 Libraries
4.5.1 KEI library KEIPER libraries have the following naming convention:

CATIA.KEI_<Library type>
Library name CATIA.KEI_RAHMEN CATIA.KEI_AUFKLEBER CATIA.KEI_3D CATIA.KEI_EDB CATIA.KEI_ANWENDER CATIA.KEI_ETC Table 1: KEI libraries 4.5.2 Customer libraries Customer libraries have the following naming convention: Explanation Library for all drawing frames KEI-, KEI-BRASIL, JCI-, DB-, LEAR areas etc. Library for KRC sticker and drawing details Library for 3D-details at Keiper Library for drawing frames used by EDB Open users' library. Project-specific details are saved by the user via this library. Library for ETC

CATIA.KEI_<Library type>
In the case of customer libraries, the name may be specified by the customer (e.g.: VW:"TLIB, AUDI: "VA). Library name CATIA.KEI.LIB.OPEL_NEU CATIA.KEI.LIB.PORSCHE CATIA.KEI.LIB.LEAR_I CATIA.KEI.LIB.JC CATIA.KEI.LIB.BMW CATIA.KEI.LIB.COLORADO CATIA.MB#ZNORM.P#019.MAP TLIB VA Table 2: Customer libraries Explanation Drawing frame OPEL PORSCHE drawing frame and formats LEAR Italy - drawing frame JCI drawing frame BMW library Drawing frame to COLORADO project DaimlerChrysler library VW library AUDI library

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4.6 CATIA file

At the beginning of a project the CATIA files are created by ICT as open files for CATIA models. There are three CATIA files for every project corresponding to the approval status of the models. The basis for naming is the project description. CATIA-FILE <Project>_WORK_EDB<Facility> <Project>_AKTUELL_EDB<Facility> <Project>_ARCHIV_EDB<Facility> Table 3: Syntax for CATIA files for projects Example for project FIAT192 at Facility Kaiserslautern (KL): CATIA-FILE FIAT192_WORK_EDBKL FIAT192_AKTUELL_EDBKL FIAT192_ARCHIV_EDBKL Explanation Models in hand Approved models Invalid or archived models Explanation Models in hand Approved models Invalid or archived models

Table 4: Example CATIA files for project FIAT192 The following CATIA files are available for our customers' incoming original models: CATIA-FILE ORIG<Projekt>_WORK_EDB<Standort> ORIG<Projekt>_AKTUELL_EDB<Standort> ORIG<Projeck>_ARCHIV_EDB<Standort> Table 5: Syntax for ORIG CATIA files All CATIA files with the abbreviation "EDB are administered via the database CADIM/EDB. Access to these models is effected via the function CATEDB 5 | MODEL | OPEN | .... There are also the following CATIA files for special applications: CATIA-FILE EXIMP_IMPORT_EXT EXIMP_IGES EXIMP_VDA EXIMP_KVS_IMPORT EXIMP_KVS_EXPORT EXIMP_COPY Table 6: Special CATIA files Explanation Models received from external sources Models for conversion to IGES format Models for conversion to VDA-FS format Models for KVS import (VW) Models for KVS export (VW) Special CATIA file for temporary open files Explanation Customer models read into database Valid customer models Invalid or archived customer models

Page 11 of 44 KN 15 : 2005-02-14 There are CATIA files for exchange between the facilities, the contents of these files are compared with the destination facility at regular intervals: CATIA file EXPRESS_TRANSFER_<Standort_1>-<Standort_2> Explanation Models from facility_1 compared with those from facility_2

Table 7: CATIA files in comparison to the facilities Generally the models of all AKTUELL-EDB directories for the respective facilities are compared with each other overnight. Models from other pots must be copied into the above mentioned EXPRESS_TRANSFERpots to make them available to the respective facility.

5 Reference co-ordinate system

The co-ordinate system to which the components are to be referred must be defined prior to the beginning of a project. In most cases, the customer stipulates the co-ordinate system. In the case of repeated use of assemblies and individual parts, a spatial position must be found to make easy transformation of the vehicle co-ordinate system possible. Example of local axis systems: Joining elements A bolt-on point and inclination of lower track Rear and front edge inclination of lower track Backrest swivel axis and the inclination of the recliner upper part Table 8: Examples of reference co-ordinate systems The co-ordinate origin of assemblies and individual parts which are used repeatedly must refer to structural features (e.g. edge or hole centre). Allocation For seat / lower part For seat / lower part For backrest adjuster

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6 Name conventions
No special characters or umlauts are permissible when naming CATIA models and the elements (see also paragraph 9.10.3). The permissible characters are restricted to "A B C....X Y Z and "0 1 2 ....9 0 and the special characters "- + _ and the space bar. Element names with "$" at the beginning and/or with the prefix "EX..." are not permissible. Such elements are created when MERGE is used. They are then to be processed with the function IDENTIFY | UPDATE ("EX..." is removed) or IDENTIFY | RENAME (definition of a new name). In principle, all elements may be renamed with a reasonable name starting with their standard identifier.

6.1 Model names

The KEIPER name convention applies to the naming of CATIA models. The model name may have a maximum of 70 characters. Longer model names are not permitted. The name is divided into individual fields separated by "+".

...................+...+..+.+..+..+...+........................+...... ---------1---------2---------3---------4---------5---------6---------7 ..... = Field entries

The combination of the 4 fields: File number Version (amendment index) Special application Variant in the model name must be clear. Clarity is checked and ensured by CADIM/EDB (according to KN 200). Generally there are several versions of a file number and several variants or special applications to this. CADIM/EDB ensures that only the same variant can be approved for the same version of a file number.

+ = Column separation

Columns 1 to 19

CAD model number according to KN 200

The issue of clear CAD model numbers is effected centrally via the database CADIM/EDB when a new model is created. The macro /m name also receives its CAD model number from CADIM/EDB. KN 200 describes the numbering system applicable at KEIPER and is the basis for number in the CATIA model names.

Columns 21 to 23

Version

Consecutive numbering beginning with 000, 001, 002 etc..

Columns 25 to 26

Special application

This field is used to identify the special models derived from the original model, in order to fulfil particular requirements in the process chain.

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Abbreviation ..(blank) S1 to S9 D1 to D9 AD BA BM CE CS DC EX FU KF K1 to K9 KI ME MZ NC RB TA TU TB TM VV V1 to V9 VM

Type of special model Model with space and draw Space model No.1 to No.9 in the case of several models per part Draw model No.1 to No.9 - in the case of several models per part Models for ADAMS Sheet completion Construction space model / package model CATSURF model with error CATSURF model Simplified model created referring to standard of customer DaimlerChrysler Explosion drawing model Unrounded face model Model for being released by customer Model No. 1 to No. 9 for being released by customer- when more than one model p. part Kinematics model Merge model Empty model (in case that only a manual drawing exists) NC model ROBCAD model Tolerance elevation Tolerance investigation Model for technical calculation Model of a TAB drawing (TAB-model) Pre-version Pre-approval models Simplified model, without technical detail information

Table 9: Abbreviations for special models

Column 28
Abbreviation E B S

Phase
Phase Development Procurement Series

Table 10: Abbreviation design phase

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Columns 30 to 31:
.. (blank) _D _F _S _0 _A _Z ZD ZF ZS ZA ZO

Model type

Abbreviation Type of modelling Manual drawing Wire modelling Face modelling Solid modelling Overlay structuring EDB-Assembly structuring Drawing Drawing derived from wire model Drawing derived from face model Drawing derived from solid model Drawing with EDB-Assembly structuring Drawing with overlay structuring

Table 11: Abbreviations modelling type

Columns 33 to 34:

Identification of laboratory / office according to KN 127

The laboratory/office is identified according to KN 127

Columns 36 to 38:

Model author

GTD keeps a central list of ID abbreviations for CATIA users and external authors of CATIA models. The ID abbreviation for a CATIA user is issued with its set-up and is only issued once respectively. This ID abbreviation is entered in the amendment field of the drawing.

Columns 40 to 63: Columns 65 to 70:

Model title (observe KRN 110) Variant (example: date, construction status)

This field does not have to be filled in. It serves as an additional differentiation between different variants. Variant fields are required to be identical in the approval of additional special applications. The name is created from the form boxes completed and checked by CADIM/EDB.

User and supplier abbreviations are requested via the macro /m sign or Infos | /m sign. 6.2 SET names
There is only ever a set (*SET1) for individual parts. In the case of kinematics, package and multi-model sessions, a clear name for the sets included must be selected. FILE NUMBER+TITLE

Example:
82000421+3+REAR SUSPENSION 82000443+4+COULISSE

Page 15 of 44 KN 15 : 2005-02-14 or for components used repeatedly: CARRIER GEAR RIM

6.3 LAYER filter names

Filter names are to be selected so that no further explanation is required.

Example:
outside, inside, A side, B side

If two component sides are modelled separately in a face model, then a filter should be defined for each side.

6.4 Window and screen names

Windows and screens serve to simplify and accelerate control of the screen display. If windows and screens are to be created, then clear names ensure that model processing by third parties is problem-free. Window names always begin with WI, screen names always begin with SC. The space bar is used to separate. Window / screen name WI FREIGABE WI DRAW X SC DRAW/SPACE SC DRAW Description Window for release; shows entire drawing or 3D geometry Window draw on detail X Screen with simultaneous display of space and draw Screen for draw

Table 12: Examples of titles of WINDOWs and SCREENs To be released, the window WI FREIGABE has to be created (see paragraph 9.10.3)

6.5 View names

The view of the frame contains the drawing frame and is always called RAHMEN. The following abbreviations for the view names are to be used for standard views:

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View name SAL SAR DS VA XY XZ Rahmen

Description Side view from left Side view from right Top view Front view View on X/Y plane View on X/Z plane View drawing frame

Table 13: Examples of titles of views Further views are to be titled according to purpose: View name A-A B-B Z Y X Description Sectional view A-A Sectional view B-B Detail Z Detail Y Detail X

Table 14: Examples of view titles (sectionals and details) If standard views are needed repeatedly (variant displays), then the subsequent numbers are to be increased consecutively (Z1, Z2, Z3 ...). If a filter is used on a view (LAYER | FILTER | APPLY | VIEW), then the view identification is also to be used for the filter (view: VU A-A, filter: A-A).View filters are only permitted in transparency mode.

6.6 Transformations
Transformations must be given a reasonable name in CATIA if they are saved in a model. These begin with TR for Transformation, followed by R for Rotation, S for Symmetry or T for Translation. The value of the shift then follows. The space bar is used for separation. Transformation TR R X35 TR S Y0 TR T X20Y0Z-50 Description Rotation around the X-axis by 35 Symmetry to XZ plane Translation vector with 20,0,-50

Table 14: Examples of transformation titles Transformations are copied with MODELS | COPY | ELEMENT or MERGE | SELECT | ELEMENT.

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6.7 Kinematics
Kinematics sets must be given clear names. These always comprise the description of the kinematics and the kinematics limits data. Description HEIGHT ADJUSTER LIMITS OF 10-35 DEGREES LONGITUDINAL POSITIONING LIMITS OF 100-250 MM FOLD DEVICE WITHOUT LIMITS Table 15: Examples of kinematics set titles Geometrical sets within kinematics must be titled according to the rules for sets. Laws of kinematics are named corresponding to their allocation to drives and their definition range. Explanation Kinematics for height adjuster , with the limits 10 and 35 Kinematics for longitudinal positioning, with the limits 100 mm and 250 mm Kinematics for a fold device, without limits

Kinematics sets are copied with MERGE | SELECT | SET | SPECIFIC.

6.8 LAWs (not kinematics laws)

Available laws must have a respective purposeful name. The allocation of a law to the faces must be clear. Example: LAW ROUNDING R5 TO R20

The function ANALYSE | LOGICAL | PARENTS shows the allocation of laws to the surfaces.

6.9 AXIS
Axis systems created manually must be given reasonable names. These are to be marked as space text on the axis system. The CATIA standard identifiers are not meaningful enough and thus have to be renamed. Axis name Zero point FIAT_192 W-Lage BR240 Description Reference axis system project FIAT_192 Reference axis system for W-Lage project BR240

Table 16: Example of titles of axis systems

7 Model structuring
The following chapter illustrates the structuring possibilities for CATIA models. CATIA offers numerous structuring possibilities particularly in their combination. Thus, uniform handling is very important. In particular, non-observance leads to considerably more effort needed to create drawings of multi-model sessions. Furthermore, unnecessary information is to be deleted and auxiliary geometry reduced to the minimum required to achieve compact and easily-to-handle models.

7.1 LAYER
Geometry or drawing elements are structured with the CATIA function LAYER.

Page 18 of 44 KN 15 : 2005-02-14 7.1.1 Layer assignment Assignment of the 255 layers (0 to 254) is to be observed according to the following system:
Layer 0 is available as working layer. Layers 241 to 254 are reserved for special applications. Layers 1 to 240 are divided into blocks of 5 layers respectively. One block is intended to represent one part respectively. LAYER with end digit 1 or 6 Allocation WIRE Wire geometry (Line geometry basic body) Contents Axis systems Body edges, line drawings, visible edges Penetrations with centre point Holes with centre point Theoretical body edges PLANE elements FACE elements SKIN elements SURFACE elements VOLUME elements POLYEDER elements SOLID elements PIPE elements STRUCTURE elements Amendment fields Process identification annotations Process additions Dimensioning Bending and rupturing lines Form tolerance ID Thread boundary Boundary positions Main axis of component Geometrical tolerancing ID Light edges, hole circles and centre lines Fitting dimension table Section edges, lines and arrows Hatching Welding seams Symmetry lines, arcs Texts, general Contours, hidden edges Drawing frame, text boxes and symbols Completion Connecting points and axes (KINEMATICS, ROBOTIC PIPING, SCHEMATIC) Connecting contours and faces Auxiliary constructions Cross-sectional contours and faces Centre of gravity Processing vectors (centre lines) Sectional elements (edges)

2 or 7

SURFACE / FACE Face geometry (Face proportion basic body)

3 or 8

SOLIDS Body geometry (Geometry in facetted display)

4 or 9

ANNOTATION Descriptive elements

5 or 0

SPECIAL Free or for special elements

Table 17: Layer assignment general Layer 115 240 to 254 241, 242 243 Explanation Material thickness (4.6.4), show removal direction (4.6.5) These layers are used for special applications. Auxiliary program CATSURF Auxiliary program CATCLN

Table 19: Layer assignment for special layers

Page 19 of 44 KN 15 : 2005-02-14 7.1.2 Amendment management For the purposes of increased clarity and traceability of amendments, altered areas in models are to be specially marked. To this end, the altered elements of face models are clearly identified with a colour in SPACE. Only identify the elements affected as alterations, not newly trimmed FACEs. Exception: removal or insertion of holes.

7.2 SETs
Logically differentiable geometry units within a model are structured with the function Set. Generally the following applies: an individual part model only contains one set. The exceptions to this are kinematics and package models. In the case of multi-model sessions EDB-Assembly resp. Overlay is to be used. Drawings of multi-model sessions can be structured via sets. Most customer standards also only accept one set in the model for multi-model sessions. Thus corresponding layer assignment is required in this case.

Sets not required must be deleted or linked (macro: TANDEM | /m #ydel).

7.3 SYMBOLs
Use of the function SYMBOL (symbols) is not permissible.

7.4 DETAILs
Details are separate workspaces in a CATIA model (in draw or space respectively) and may contain all CATIA elements in any combination. Details are used as references (Ditto) in other workspaces. The use of such Dittos saves memory space, since only one indicator is used per ditto (SPACE dittos are not selectable by mulitselect). All workspaces refer to the so-called master workspace. Details are differentiated into model -DETAILs and library-DETAILs. Library-DETAILs are stored in a library and are used in a model according to requirements. There is a reference from the model to the library detail until execution of the function DETAIL | MANAGE | DROP. This reference is deleted with DROP, however a copy of the detail available beforehand. The same rules apply, logically, in the detail workspace as for the entire model. Details are to be used as COMPACT DITTOs with DETAIL | LIBRARY | MODEL | COMPACT | ... i.e. the dittos are allocated to the current layer. (The exception is SPACE DETAIL in transparency display). Creating a further detail structure below a detail workspace (interleaved details), that is creating DITTOS in detail workspace is not permitted. The use of filters on ditto (function LAYER | APPLY | DITTO) is not permitted. Creating multi-model sessions with detail technique is not permitted. All unused details (exception: the detail of the overlay macros) must be deleted. Used details must be separated from the library (macros: TANDEM | /m #ydel and TANDEM | /m #jdrop).

The welding sign of the function SWZ-CAT may not be saved as a user-defined element.

7.5 Colour display of elements

Colours are important for good optical differentiation of details in the components. Model colour tables may not be altered (STANDARD | COLOR).

Page 20 of 44 KN 15 : 2005-02-14 Elements with the colour NONE can be colour adjusted according to type or assignment to a set, view or layer with the function STANDARD | COLOR | TYP \ SET \ VIEW \ LAYER. However, to this end, a colour for set, view or layer must have been given. The colour assignments for the element types may not be altered.

7.6 Transformations
Transformations no longer required in the model must be deleted.

7.7 DRAFTs
Every drawing receives exactly one Draft: Blatt 001. Generally the following rule applies: only one drawing and thus only one draft per model.

7.8 VIEWs
Every drawing view / section must be assigned its own view which corresponds to the correct reference to the space. The elements of a drawing view must be assigned to the appropriate view. Views which do not contain any elements are to be deleted. Views are created and modified with the function AUXVIEW2.

7.9 GROUPs
Use of the function GROUP is not permitted. Models may not contain any saved GROUPs.

7.10 LAYER filter

The basic filters containing wire, face and solid descriptive elements are available in the KEIPER start model as follows: Filter name DRAHT FLAECHE SOLID ANNOTATION LAY 001-005 TEIL 1 LAY 006-010 TEIL 2 LAY 011-015 TEIL 3 Table 18: LAYER filters The filter preset via the start model may not be deleted. Additional layer filters created by the user which are no longer required in the model are to be deleted. Description Wire geometry Face geometry Solid body Drawing derivation Layer block 1 part Layer block 2 part Layer block 3 part
rd nd st

7.11 PICK - NO PICK

Models may not contain any elements in NO PICK.

7.12 Comment
As long as there is no drawingl with its own amendment text box to a space model, then the alterations are administered in FILE | INFORMATION | COMMENT of the space model (see 11.2.8).

7.13 SHOW - NO SHOW

In NO SHOW there are SURFACEs on which FACEs have been created and creation geometry of SOLIDs as well as logically linked elements such as PLANEs and AXIS. If faces have been used in a solid model, e.g. for sewing, then these faces are also to be placed in NO SHOW as auxiliary geometry. The layer assignments also apply to NO SHOW.

Page 21 of 44 KN 15 : 2005-02-14 In SHOW the descriptive outer geometry is structured from FACEs, SKINs or VOLUMEs, that is, SOLIDs.

7.14 AXIS (axis systems)

Left aligned axes are not permissible, the exception to this is geometry creation in the downstream process steps such as CAM and measurement technology. Unneeded axes must be deleted. KINEMUSE | DRESSUP | ATTACH creates an axis for every model in Assembly structure or Overlay list in NO SHOW. This must not be deleted; otherwise the ATTACHMENT of the passive model is lost!

7.15 Double elements

Double elements are to be avoided. Always work with the option FAMILY when moving, rotating or duplicating solids via the function TRANSFORM. This ensures that creation elements are also moved, rotated or duplicated.

Double elements are found and deleted with the VDA checker resp. Q-Checker (criterion Identical Elements). If double elements are still available as "in use" subsequently, then the creation geometry of solids is to be checked and moved correctly (option FAMILY).

Page 22 of 44 KN 15 : 2005-02-14

8 3D modelling types
There are two types of complete description of 3D geometry: Face modelling: description of geometry via a skin Solid modelling: description of geometry via a solid Wire models serve only as a sketch display of geometrical proportions and are not suitable for further use in the process chain. Generally wire models, that is sectional models or scan data serve as the starting base for further CAD work. New components should be created via solid modelling as far as possible. In the case of face modelling, work should be carried out with simple surface elements (SURF1) as much as possible. Creation geometry for faces must, as far as is technically possible, be canonical (circle, line, ...). Generally it must be ensured that the information in the 3D model and that in the drawing correspond to one another!

8.1 Wire model

Wire models contain lines, curves (splines,..), circles etc.

8.2 Edge model

Theoretical edges, holes and penetration must be represented. Example: sheet parts

8.3 Sectional model

The sectional model comprises a number of possible cross-sections. Example: upholstered parts, covers A special type of section model is scan data (points, constraints, Polysurf elements).

Figure 1: Edge model

Figure 2: Sectional model

8.4 Face model

All surfaces must be assigned FACE elements. Modelling on production-specific details is to be kept as low as possible for cost reasons. Outer and inner contours must be on separate layer blocks. Canonical elements (lines, circles etc.) are to be used in preference as far as is technically possible when creating wire geometry for faces. Face models should be maintained in development once rounded and once unrounded, so that alterations are easier to include. 8.4.1 Unrounded face model The FACE edging forms the theoretical sectional edge and the filleting of the component spatially. The formdefining fillets are present.

Figure 3: Unrounded face model Unrounded face models are marked by FU (/m name) in CATIA model names (box: special applications).

Page 23 of 44 KN 15 : 2005-02-14

Theoretical corners must lie exactly on a point. 8.4.2 Rounded face model The faces are rounded completely to the agreed production-defined radius.

Figure 4: Rounded face model 8.4.3 Hole image display Hole images are always included as limits in the CAD face of the parts. The hole centre and centre lines are to be shown (both points in the case of slots). If necessary, the original curve (curve before projection onto the face) is to be saved in addition to the reference point and projection direction. The component sides designed must be described complete with surfaces, despite holes in order to ensure producibility. 8.4.4 Normal line alignment The surface normal lines are to be aligned uniformly and in the direction of the material. The surface normal lines are aligned uniformly supported by automatism with the VDA checker (/m vdacs) resp. Qchecker. 8.4.5 Expansion / extension of surfaces If enlargement / extension is necessary, then care must be taken that no waviness or folded normal lines arise.

8.5 Solid models

Only EXACT SOLIDs (function: SOLIDE) may be used in model creation. Their surface is represented via FSUR (Functional Surfaces) with ISO parameter lines. In the interests of better convertibility after CATIA V5, all parts should be created with SOLIDE as far as possible. If this is not possible or only with great effort, then face modelling must be resorted to. However, in this case the conditions for technical mathematical data quality (VDA checker resp. Q-checker) are to be observed. 8.5.1 General information on SOLIDS Elements in GHOST mode are not permissible. External SOLIDs or their import are not permissible. 8.5.2 Creation geometry: When creating primitives, curves with canonical description i.e. lines, circles, ellipses are to be used as far as possible. In the case of type *CRV curves, attention must be paid that the number of ARCS and the degree of polynomial of the ARCS is as low as possible. Creation contours of PRISM should preferably be structured with the Sketcher. Contours must be created as simply as possible for a solid. Contours which will subsequently become

Page 24 of 44 KN 15 : 2005-02-14 superfluous due to Boolean operations must be replaced by lines before the solid is created.

Figure 5: Creation geometry incorrect method Superfluous contour: only the left hand section of the contour is required after the split. 8.5.3 Selection of basic body:

Figure 6: Creation geometry correct method Simplified contour

Structure solid basic geometry with PRISM as far as possible. Dispense with CUBOID and PYRAMID as far as possible to guarantee subsequent data transfer in V5. If the solid is structured via a volume, then the volume should not contain any drill holes if possible. 8.5.4 Geometry used repeatedly Repeated use of creation geometry is possible. The message "SHARED CONTOUR indicates this. Divided creation geometry is to be avoided since it cannot be processed subsequently (sketcher). Details may not be used. The function SOLIDE | TRANSFORM is to be used! Work with the function SOLIDE | TRANSFORM for repeated use of branches of the CSG tree or primitives.

Page 25 of 44 KN 15 : 2005-02-14 8.5.5 Correct penetration of primitives Correct penetration avoids unclear geometrical situations. The work involved in modifications is minimised. Example: Use of UNTIL | FROM TO possibility to create solids. The cylinder is subtracted from the cuboid.

Figure 7: Penetration of primitives- incorrect method If the cuboid is enlarged beyond plane 3 then the drill hole does not penetrate the cuboid completely.

Figure 8: Penetration of primitives correct method The drill hole is created from boundary face 1 to boundary face 2. If the cuboid is enlarged, then the boundary of the drill hole is automatically adjusted.

8.5.6 Split at a surface: When splitting at a surface attention must be paid that the surface is of sufficient size. If draughts are attached, then an update must be possible with and without draughts. Incorrect method:

Figure 9: Split at a surface spatial view

Figure 10: Split at a surface view without draughts

Figure 11: Split at a surface view with draughts

The surface at which the split takes place is somewhat larger than the boundary of the cuboid, however not sufficiently large. After attachment of draughts, the surface does not divide the cuboid completely; an update is no longer possible.

Page 26 of 44 KN 15 : 2005-02-14 Correct method:

Figure 12: Split at a surface spatial view All surfaces must be created of sufficient size on design begin. 8.5.7 Avoidance of locally congruent surfaces:

Figure 13: Split at a surface view with draught

Locally congruent surfaces (or edge curves of prisms) are to be avoided. This often requires an alteration of the creation contour of the primitive. The cause lies in the IDENTICAL CURVE TOLERANZ. Locally congruent surfaces (or edge curves of prisms) are often processed error-free, however Boolean operation in connection with transformations are often not calculated due to rounding errors.

The error occurs with BOOLEAN OPERATIONS. Remedy: provide primitives with sufficient dimensions or use the option "UNTIL FROM TO.

Figure 14: Locally congruent surfaces incorrect method Both contours have the same geometry in a section.

Figure 15: Locally congruent surfaces correct method The arc from contour 1 has been replaced by a line.

The result is the same in both cases after a UNION operation of both primitives.

Page 27 of 44 KN 15 : 2005-02-14 8.5.8 Tangents between drill hole and outer side: In the following example, the drill hole is tangent to the outer side of the prism. If design-permissible, a slight alteration in the geometry is the solution.

Figure 16: Unfavourable geometric proportions

Figure 17: Favourable geometric proportions

The problem of local zero thickness is eliminated by slight movement of the drill hole or enlargement of the prism.

Page 28 of 44 KN 15 : 2005-02-14 8.5.9 Fillet Filleting must be taken into account in the creation geometry of the PRISM. All functional radii to chamfer edges are created with the function SOLIDE | OPERATION | FILLET.

Figure 18: Filleting - solid

Figure 19: Filleting CSG tree

Filleting between different primitives is also created under the function SOLIDE | OPERATN | FILLET. Filleting which cannot be created under the function SOLIDE | OPERATN | FILLET due to system restrictions, must be created as a face and attached using the function SOLIDE | OPERATN | SEWING. 8.5.10 Structure of the CSG tree A "clean" tree structure avoids errors in updates and reduces calculating times. in addition, the component is easier to modify if the tree structure is logical. Do not carry out subtraction with isolated solids. Make the CSG tree as flat as possible. Take the geometrical allocation of the component in the CSG tree into consideration.

Use the SMART functionality for modification.

Page 29 of 44 KN 15 : 2005-02-14 8.5.10.1 Fewer basic bodies: The number of primitives is to be kept as low as possible in the CSG tree. Operations can be reduced by corresponding creation contours. Improved clarity of the CSG tree is ensured. Multiple basic bodies:

Figure 20: Solid Fewer basic bodies

Figure 21: CSG tree

Figure 22: Solid

Figure 23: CSG tree

8.5.11 Correct arrangement of operations in the CSG tree: Operations must be carried out on the level in the CSG tree on which the primitive is located which is to be altered by this operation.

Figure 24: Solid

Page 30 of 44 KN 15 : 2005-02-14

Fig. 25: Unfavourable positioning Cylinders (CYLN 3 and CYLN 4) are subtracted in the last operation. However only prism 1 is affected by this operation. 8.5.11.1 Combination of several primitives

Figure 26: Favourable positioning In this CSG tree the drill holes are taken into consideration directly after the creation of PRISM 1.

If several primitives are altered by the same operation, then these primitives must first be combined. Subsequently, the operation is only carried out once.

Figure 27: Solid

Figure 28: Unfavourable positioning

Figure 29: Favourable positioning

Page 31 of 44 KN 15 : 2005-02-14 8.5.11.2 Grouping primitives A CSG tree must be structured so that primitives logically belonging together are combined in one "branch". If a component is created with an inside and outside description, then the complete inside description is to be deducted from the outside description in only one operation.

Figure 30: Solid

Figure 31: Unfavourable tree structure 8.5.11.3 Deleting unneeded primitives

Figure 32: Favourable tree structure

An operation may not be cancelled out by additional operations. All primitives no longer required are therefore to be deleted from the CSG tree. Example: the left drill hole must be removed.

Figure 33: Starting model

Figure 34: Result

Page 32 of 44 KN 15 : 2005-02-14

Figure 35: Incorrect

Figure 36: Correct

The geometrical result is the same in both cases. The number of operations is different. 8.5.11.4 Execution of geometry modifications directly on the primitive If geometries alter subsequently, then these must be altered directly at the primitive within the CSG tree. The primitive does not have to be released from the CSG tree to do so. If the alteration is carried out using the sketcher, then the subsequent operations dependent on the primitive (contextual features) such as fillets, drafts and thickness remain.

Figure 37: Starting model

Figure 38: Result

Figure 39: Incorrect An additional primitive with the missing geometries (Prism 2) is created and inserted in the tree.

Figure 40: Correct In Prism 1 the creation contour is modified using the sketcher.

Page 33 of 44 KN 15 : 2005-02-14 8.5.11.5 Structuring using the Solide/Transfor function The Solide | Transfor function replaces work with details. Duplicated geometries are automatically adjusted with alteration of the starting solid and the CSG tree becomes smaller and clearer:

Figure 41: Starting model

Figure 42: Result

8.5.12 Update capability: Every model must be updateable -> Force Update must run without errors. Solids should always have a history. Solids without histories, i.e. created directly from a volume, are to be avoided. Deletion of all design elements no longer needed (e.g. planes, points,...). Deletion of all unnecessary primitives from the CSG tree. Conversion of smart solids into unsmart solids. Execute SOLID-UPDATE. Switch SMART-SOLID to unsmart, then execute Force Update. SOLID must be convertible to a different geometry form (VOLUME; SURFACE etc.). SOLID must contain a history.

8.5.13 Model size:

8.5.14 Approval or archiving of SOLID data

Page 34 of 44 KN 15 : 2005-02-14

9 Drawing models
The drawing model contains the derived geometry from the 3D model as well as drawing elements (views, dimensioning). There is a differentiation between: Individual part drawing (EZ) Drawings of multi-model sessions (ZB)

Alteration captions are administered in the drawing frame from the preparation of drawings. If a 3D-model has already existed before the preparation of drawings (see 11.2.8), the preparation of drawings leads to a higher release level. Drawing created

AIX 000-004 changes to 3D The multi-model session model must either be given an overlay list or an EDB-Assembly structure must be stored in the EDB to the ZB data set.

Drawing and 3D model may not be altered independent of one another.

9.1 Structure of a drawing

Example drawings for the various drawing types are stored via the EDB. Drawing No. Title 82051203 82051204 82051321 82051521 82051641 Beispiel 1 CAD/CAM Gesetzeszeichnung Beispiel 2 CAD/CAM Explosionszeichnung Beispiel 3 CAD/CAM Lieferantenzeichnung Beispiel 4 CAD/CAM Entwicklungszeichnung Beispiel 5 CAD/CAM Serienzeichnung

Table 19: List of KEIPER example drawings Example drawings on geometrical tolerancing see KN 11-4. 9.1.1 Views In the case of thin-walled sheet part (face model) it is permissible to create only one component side (functional face for connecting pieces). Material thickness is shown in a sectional view or is stated in the drawing frame. Bolts and screws are drawn horizontally and always have their head left.. An indication to connecting pieces is effected on functional faces. Vehicles always drive to the left in drawings. If this is not clear due to the grid definition, then it must be marked.

9.1.2 Dimensioning Dimensioning is to be carried out according to DIN 406ff. All dimensions are provided with functionally required tolerances. Observe symmetrical tolerances.

Page 35 of 44 KN 15 : 2005-02-14 If necessary, show test dimensions. All other contours refer to the CAD model and the permitted deviation between face and trim is stated in the comment box (see comment box series drawing).

9.1.3 Drawing frame The left margin above the comment box remains free of views and dimensions to a sufficient width. The general tolerances according to DIN/ISO define the tolerances for the respective production process and the material. The weight table has to be completed. The design order number is entered in the amendment box Amendments are to be listed in detail in the amendment box. The version number is to be increased on phase change. If the amendment box has been completed then the text is deleted and the current version noted again at the top. The 3D model and the drawing must contain the data and information necessary for further processing (planning, cost calculation and production.

9.2 Developmental drawing

Requirement for simplified CAD drawing can be seen in VDA 4953 Part 1! A development drawing must be created at the start of component development.

Contents:
Drawing frame Drawing text box Amendment text box ISO view Material data General tolerances Dimensional tolerances The following information may be added for improved understanding: Material thickness Section Grid definition

9.3 Series drawing Contents:

Drawing frame Drawing text box Amendment text box

Views and sections required for manufacture An additional 1:1 view for enlarged main views

Reference system Toleranced dimensions Geometrical tolerancing Tolerances general Material information - observe TL Material thickness Surface finishing Functional dimensions with tolerance General tolerances The following information may be added for improved understanding: Further main views Sections Additional text box Grid definition

Page 36 of 44 KN 15 : 2005-02-14

9.4 TAB drawing model

TAB drawings are only drawings with an assembly-structure stored in the EDB resp. an overlay list of the TAB models stored in the model itself. Every TAB-model should have a 3D model (reflection is not modelled). Numbering system for TAB-models according to KN 200.

TAB-models are marked in CATIA model names with TM (macro: /m name). In every index increase of a part on the TAB drawing, the corresponding TAB-model TM must be versioned.

9.5 Explosion drawing model

Explosion drawings can be created via CATIA and using the 4D Navigator. The individual parts are administered via an overlay list or via EDB assembly in any case. The following procedure is recommended for the 4D Navigator: The individual parts are loaded via the overlay list. These are shown in their respective positions in the 4D Navigator as skins via VIEW | 4D NAVIGATOR ... . The positions of the individual parts are determined in space using "drag and drop". The individual parts with new positions are exported as passive models into CATIA. The view selected in the 4D navigator is also exported to CATIA, there a window is to be defined using it. The overlay list available there is thus updated and is to be saved.

If a ZB drawing exists, the explosion drawing is assigned; i.e. file number, version and variant are identical. They are differentiated by D1, D2 etc. in the CATIA model names.

9.6 Package model

The model contains the drawing and an assembly structure. Every component is marked with one colour in all views. In the case of moveable parts (e.g. height adjuster) kinematics must be created. The assembly structure of the package model then contains the corresponding kinematics model. Structuring with sets, see 7.2 (model structuring with SETS) Environment geometries (vehicle data, dummies etc.) are placed in their own layer. It is recommended that the geometries in space are cut and shown as transparencies in draw. Every structuring via layer must have its own defined filter.

9.7 Law drawing (typing drawing)

Law drawings are created according to customer specifications. They contain little detail information. No modifications may be carried out on the product unless approved by TV or the customer. Caution with multiple-use parts (e.g. seat 2000)

9.8 Supplier or spare part drawing

The supplier drawing is copied completely into a customer or KEIPER drawing frame.

9.9 Standard parts

KN 154 applies, except for catalogue goods. In this case, no drawing is to be created. For this you have to use the standard part form of EDB.

9.10 Drawing standards

9.10.1 Drafts The function DRAFT may not be used.

Page 37 of 44 KN 15 : 2005-02-14 9.10.2 Line thickness All drawing lettering and dimensioning is to be represented with 0.25 mm. Customer-specific requirements are to be taken from the standards of start models. 9.10.3 Text creation / character set Only the following font is permissible: EUDT_VCF

The font used in a CATIA model can be seen under the function TEXTD2.

German umlauts and special characters are not permissible. The two-letter substitute (ae, oe, ue) is to be used for , , . For vou have to use: Masse as weight and Masze as plural of Masz as dimension. 9.10.4 Dimensions and tolerances Geometry models must correspond exactly to the size of the product to be defined. Nominal dimensions must be in accordance with the geometry. Drawing dimensions state the final status of the part, including metallic surface protection. Drawing dimensions may be to a maximum of 3 decimal places and may be rounded depending on their tolerance scale.

Example :
Model dimension 15.368 15.368 15.368 Tolerance Drawing dimension 0.01 0.1 1 15.368 0.01 15.37 0.1 15.4 1

Drawing dimensions are always to be tolerated with the same upper and lower tolerance. One-sided tolerance are only permissible in the following cases: for all ISO fitting dimensions for all diameters, drill holes and parts which are formed by cores or pins in the tool etc., in so far as no form contours are suspended from them. for angle dimensions at shaping points of sheet parts. One-sided tolerance is only permissible in frame spring direction (Example see Figure 14). Functional test dimensions are to be marked according to the symbols of the drawing frame. Exception: (drawing adjustment on faulty part): If the original drawing tolerances are exceeded in a faulty part and it becomes necessary to document this excess in the drawing, then the following procedure is to be followed providing that the function is not affected: The nominal dimension (model dimension) may not be changed, the drawing tolerance is to be extended evenly according to if possible, if this is not possible then the tolerance can be extended in one direction, whereby the other direction must remain in the original position.

Example 1 :
Original dimension was Faulty part is General tolerance extension to Or one-sided tolerance extension to Original dimension was Faulty part is One-sided tolerance extension to 10 0.1 10 + 0.3 10 0.3 10 + 0.3 / - 0.1 is permissible. 10 0.1 10 + 0.3 10 +0 / + 0.3 or 10 + 0.1 / +0.3 is not permissible.

Example 2 :

Page 38 of 44 KN 15 : 2005-02-14

9.11 Material display

If a surface model is designed with only one side, then the information on material alignment and thickness is stored for every component in layer 115.

Figure 43: Display of material thicknesses on the part The material thickness is marked via a component section, plus 3D text (function TEXT | CREATE). The nondesigned side is marked as a dashed line. Alternatively, the material thickness is stated by a 3D arrow. The length of the arrow corresponds to 100 times the material thickness. If necessary, the removal direction is shown as a PLANE element with a line normal to the plane.

Page 39 of 44 KN 15 : 2005-02-14

10 ZB models
The structure of the ZB model in CATIA must be clarified before the project start. ZB models are always created in one of two ways:

EDB-Assembly or Overlay
MERGE or MODELS | COPY (please note paragraph 10.3)

10.1 Assembly
ZB structures are to be created using EDB-Assembly. This proceeding replaces the previous one with Overlay.

10.2 Overlay
The individual parts are temporarily loaded with the function:CATEDB5 | MODEL | OPEN | ADD PASSIVE. The ZB structure must be saved with the macro /m ovl. After approval, the position of the CATIA model in the CATIA-FILEs (WORK -> AKTUELL; AKTUELL -> ARCHIV) changes automatically. These changes are automatically included in the data structure of the OVL macro via /m syncovl. Work with the macro /m ovl is the basis for all work with passive models and ZB structures or various positions of components at KEIPER. The data volume here is the lowest and it can be ensured that the current status is only ever loaded. Work with MERGE is only permissible in exceptional circumstances. Loading of the draw environment for additionally loaded models via the option OPTIONS | DRAFTING ON/OFF is suppressed via FILE | OPEN

Several multi-model-sessions created with overlay are loaded together and saved to a new overlay model (interleaved overlay structures).

Kinematics models are created with overlay. The models are allocated to the kinematics sets with the function KINEMUSE | ATTACH.

In the case of Keiper's own "Know-how parts" a check is to be made whether the individual part drawing from ZB models is to be deleted after dispatch for reasons of secrecy. In this case, the box S = SPACE in the EDB data exchange form is to be completed.

10.3 MERGE
The CATIA elements are copied into the model with the merge function. This function is only to be used if customer or supplier require identical data, but do not have the overlay macro. The amendment administration of these models is very complicated.

Page 40 of 44 KN 15 : 2005-02-14

11 Model release
Model release is effected in the database CADIM/EDB. The following points have to be taken into consideration before the audit step 1130 (techn. audited). Work Instruction KQ040K01 is to be observed (in preparation). KN 11-3 is to be observed. An overview of possible release status is located in CADIM/EDB under:

CATIA | Info | Pruefablauf Catiamodelle 11.1 K.O. criteria

11.1.1 CATCLEAN Call up is effected with /cln. The program "cleans up" model-internal errors in the data structure. KEIPER models may not have any CATCLEAN errors. KEIPER models have to be checked with the Qchecker (current KEIPER profile) Recommended settings for working with /CLN : Type CAT 1 CAT 2 CAT 3 FMT Setting LAYER 254 MODIFY PACK ALL

Elements with errors in category 1 must firstly be moved to the special layer 254, analysed and replaced by newly generated elements. Elements with errors in categories 2 and 3 are "cleaned during the run. A repeat run is sometimes necessary. KEIPER models have to be checked with the Qchecker and achieve the test status OK.

11.1.2 KEIPER start model Only data based on the KEIPER start model and the KEIPER project environment are accepted in KEIPER projects. In customer projects, the current customer start model of the project (OEM) always applies. The KEIPER start model as well as the customer start model are subject to the amendment service and are versioned and approved. 11.1.3 SOLIDs unsmart and updated Supply and approval status for solids is the mode UNSMART. Solids has to be updated in this mode. Furthermore the capability to be updated using FORCE UPDATE has to be granted. 11.1.4 Skin capability In the case of an unclosed face model, there must be a skin available which contains all FACEs. Thus has to be creatable completely and without any errors at any time with the function LIMIT2 | SKIN | CREATE. If the face model is closed, a volume resp. SOLID has to be created. Gaps greater than 0.02 mm (Tolerance for IDENTICAL CURVES) are not permissible. When using CURVE1 | BOUNDARY on the skin, only curves at the edge of the skin may arise. If curves arise within the skin then there are gaps. The direction of the skin normal lines has to be the direction of the material.

Page 41 of 44 KN 15 : 2005-02-14 11.1.5 Mathematical technical data quality The designer is responsible for the quality of CAD-data he produces. Newly created models have to be checked with VDA-checker using standard DB-MIN. The models may not contain errors. Checking is done using multi select SPC+DRW-*SOL. Newly created models are all non released parts or assemblies that have release level 000 after this standard is established. After Q-Checker is established the agreed checking-profile has to be used. Recognized errors referring to the models history should be fixed during a re-design, it the effort is reasonable.

11.2 Model organisation

11.2.1 Layer assignment The KEIPER layer assignment is to be observed. 11.2.2 SHOW / NO SHOW To be released, the geometry used for the creation of the space elements has to be in NO SHOW. In SHOW youll only find describing geometry. (Especially important for components) Example: A component is created using SOLIDE. The solid is shown in SHOW. All geometry used for the creation of the solid, like curves, points, planes, sewing-faces, skins and volumes, is to be found in NO SHOW. 11.2.3 PICK / NO PICK No geometry may be in NO PICK when a model is released. 11.2.4 Element limits All elements (lines, surfaces etc.) are to be explicitly limited to the dimension necessary. 11.2.5 Reorganisation of elements Execute the function IDENTIFY | RENUMBER | ELEMENT | AUTO ID or IDENTIFY | UPDATE | YES: ACCEPT. 11.2.6 Display modes (NHR, HRD, HLR, SHD) In CATIA model geometry can be shown shaded or the hidden edges can be removed. In the case of problems with shaded display, the graphic fine adjustment (discretisation) must be increased with the function GRAPHIC | MOD VISU | CHOOSE | DISCRETN (SAG-value) and the elements set to CURRENT MODE SENSITIVE. To avoid display problems with assembly resp. overlay, all face and solid elements must be saved in CURRENT MODE SENSITIVE with the function: GRAPHIC | MOD VISU. All surfaces may only be stored in NHR (NON HIDDENLINE REMOVAL) mode. It is possible to convert shaded models into a plot file (e.g. Tiff) by using Capture (ALT K); XV, SCREEN GRAB and CATPOV. After this they can be used for PC applications. 11.2.7 Storage status If a drawing is available, then it is stored so that the entire drawing is visible on call up of the model. If there is only a 3D model, the entire 3D portion should be visible after repeated loading. The models may only be saved in NHR mode in order to reduce waiting time on re-loading.

Page 42 of 44 KN 15 : 2005-02-14 11.2.8 Comment Additional information on the model can be saved in the comment. Information which is not documented in a drawing or in the EDB, is documented in the model comment (e.g. 3D model without drawing). As long as there is no drawing existing for a 3D model, the legend of alterations is documented in the comment.

The comment is part of the CATIA model and is sent in CATIA native format during data transfer.

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11.3 Release status

Element Active window Active workspace Active layer filter Active draft Active axis system Active layer Active image mode Active view Draw/Space button Qchecker Table 20: Release status Setting WI FREIGABE (geometry in 3D or complete drawing) Workspace MASTER ALL BLATT 001 AXIS1 Layer 000 NHR (No Hiddenline Removal) RAHMEN If a model contains a drawing, button is in position DR. If a model contains geometrie, button is in position SP. Test status OK

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12 Observance of CAD/CAM guidelines

In principle, there is the following differentiation:

Internal KEIPER projects Projects on commission by the customer (respective OEM)

In order to save costs, the customer requirements and KEIPER guidelines on CAD/CAM are to be brought into use prior to project start and measures must be initiated for the observance of these requirements and guidelines. This particularly includes all suppliers of CATIA data being obliged to observe the KEIPER or customer requirements. For observance of the CAD guideline the Achecker with the latest KEIPER test profile has to be used! Only models classified by the Qchecker as OK may be released.

12.1 KEIPER projects

In the case of KEIPER internal projects, the KN 15 guidelines for data quality and model organisation of CATIA models to be supplied and created are to be observed. Generally, no deviations from the standards specified in KN 15 are permissible. Such deviations mean additional work in design and must thus be additionally calculated or offered. Every designer is obliged to maintain this standard in his work with CATIA that is on receipt of models, to check these and to take remedial measures on non-observance.

12.2 Customer projects

In the case of customer projects, our customers' (OEM) specified guidelines or CAD/CAM manuals apply. In this case no deviations are permissible. Every designer is obliged to maintain this standard in his work with CATIA that is on receipt of models, to check these and to take remedial measures on non-observance. Before dispatch of models to customer, a check is to be made that their standards have been observed. Customer requirements which deviate from the CAD/CAM manual are accessible via the ITIntranet site.

Bilateral agreements between the customer's contact person and KEIPER are not permitted. In any case, ICT is to be notified. Agreements may only be implemented together with ICT.