Mechanical Design

1. Software-specifications for preparing the basic 3D digital twin of product

1.1. Ability to create parametric planar sketches and curve-based product definitions in 3D space
1.2. Solid Modeling and surfacing features to include extrude, revolve, sweeps, lofts, mesh of
curves and blends supporting up to G3 continuity. Underlying sketches and curves can be
fully-, partly- on un-constrained.
1.3. Math-engine & Expressions must include capability to create formulae, rules, inter-part
expressions, nested loops and conditionals, read-write from/to external spreadsheets and
standard engineering formulae.
1.4. Built-in Material Tables should include a basic set of standard materials and support easy
definition of new materials as well as import / export of material definitions in bulk using
XML files.
1.5. Capability in the solid modeling environment to directly edit 3D models that may or may not
have any feature history. Intelligence in the software to preserve design intent of 3D parts
when faces are dynamically dragged for re-orienting and re-positioning.
1.6. Provision to create driving dimensions directly on features or faces
1.7. Intelligence in the software to automatically select groups of faces that appear as generic
engineering features like bosses, ribs, holes, pockets, slots, etc.
1.8. On selection of one face, software should have built-in intelligence to automatically select all
tangential, coaxial, coplanar, symmetric or offset faces or faces that resemble engineering
features like bosses, ribs, holes, pockets, slots, etc to edit all in unison.
1.9. Design re-use & automation capabilities should include the ability to define parametric
template parts & assemblies driven by their own customized dialog-boxes with bitmap
image, pull-down values, upper-lower limits for part-sizes, etc., using a completely code-free
environment.
1.10. Ability to model standard straight-brake sheet metal features flanges, jogs, bends, various
types of corner and treatments thereof, etc. as well as standard form-features like dimples,
louvres, gussets, beads, etc.
1.11. Ability to create flattened 2D profiles and 3D shapes of straight break features.
1.12. Advanced sheet metal features should support flattening of flanges along curved edges and
joggles.
1.13. Ability to create flat-profiles of complex sheet-metal parts using FEM analysis and provide
estimates for stress, strain, thinning, etc for formability analysis.
1.14. Capability for creating 3D assemblies using both top-down and bottom-up approaches.
1.15. Ability to define positional and geometric constraints between parts and subassemblies and
easily manage complex hierarchy of relationships of very large assemblies.
1.16. Support for handling very large assemblies by allowing the user to selectively control loading
and display of components. Ability to selectively load assembly representations at various
levels of details to optimize hardware performance and user-experience.
1.17. Capability to check interferences and clearances between different sets of components, set
exceptions beforehand, isolate and study the interferences in detail and save the results as a
report. Support even lightweight / facet representations of components for quick study.
1.18. Capability for associative inter-part modeling so that geometric entities of one part can be
linked to another part and even complex network of links can be managed through a
dedicated user interface.
1.19. Capability to define assembly/disassembly or motion sequences by defining components’
start and end positions and report any collision with other bodies arising out of such motion.

Reverse Engineering & Styling

 1.20. Capability to iteratively assess the optimal path to extract a component by avoiding collision
with neighboring parts for serviceability and manufacturability analyses. Provision for
reporting the same as motion-envelope solid-body representation.
1.21. Capability to analyze weights data of a complete assembly by simple click of a button, report
it in textual format or in a spreadsheet and store the computed weights data of all
components during file-save
1.22. Advanced surfacing
1.23. Styling and reverse engineering should include capabilities for processing facet data, curve
and surface fitting operations and techniques to minutely edit both freeform shapes and
underlying mathematics (knots, degree/order, etc.)
1.24. Ability to perform subdivision modeling for building curvature-continuous styled shapes
quickly.
1.25. Availability of surface analysis tools like curvature plots, reflection studies, deviation &
continuity checks, etc.
1.26. Dynamic & photorealistic rendering abilities for product visualization in 3D environment with
high-definition background images, shadows and lightings, floor reflections and a library of
materials having different reflective & glossiness properties.
1.27. Availability of a library of standard 2D cross-sections and 3D electrical components for
designing electrical cables, wires, shields, dressings, etc. and connectors, conduits, terminal
boards, junctions boxes, supports & u-bolts, etc. respectively. The libraries should be
configurable and pre-populated.
1.28. Ability to create a routing path in context of a 3D assembly and break it in to multiple paths
or join them together to define wire harnesses.
1.29. Ability to define and edit different types of insulations, sleeves, space reservations, etc.
1.30. Define wire-paths associatively in context of the assembly components so that changes in the
position of the referenced parts should trigger a re-routing of the affected path.
1.31. Ability to interpret connection and wiring-details from text / XML reports of Electrical-CAD
software and show each individual end-to-end connection on-screen in the context of the 3D
assembly.
1.32. Ability to interpret the ECAD logical attributes, like wire-gauge, cable type, color, etc., in
building the 3D harness and guide the user in case any wrong connection has been made.
1.33. Ability to define the logical connections, in case ECAD information is not available
1.34. Ability to validate the harness based on configurable design-rules. Validation against these
rules should be automatically triggered on-the-fly as the designer builds or edits the routing
assembly.
1.35. Software should have an ability to export the logical connection details with the length
information in different file formats like ASCII, XML and PLMXML.
1.36. Capability to create flattened 2D representations of the 3D harness and create associative
Formboard drawing basis the user’s preferred layout
1.37. Full-fledged 2D drafting capabilities including support for various types of annotations labels
and balloons, section and detailed views, orthographic and projected views, multi-sheet
drawings, rendered views, parts lists, etc.

2. Specifications for attaching systems engineering definition to 3D digital twin of product

 2.1. Ability to build interlinked systems engineering models (Requirement model, Functional model
and Logical model).
2.2. Ability to collaboratively define and document the R-F-L characteristics assigned to a machine
concept.
2.3. Ability to create concept consisting of mechanical elements and associate them with the
functional or logical model elements.

3. Mechatronics concept
3.1. Ability to apply physical properties such as rigid / collision body, transport surface, object
source / sink, spring damper, Force / torque to elements.
3.2. Ability to create various joints such as Hinge, Sliding, Cylindrical, Screw, Planar, Ball, Fixed,
Spring, Curve on Curve, Point on Curve, Chain between the elements.
3.3. Software should provide functionalities to create various actuators such as Speed and Position
controls, Hydraulic & Pneumatic.
3.4. Software should automatically create position actuators and motion controls using target
positions as the driving parameters.
3.5. Ability to process runtime feedback to define event-based behavior.
3.6. Ability to define various sensors and relays to mechatronic system.
3.7. Ability to define different types of couplings such as cams (both mechanical & electronic),
gears, rack & pinion, pulleys & belt.
3.8. Capability to design the logical behavior of the machine including time-based as well as event-
based conditional operations.
3.9. Capability to convert operations to sequential function logic.
3.10. Software should display the operations in the system and their sequence in a navigator like a
Gantt chart
3.11. Ability to simulate i.e. animate, visualize and evaluate the motion based on the defined
operations with time scale option to play the simulation in slow motion or speed it up.
3.12. Ability to export device list for use in ECAD systems
3.13. Ability to export motor profiles to select drivers from SIZER catalog
3.14. Ability to use variables and formulas to control the physics properties of elements.
3.15. Ability to create, modify, export and import profiles for coupled motions like cam profiles.

4. Detailed mechatronics definition to 3D digital twin of product

4.1. Software should have functionalities to replace rough geometries created during the concept
stage with detailed geometries. These replacements should allow the automatic updating of
mass properties and collision shape properties.
4.2. Software should provide the functionality to reuse mechatronic definitions of subsystems in
the context of a higher-level assembly.
4.3. Software should support reuse of mechatronics knowledge, the reusable components should
contain multi-disciplinary data such as kinematics/ physics, 3D data, Functions, Sensors /
Actuators, Cams / Gears and Operations.
4.4. Software should have provision to import the machine / component details in neutral format
such as IGES, STEP, PARASOLID from other CAD platforms if required.
ELECTRICAL DESIGN
 4.5. Software should allow running of simultaneous simulations of different subsystems in
different windows.
4.6. Software should allow to monitor the runtime parameters of selected objects in simulation
and manage simulation recordings.
4.7. Software should have functionalities to analyze and report the behavior of the detailed
machine design – measure, graph and record various kinematic parameters like speeds,
accelerations, inertia forces, etc. of selected objects during simulation.
4.8. Software should have the ability to store a specific positional arrangement of the kinematic
model at a specific snapshot of time during simulation for detailed study.
4.9. Ability to display an envelope of all the positions of a rigid body during a simulation for
collision detection.
4.10. Ability to export the mechatronics logical model to ECAD softwares like EPLAN P8 using a
configured reference designation structure which can be mapped to the device aspect
designation structure of ECAD.
4.11. Ability to import electrical device-list from ECAD into logical models.
4.12. Ability to import electrical devices from EPLAN P8 into the logical model of Mechatronics
Concept Designer
4.13. Ability to export and import cam profiles for SCOUT integration
4.14. Ability to export load curves to SIZER and import selected drive components from it
4.15. Ability to encapsulate runtime formulas and define boolean, integer, and double-word signals
to connect to an external signal, such as an OPC server signal.

5. Specifications for connecting a mechatronics model to external controllers for

virtual commissioning of the 3D digital twin of product
5.1. Ability to create and export signals based on the runtime parameters referenced by
operations. The signal data should include name, I/O type, data type, address, initial value
and comments
5.2. Ability to use the tags to read and write physical properties.
5.3. Ability to recognize external signals from physical or virtual controllers through various
protocols such as MATLAB, OPC DA, OPC UA, PLCSIM Adv, Profinet, SHM, TCP and UDP.
5.4. Ability to allow easy mapping of external signals to the internal mechatronic definitions in the
digital twin of product.
5.5. Software should allow easy switching between using the original physics object values in the
simulation and the external signal connections.
5.6. Software should allow to monitor the runtime parameters of selected objects during virtual
commissioning and allow recording of the motion.
5.7. Software should have functionalities to analyze and report the behavior of the digital twin –
measure, graph and record various kinematic parameters like speeds, accelerations, inertia
forces, etc. of selected objects during simulation.
5.8. Software should have the ability to store a specific positional arrangement of the kinematic
model at a specific snapshot of time during simulation for detailed study.
5.9. Ability to display an envelope of all the positions of a rigid body during a simulation for
collision detection.
6. Robotics simulation to the 3D digital twin for part-manufacturing applications
(CAM)
6.1. CAM application should be integrated or associated with CAD such that any changes in
CAD model will reflect in CAM software and re-importing of CAD geometry is not required.
Also for change in CAD model, CAM software should Notify programmer that programs
are out of date with CAD model and allow for Automatic Regeneration of programs.
6.2. CAD software should be able to import standard data translation formats like (STEP, STP,
IGES, Parasolid, JT, STL etc and also standard CAD file formats like PROE (.prt), Catia
(.catpart), Nx (.prt) etc
6.3. Software vendor should also provide CAD software for Parametric Solid Modeling, Direct
Modeling and Advanced Surfacing capability. CAD software should be able to create
assembly models for Fixture design and Drafting for shop drawing. CAD software should
be from same Software vendor and not from third party vendor.
6.4. Feature Based Machining which automatically identifies features & Creates Complete
programs with appropriate tool selection from Library, also within the same software and
User Interface.
6.5. CAM Software should be able to analyze Draft, Minimum Radius, and Undercuts from
model and be able to remove undercuts within the CAM software. CAM software should
be able to patch or delete holes within a single option for Milling.
6.6. CAM software should be able to program Wire EDM, Turning, Feature Based Machining,
Milling of 3axis, 5axis and Advanced Mill-turn machines in Single software and User
Interface. CAM software should be able to machine on Solid, Surface and Facet data
models.
6.7. On Machine Inspection program generation using Renishaw Probe should also be possible
within the same Software & User interface. CAM software should be able to program 5axis
inspection.
6.8. Same CAM software should also be able to output DMIS 5.1 compliant program code for
CMM within the same user interface.
6.9. CAM software should have facility to build Post processor for all Milling, Turning and WIRE
EDM machines through a simple User Interface. The Postprocessor creation user interface
should allow for selection of type of machine, controller (Fanuc, Siemens, Heidenhain
etc.), configuration of machine (2.5-5axes) etc. and create postprocessor automatically.
6.10. CAM Software should have Tool Library which can store Tool information such as Tool
Type Tool Geometric Definition, Tool Material, Tool Feed & Speed based on Part Material
Machined & Tool Feed & Speed based on Process (Roughing, Semi-finishing, Finishing)
6.11. CAM Software should be able to verify Programs through Gouge check, Holder collision
Check, 3D Simulation & Machine Simulation within the same User Interface. Machine
Simulation should be based on G-code simulation, i.e. it should Simulate G-Code of
programs. Machine simulation should also be able to simulate programs created
externally or manually using controller MDI.
6.12. CAM Software should have Integrated Verification and Machine Simulation and not use
any external third-party software for the same. Integrated Verification and Machine
simulation should be capable of handling turning machines, 3 - 5 axis milling machines
(orthogonal & Non-orthogonal machines) & Mill-turn machines with multi channels.
6.13. Cam Software should support time-based program operation Synchronization of
machining channels in Mill-Turn machines.
 6.14. CAM Software should also support Tombstone Machining within the same User Interface.
6.15. CAM Software should be easy to use and be able to adjust User Interface based on level of
user, such that it improves productivity of beginner and advanced user.
6.16. CAM Software should be able to create Templates or Macros for automation of milling
and Turning Programming.
6.17. CAM Software should be able to create Shop Documentation for machining programs with
all relevant machining information like Tool Definition, Holder Definition, Feeds & Speeds
Cutting and Non-Cutting Air time etc.
6.18. CAM software should have inbuilt tutorials to train programmer on software.
6.19. CAM Software should support automation using programming languages.
6.20. A single intuitive look and feel for Robotics Programming
6.21. Software should Supports robots from many vendors like Fanuc, ABB, KUKA, Siemens,
Yaskawa, Staubli, Kawasaki etc.
6.22. Ability to Articulated six-axis robot with support for external axes, such as positioner and
rails
6.23. Ability to define 3D kinematic assembly modeling to define heads, holders, positioners,
rails and other robotic peripherals
6.24. Ability to check Static and dynamic analysis of collisions, reachability and singularities
6.25. Ability to define Robotics rules control tool orientation, robot configuration, start and end
poses, robot motion along rail and positioner behavior and OLP commands.

7. Specifications for virtual reality software for the

3D digital twin
7.1. VR environment should support shaded rendering
7.2. Ability to display a floor grid composed of X-Y axes, with the Z-axis as the up vector
7.3. Allow navigation throughout the entire VR environment instead of just in the area of the
model
7.4. Ability to translate and move toward, away, side to side, and around the model, as well as
elevate up and down, scale, and rotate.
7.5. Ability to explore the model using real-world movements, such as walking, looking around,
moving in strides and teleporting across the VR environment using the controller
hardware
7.6. Ability to select objects using a virtual laser pointer for visualizing them better by hiding or
isolating them
7.7. Ability to view component and part attributes
7.8. Ability to rotate, scale, or translate the viewpoint in the model and change visibility
controls
7.9. Ability to create measurements using a virtual ruler.
7.10. Ability to save a VR state of the model as a Snapshot that can be used to quickly revert to
in the VR session
7.11. Ability to create section plane through the model by pointing the controller and pressing
the trigger.
7.12. Should be compatible with HTC VIVE™ VR hardware (including headset, a link box, 2 hand
controllers, one for each hand and 2 base stations)