Another Take on Decals

by Jason Baggett, Rheem Manufacturing Co. A/C Division 

Following up on John Randazzo’s tips for using decals (Fall 2004 issue), this article describes another approach to enhancing the realism of your Pro/ENGINEER^® models. By structuring Pro/E’s hidden capability to create labels, you can incorporate a representation of an actual finished product in your parts and assemblies. In addition to being flexible, intuitive, and natural, this technique also overcomes several problems related to the application of decals to an end product.

Here are a few things you need to do before you get started.

Setting Pro/ENGINEER Operating Parameters

In order for Pro/ENGINEER to understand what you are doing, you need to define the system option config.pro. You should set this up right away so that you have no problems locating the information source once you begin the procedure. This option is the hidden key to success.

In Wildfire™ 1.0, access the config.pro settings under the pull-down menu Tools, Options. The setting to add is the highlighted text in Figure 1.

Figure 1

The option texture_search_path allows you to assign a directory to access images for label application. This option maps the storage location drive that will be needed on all subsequent operations. The Value in the Options window will be the location where the images are stored. I suggest that this location should be a secure environment that’s not easily accessed by unauthorized users. By adding this option, you’re not only giving intelligence to the part with graphics, but also enabling Pro/ENGINEER to recognize target artwork.

Creating the Label Graphics

Before continuing, you need to decide how you want to create the artwork. The two methods I’ve found that work are to use a quality graphics program or to scan an existing graphic. Whichever approach you take, the end result should be a graphic file with a TIF extension. While more labor-intensive, the graphics program may give a better image. Scanning is faster but it creates a larger file size and more distortion when the image is closely examined.

I use Adobe Illustrator^® to create my graphics. This program lets you create multi-colored images and text that can also be used for your label vendor. It also enables you to efficiently manage the artwork in a controlled environment. Saving the finished piece as a .tif file allows close zoom ratios without distortion while maintaining small file sizes. You can also edit the files using Illustrator, which you cannot do with the scanned image.

Label Name

When your artwork is done and you’re ready to save it, there is one major consideration. The file name of both the artwork and the Pro/ENGINEER part have to be the same. This is mandatory when the label is mapped to the Pro/E part. This process looks for similarity by naming convention. If it’s not an exact match, Pro/ENGINEER will not remember the location or file and you will have to reapply the image each time you open. This takes care of the intuitive aspect of this procedure. Because of the name commonality, Pro/ENGINEER creates a relationship so that once this part is mated with the image, it will appear everywhere that part is found.

Label Sizing and Geometry

Both artwork and Pro/ENGINEER data can be made to the exact size that they are to appear. By doing this, you are creating realism for your product with actual geometry. The label can be easily maneuvered to cover the surface of the part. When you place the image, you can do it on a flat surface or any nonplanar surface. While the mechanics of placing / sizing a graphic may vary, the final product should be the same.

Once you have a label file and have set the Pro/ENGINEER parameters, create a part file that has the exact dimensions as your label. You need not be concerned about label geometry. The label can be placed on the part file no matter whether it’s a circle, square or other shape. All you have to do is maneuver the image to fit properly in the Colors and Appearance area.

Procedure

Applying the label is relatively simple. Before proceeding, investigate the procedure and become acquainted with all the functions and instructions. This will allow you to apply correct placement settings for the graphics.

It is easiest to have the solid part oriented to the front. This places the surface that will have the label facing you. In Pro/ENGINEER:

1.     Create a new solid part named the same as the label (Figure 2).

2.     Part thickness needs to reflect actual material thickness of the label.

3.     From the View pulldown menu, select the Color and Appearances option. This opens the Appearance Editor.

4.     Add a new color to the Appearance Editor.

Figure 2

5.     Under the Map tab on the Appearance Editor (Figure 3), check the (white) toggle box opposite “Decal” and then click in the preview box just to the left of the toggle box. This maps the label graphics file and opens the Appearance Placement dialog box (Figure 4).

Figure 3

Figure 4

6.     Add the label texture by clicking the “+” on the Appearance Placement dialog box (top right).

7.     This opens a file selection dialog box. Navigate to where the graphic images are stored, select the desired image, and click the open button

8.     The .tif file is now attached and ready to be placed on the part surface.

9.     Highlight the graphic image and then, from the Appearance Placement dialog box, start applying constraints to label positioning.

A.    Set the Mapping constraint to Planar for a one-sided application.

B.    Set the Copies constraint Single.

10.   Close the Appearance Placement dialog box, which returns you to the Appearance Editor (Figure 5).

11.   Under Assignment, select Surface from the pulldown menu.

12.   Select the surface to which the graphic should be applied. Accept this surface by pressing the middle mouse button. With your desired surface assigned, click Apply.

Figure 5

13.    The label may come in perfectly the first time. Typically it will come into the surface where you have to maneuver it or adjust the sizing and placement. Don’t worry if you don’t see it— it’s there and just needs to be reoriented.

Figure 6

14.    Notice that the image has appeared to the right of the Decal area of the Appearance Placement dialog box. This confirms the decal is mapped.

15.    To adjust sizing and placement, click the preview box displaying your image. The Appearance Placement dialog box allows you to apply the correct placement settings for the graphics. Scale and Position may need the most work. Scale does exactly what it says: X scales left to right, and Y scales top to bottom. Position works the same way, moving the image up and down or left to right. The Rotate option may come in handy at some point during your practice or work.

16.   Once you are satisfied with the placement and sizing, simply close all dialog boxes and Save the part.

When the finished label is used in assemblies, it adds to the realism of the finished product (Figure 7). Note that this procedure lets you place the part in assemblies but not in drawings. I understand that a future release of Wildfire will address this issue.

Figure 7

Visualization

ProductView^® 7.0 has the capability of publishing textures by using the above method. By publishing the labels in ProductView, you will be able to mimic the actual end product. To publish the labeled parts, however, you will need an updated Object Adapter with the texture option.

1. Initial ProductView 7.0 setup depends on your individual situation. To publish the labeled parts and assemblies, you need to specify a setting in the rcpedit dialog box. Navigate to PTC/productview_adapters7.0\bin on your hard drive and drag the proe2pv.rcp onto rcpedit.exe. 

2. This opens the rcpedit dialog box. Under Advanced at the top, go to the Miscellaneous tab. At the bottom left you will see Convert. Check the box beside Textures and Save (Figure 8). Specific to your installation, you may have to alter other rcpedit options to acquire the end result of the published textures.

Figure 8

3. Now that the settings are established, you can publish Pro/E parts and assemblies that have textures. The task is no different than before, with exception of the new rcpedit option. Once the part and/or assembly have been published, you now have a realistic model of the actual product (Figure 9). This helps in visualizing end products with appropriate colors and placement.

Figure 9

By using this method and the part and texture naming convention, you also enable an exact Bill of Materials within both ProductView and Pro/ENGINEER.

Jason Baggett is a senior draftsman at Rheem Manufacturing Co. A/C Division in Fort Smith, Arkansas, USA. He can be reached by email at jbaggett@rheemac.com.