PRINCIPLES OF ENGINEERING 3

PRO/ENGINEER TUTORIAL 1 – TOY CAR

Objective:
Create a small, simple toy car that demonstrates the basic features
and assembly procedures of Pro/Engineer Wildfire 3.0 Schools
Edition (Pro/E).

Overview:
As you work through this tutorial, you will create four parts that involve three basic functions of any
parametric program. Once these are created to specifications you will assemble the parts, and do a
simple rendering to complete the car. As you start, note the following:

Terminology Used in This Tutorial:

Left-click Press and release the left-hand mouse button
Right-click Press and release the right-hand mouse button
Middle-click Press and release the middle mouse button
Left-drag Press and hold-down the left-hand mouse button and move the mouse
Middle-drag Press and hold-down the middle mouse button and move the mouse

Grading:
5 pts files named correctly & saved in right place
10 pts body complete with all features & accurate dimensions
5 pts axle complete with all features & accurate dimensions
10 pts wheel complete with all features & accurate dimensions
10 pts driver complete with all features & accurate dimensions
20 pts assembled car complete with all features & accurate dimensions
Task 1: Getting Started

1. Create a new folder inside your personal folder on the

"users" drive and give it the name "toy_car".

2. Start Pro/E.

3. In the Navigator Window (down the left-hand side of

Pro/E), browse to the “toy_car” folder you just created.
If the Navigator is not displaying Folders left-click the
Folder tab at the top Navigator Window.

4. Right-click the “toy_car” folder, and in the menu that

appears select Set Working Directory.

Note: you need to set the Working Directory every time you start up Pro/E.

5. Left-click the File menu, then left-click on New. You will see the window
at right. A model in Pro/E is made up of parts, which are then put together
into an assembly. You will create the parts first – the body, axle, wheel, and
driver of your toy car. For "Type", select Part. You will be creating the body
of the toy car first, so change the Name to "body". Then left-click on OK.

6. Your screen will change to look like the one below right with the 3 "Datum
Planes" as shown. Datum Planes are reference planes that you use to
draw sketches of the parts of your model. One of the basic processes in
Pro/E is to create a 2D sketch on a Datum Plane, and
then turn the 2D sketch into a three dimensional
shape. The Datum Planes refer to the standard
orthometric views of an object – the front view, the top
view, and the right view. You should always try to
draw the actual front view of your model on the
FRONT Datum Plane.
Task 2: Extruding a Part (the car body)

1. To make the body of the toy car, you are going to do an extrusion. This basically involves taking a
flat, 2D sketch and thickening it or extending it into a 3D shape.

2. left-click on the Extrude tool. You can find the Extrude tool (shown at right) on a toolbar
along the right side of the Pro/E main window.

3. When you click on the Extrude tool, it may not look like anything has changed, but if you look along
the bottom of the Pro/E window, you can see what is called the "dashboard" for the Extrude
command:

4. You don't see the main view change, because Pro/E is waiting for you to provide it the information it
needs to create the extruded shape. The first information it needs is highlighted in red – it needs to
know which datum plane you want to draw your 2D sketch on. Left-click on the red Placement
menu on the dashboard.

5. You will now see the menu at right open up. In this case, Pro/E
is showing you what it wants next by a red dot. The item it
wants you to define is the datum plane you will be sketching
on. Left-click on the Define... button.

6. Now you will see a Sketch window pop up, as shown at right. To start
sketching, you need to tell Pro/E what plane you want to sketch on, and
also what orientation you want to use (which way you want to look at the
plane as you draw on it). Left-click on the FRONT datum plane. Notice
that now the Sketch Plane box says "FRONT", the Reference box says
"RIGHT", and the Orientation box says Right. These settings are fine
for us, so left-click on the Sketch button at the bottom of the Sketch
Window.

7. Pro/E now changes the main window to a Sketching window, as shown below right, and the tools
along the right side change into tools for drawing sketches. It also re-orients the view so you are
looking straight down onto the FRONT datum plane that you chose for your sketch.

8. To start the sketch, left-click on the Line tool from the toolbar on the right of the
screen.
9. Draw a straight horizontal line on the screen, as shown at
right. Left-click somewhere along the dotted line labeled
"TOP". Then left-click again somewhere to the right. If
you position the cursor reasonably level as you draw,
Pro/E will assume you want a horizontal line, and will draw
it that way. Pro/E even shows you this by showing a letter
"H" above the line, so you know it will make the line exactly
horizontal, even if you don't draw it exact.

10. To end the line you drew, middle-click, and then middle-
click again to get out of the Line drawing command. You will
see the line, and also a couple of dimensions showing the
length of the line and how far from the origin the line begins.
These dimensions are not the correct ones for the toy car
you want, but you don't need to worry about that now – you can change them later.

11. The line you just drew is the bottom of the toy car, which is, of course, flat. Now you need to
draw a curved line that will have the shape of the front, top, and back of the toy car. One way
you can draw curved lines is using a Spline tool. Left-click on the Spline tool in the
sketching tool bar.

12. Left-click on the left end of the line you just drew. If you
hold the cursor close enough to the end of the line, Pro/E
will assume you want to start at the end of the line. To
make the curved line you want, click on points along the
line, and Pro/E will curve the line so it fits all the points.
Continue clicking points until you have created a profile
of a car, like the one shown at right. Your last point
should be on the other end of the first line you drew. When you are done, middle-click twice to exit the
Spline command.

13. If you don’t like the spline that you drew, you can left-click once on the line, and then hit the [delete]
key on the keyboard to delete it. If you just want to modify the spline, you can left-click on a point of
the sketch once to highlight it, then left-click a second time and hold and drag it to a new locations until
you have the sketch that you like.

14. When you are satisfied with the whole sketch, left-click on the blue check mark on the
sketching tool bar. Once you do this, if you have a “valid” sketch, you will be taken back to
the main window, where you will see the extrusion of your sketch.

15. At first look, your car body still appears to be a

2D sketch. But that is because you are still
viewing it looking straight at the Front Datum
Plane. If you middle-drag, and move the
cursor around, you will see the body rotate so
you can see it in 3D from different angles.
16. While you have finished the sketch, the extrude is not finished. You can tell this because you
can still see the extrude dashboard at the bottom of the window, and because the extrude is
colored yellow. To complete the extrude, left-click on the green check mark in the
dashboard. The extrude command will be completed and you will see your part colored gray.

17. At some point you may need to reposition your part in the window. You can zoom in or out on the part
by rolling the scroll wheel. Try this now. You can move the part around in the window by holding down
the [Shift] key and then middle-drag the sketch to where you want it. Try this now.

18. SAVE YOUR WORK! (FILE menu, select SAVE, then select OK).
Task 3: Modifying Dimensions of a Part (the car body)

1. To the left of the part view window is a list called the Model Tree
(shown at right). The Model Tree is very useful for reviewing and
changing the features of a part or assembly. Once a part is started,
the Model Tree reflects automatically any construction that is done
on the part. It shows the name of the part, the coordinate system,
the datum planes, and the features of the part. The only feature
that our car body has at this point is the extrude you just
completed.

2. The car body that you have created is far too large for a toy – several hundred inches long and wide.
You need to change this to match the actual size of the toy car that you want to end up with. To do
this, move your cursor to the Extrude listed in the Model Tree and
left-click on the PLUS SIGN to the left of it. This will show the
Sketch that was used to create the Extrusion. Right-click on the
name of the sketch, and in the “pop-up” window, move the cursor
down to the “Edit Definition” choice and left-click, as shown at
right. This will reopen your Sketch.

3. Your sketch of the car body will open back up. There are two dimensions listed on the sketch, as you
noted before. You want to change these dimensions. Start with the dimension showing the distance
betyouen the origin and the end of
the straight line. If you double left-
click on the dimension, it will
change to a text box where you can
change it. Change it to 4.00, then hit
[Enter] on the keyboard to accept
the change. Notice that Pro/E
automatically resizes your sketch
and zooms in or out to fit the sketch
to the window.

4. Change the dimension of the entire line to 8. Then left-click the blue check mark to accept your
changes.

5. Your model now looks very different because the size of the sketch
has changed, but the Extrusion has not. Your Extrusion may not look
like the one at right, but whatever it looks like, you will correct it next.

6. Move the cursor to the Extrude in the Model Tree and right-click. In the pop-up window, move the cursor
down to the “Edit Definition” choice and left-click. This will open the
dashboard across the bottom of the screen like you had when you first
started the extrusion.
7. The extrusion thickness or width is shown in the
dashboard (at right). Left-click on it and change it to
2.5 inches and press [Enter]. Then left-click the Green
Check mark in the loyour right of the screen to accept
the change. You may need to adjust the view to see the car fully.

8. SAVE YOUR WORK!

Task 4: Adding Through Holes to a Part (the car body)

1. The next feature will be the addition of holes in the body of the car to provide a place for the axles and
wheels. A hole is treated like an extrusion, but instead of adding material, material is taken away.

2. left-click on the Extrude tool. In the dashboard, left-click on the red Placement menu. Then left-
click on the Define button. This will open the Sketch Placement window. Left-click on the FRONT
Datum Plane. You are going to draw the holes on the same plane that you drew the original body
sketch, so you know they will be lined up correctly with the body. Finally, left-click on the Sketch
button in the Sketch Placement window.

3. You now see your body sketch in 2D again, but this time
the sketch is gray shaded to show the completed
extrusion of the body. The Sketch Tools are again
available on the right of the screen.

4. left-click on the Circle tool. To draw a circle, you left-click at the center
point of the circle first, then left-click at the edge of the circle. Draw a
circle near the front of the car. Then move the cursor horizontally toward
the back of the car. You should see a small red “dash” indicating that
you are horizontal to the 1st location (see upper picture at right). Left-click and
draw the 2nd circle. Watch for an R1 to appear before you finish the 2nd circle –
this indicates that it is the same size as the 1st circle (see loyour picture at right).

5. Move your view over to the first circle and zoom in on it. ([Shift] and middle-click
to move the sketch around, Roll the Wheel to zoom in or out.) Go to the 1st circle and change it to a
diameter of 0.25 inches and make it 0.25 inches from the bottom. (Double left-click on a dimension
to change it, then [Enter] to accept the change.) Set the distance betyouen the tires to whatever
looks good to you. Remember that you can change it later.

6. left-click the blue check mark to accept the sketch, and then middle-drag the cursor slightly to see
your model in 3D.

7. To complete the holes, you must make the following changes in the Dashboard before you
end the Extrude command. Left-click on the Remove Material Button. Set the extrusion
width to 2.6 inches. (It's OK for the hole to be wider than the car – material will only be
removed where the body intersects the holes.) Then complete the extrusion - left-
click on the green check mark.

8. Rotate the part around (middle-drag the cursor) to be sure the holes go all the way through the car
body.

9. SAVE YOUR WORK! You have completed your first part! The body part should look something like
this:
Task 5: Extruding a Part (the axle)

1. The next part that you need is an axle. You are going to construct it as a separate part, not as
another feature of the body. You will use an extrusion to create the axle. Since you made the axle
holes 0.25 inches in diameter, you will make the axle diameter slightly smaller, at 0.24 inches.

2. Steps to make the axle:

 File > New > Part > Name the part "axle" > left-click on OK.
 left-click on the Extrude tool.
 left-click on Placement > Define.
 left-click on the FRONT Datum Plane > Sketch.
 Draw a circle and Double left-click on the diameter and change
it to 0.24 inches. (Center the circle on the origin.)
 left-click on the blue check mark.
 Change the extrusion width in the dashboard to 3.25 inches.
 left-click the green check mark to build the part. Middle-drag
the cursor to rotate the part to be sure it worked!

3. SAVE YOUR WORK! The axle is complete, and should look like the
one shown at right.
Task 6: Revolving a Part (the wheel)

1. The wheel will be another separate part. You could use extrusions to make the wheel, but instead
you are going to use a different feature called a “Revolve”. Basically this involves creating two
sketches on the same plane, a Sketch and an Axis of rotation. The sketch will be half of the shape
that you are interested in. The Axis will be the line that you want to rotate the sketch around.

2. Steps to get ready to sketch the wheel:

 File > New > Part > Name the part "wheel" > left-click on OK.
 left-click on the Revolve tool.
 left-click on Placement > Define.
 left-click on the FRONT Datum Plane > Sketch..

3. The first thing you will sketch is the axis of rotation for the Revolve,
which is shown using a special line called a "centerline". Look at the
Line tool on the right tool bar. There is a caret symbol (small black
triangle) next to it. Left-click on this caret to open up other types of lines you can draw. Left-click on
the last one, which draws a centerline.

4. left-click on the horizontal axis (the one labeled TOP), and

then left-click again somewhere else on the same axis.
This will create a centerline that is horizontal across the
center of the screen. It will appear red in the display (the
axes are orange). middle-click twice to exit the centerline
command. This will be the axis of rotation. (Centerlines are
lines used only for reference – they do not represent any
actual lines or edges on the finished part.)

5. left-click on the Rectangle tool and draw a rectangle

below the centerline similar to the one shown at right.
middle-click twice to exit the rectangle command.

6. Change the dimensions on the rectangle as follows (double left-click on a

dimension to edit it, then [Enter]):
 0.12 inches from the top of the rectangle to the centerline
 rectangle width 0.35 inches
 rectangle length 0.75 inches.

7. Complete the sketch (left-click on the.blue check mark). Rotate the view
to see a preview of the wheel. If it looks OK, left-click on the green check
mark to complete the Revolve. The completed wheel should look like the
one shown below.

8. SAVE YOUR WORK!

Task 7: Shelling Out a Part (the wheel)

1. Now you're going to make your wheel look a little more realistic, by giving it rims. The first thing you
need to do is remove material from the inside of the wheel. You could do this with an extrude where
you remove material, like you did with the axle holes on the body, but there is another way, called a
Shell command. The Shell command removes material from the inside of an object up to within a
distance you set.

2. left-click on the Shell tool to the right of the screen

3. left-click on one face of the wheel. In the dashboard, change the

thickness to 0.125 inches. Then left-click on the green check mark to
accept the command. Your wheel should now look like that shown at the
right.

4. SAVE YOUR WORK!

Task 8: Adding a Rib to a Part (the wheel)

1. Now you're going to add ribs to your wheel so it looks more like a tire with rims.

2. left-click on the Rib tool.

3. left-click on the red References menu in the dashboard. Then left-click on the Define button. This
opens the Sketch Placement window, just like with an Extrude or Revolve command. Left-click on
the TOP datum plane. The view will rotate around so you are looking at the wheel from the side.

4. To sketch a rib, you need to be able to see the inner parts of the wheel,
which you cannot see now because Pro/E is showing a solid 3D view
of the wheel. But you can change that view to a see-through one. Left-
click on the Hidden Line tool up in the main toolbar below the menus
(shown by the arrow in the picture at right). The view of the wheel will
change to the one shown at right. The dark lines show edges of the wheel that you
would normally see. The fainter lines show edges of the wheel that would normally be
hidden in this view.

5. Before you can sketch the rib, you also need some
reference lines – lines Pro/E can use to match up our new
sketch lines to the existing edges of the wheel. Left-click
on the Sketch Menu, then on References. This will open a
small References window in the upper right. You don't need to do
anything with this window, just select the lines on the wheel that you
want to use for reference lines. Left-click on the two lines shown by
the arrow in the pictures at right. They will become balck & white dashed
lines, showing that they are now reference lines. Then left-click on the
Close button in the References window to complete the Sketch
References command.

6. Now you are ready to draw the rib. You only need to draw the top edge of the
rib – Pro/E will fill in from the line you draw down to the surfaces of the wheel.
You can make the rib any shape you would like, using the Line tool, the Spline
tool, or both – it just needs to run from top edge to top edge of the two
reference lines you just drew, as shown at right. Draw this now.

7. left-click the blue check mark to finish the sketch.

8. To see the rib, you need to switch back to a solid 3D view.

Left-click on the Shading Tool to do this.
9. It's possible that you won't see the rib on the wheel. If so, this is because your sketch was oriented
the wrong way. To fix it, left-click on the References menu in the dashboard, and then left-click on
the Flip button. You should now see your rib previewed in the main
window. There is one more thing to do – set the thickness of the rib. You
do this just like setting the thickness of an extrusion – type in the thickness
you want in the dashboard. Do this now. Then left-click on the green
check mark to accept the command. Your wheel should now look like that
shown at the right.

10. SAVE YOUR WORK!

Task 9: Repeating a Feature in a Pattern (the wheel)

1. You could repeat the steps above to add additional ribs to your wheel, but if all of
the ribs are going to be identical, Pro/E has an easier way to do it, using a Pattern
command.

2. left-click on the Rib listed in the Model Tree to highlight it, as shown at right.
When you do this, additional tools become available in the toolbar along the right
of the main window.

3. left-click on the Pattern tool. This will open a dashboard across the bottom of the main
window. Just like with the Extrude and Revolve commands, Pro/E now needs information
from you in order to create the pattern.

4. In the dashboard, left-click on the drop-down menu that currently says

Dimension, and select Axis instead. This means we want the pattern to be
repeated in a circle around an axis.

5. Now you need to select the axis of the wheel as the axis for the pattern. This
axis is not currently visible. Left-click on the Datum axes tool in the main
toolbar. Then left-click on the axis labeled A2 in the main window to select it as
the pattern axis.

6. Now you need to decide how many ribs you want. The default is 4, but you can
change it to anything you'd like (but keep in mind, if you make it too big, the ribs will
overlap each other). Make this change now.

7. You want the ribs to go all the way around the wheel, so left-click on the Angle button to
tell Pro/E to spread the pattern around the axis a full 360º.

8. Pro/E does not show you a full preview of the pattern, but it does show black dots to indicate where
each of the repeated ribs will appear. Make adjustments until you happy with the pattern, then left-
click on the green check mark to complete the Pattern command.

9. Your wheel should now look like that shown at the right. If you want or
need to change anything, remember you can left-click on the Rib, its
Sketch, or the Pattern and select Edit Definition to make changes.

10. SAVE YOUR WORK!

Task 10: Rounding the Edges on a Part (the wheel)

1. Now you're going to round off the sharp corners on your wheel to make it even more realistic.

2. To round the edges of the wheel, left-click on the Round tool in the right-side toolbar, and
then left-click on the edge that you want to round off. In the dashboard enter 0.0625 inches
for the radius of the rounded edge. Then left-click on the green check mark to finish the Round
command.

3. Round off all the edges shown at right

(highlighted in red). These are all the
edges of the tire part of the wheel. Give
them all the same rounding radius of
0.0625 inches. Do not round off any
edges except for the ones shown.

4. Your wheel should now look like the one

shown below right.
Your wheel is now
complete.

5. SAVE YOUR WORK!

Task 11: Adding Partial Holes to a Part (the body)

1. Let’s suppose that you also need a “driver” for the car. This will require two other operations, one to
create the driver and the other to create the place in the car to put the driver.

2. First, you will put the “seat” in the car. All you have to do is create a circle on a new datum plane on
the Body part, that will be placed above the existing TOP Datum Plane, then place a sketched circle in
the appropriate position, and extrude it so that it removes material and leaves a shallow hole for the
driver.

3. If your Body part is still open, switch to it by selecting it from the taskbar.
Before you can change anything, you will need to activate it. Left-click
on the Window menu, then left-click on Activate. If your Body part is
not already open, open it (File > Open).

4. left-click on the Datum Plane tool, the one under the Sketch
tool. You will see the pop-up window at right which will allow
you to create a new datum plane.

5. left-click on the TOP Datum Plane in the main window and enter 1.5 in
the Translation box. On the screen you will see the new datum in
yellow, above the Top plane. Rotate your body to be sure that 1.5 is
high enough so the new datum plane is above the car body, not cutting
through it. If it isn't high enough, make the Translation value larger.

6. left-click on the OK button in the Datum Plane window and the yellow plane will show as red and be
labeled DTM1.

7. left-click on the Extrude tool. Left-click on the Placement menu in the dashboard, then left-click
on the Define button, then left-click on the newly created DTM1 Datum Plane. The main window
will switch to Sketch mode and the car will reposition as if you are looking down perpendicular to
DTM1.

8. Sketch a circle where you want the driver to sit.. Edit the diameter of the circle to 0.75 inches and
then finish the sketch.

9. You will see a preview of the extrude. First be sure the extrude is going down into the car. If
it is not, left-click on the Change Depth Direction button in the dashboard.

10. You want this to be a hole, not a solid piece of material, so left-click on the Remove
Material button in the dashboard.

11. Adjust the depth of the hole so it only goes into the body about ¼ inch. Rotate the
body around to a side view so you can see this clearly.

12. Finish the extrude. Your car body should now

look something like this:

13. SAVE YOUR WORK!

Task 12: Making a Complicated Revolve (the driver)

1. Now to design the driver. You will use the Revolve command to create the driver, but the sketch that
you will revolve is a little more complicated this time.

2. Steps to get ready to sketch the driver:

 File > New > Part > Name the part "driver" > left-click on OK.
 Left-click on the Revolve tool.
 Left-click on Placement > Define.
 Left-click on the RIGHT Datum Plane > Sketch.

3. Draw a vertical centerline aligned with the Datum Plane.

4. Draw a circle with its center along the vertical centerline.

5. Draw a horizontal line out from the centerline to the right.

6. Draw a second line straight up from the end of the first line.

7. Connect the end of the second line to the center of the circle. Your
drawing so far should look like the drawing at right.

8. There are unnecessary lines on this drawing – all you want is the outline of
the driver. You will need to trim off parts of the circle and the third line you
drew to make the drawing look like the lower drawing at right.

(a) Left-click on the Dynamically Trim Section Entities tool.

(b) Click on the parts you want to trim away. As you hold the cursor
over a line, the part that will be trimmed will turn blue. Left-click to trim off
that part.

(c) Middle-click when you are done trimming to end the command. Your
drawing should now look like the drawing at right.

9. To set the height of the driver, you will need to add a dimension. First, draw a line from the
bottom of the driver to the top. Then left-click on the Create Defining Dimension tool.
Left-click on the line you just drew. It will turn red. Middle-click to the left of this line – a
dimension will be created showing the length of the line. Middle-click again to exit the Create
Dimension command.
10. Change the dimensions to those as shown at right:

 head circle radius – 0.25 inches.

 total height – 1.25 inches.

 base height – 0.25 inches.

 base width – 0.375 inches.

11. End the sketch.

12. End the revolve. Your driver should

look like this:

13. SAVE YOUR WORK.

Task 13: Assembling Parts (making the car)

1. Now you have all the parts that you need to make the toy car – you just need to put them together.
Pro/E allows you to put parts together into what is called an "Assembly”.

2. To start the assembly, select FILE > NEW just like you did before, but instead of creating a part,
select Assembly. Name the file "car", and left-click on OK.

3. The toolbar on the right has changed to new tools that are used in making and modifying
assemblies. The one you need to use now will add a part to your assembly. Left-click on
the Add Component tool. This will open a window that shows a list of all the parts you
have made. Left-click on the body part and left-click on the Open button.

4. You should see the body of

the car in yellow. Along the
bottom of the screen, a new
dashboard has opened
(bordered in red on the
picture at right), which will
allow you to position your
body part where you want
it. As you continue, it will
be important that you use
several of the options that
are available in the
dashboard.

5. Each part you add to an assembly needs to be oriented relative to the other parts – this is called
"constraining" the parts. The dashboard shows you if a part has been properly oriented, or
constrained, where it says "STATUS" (circled in blue above). If the Status says "No Constraints", then
your part has not been correctly constrained. If it has been correctly oriented, the Status will say
"Fully Constrained".

6. Since the body is the first part you have added to the assembly, you can fully
constrain it by fixing it in place. To do this, left-click on the drop-down menu that
currently says "Automatic", and left-click on Fix. You will see that the Status
changes to "Fully Constrained". Left-click on the green check mark to finish
adding the body to the assembly. The color of the car body should change to
standard gray.

7. Now you will add the driver to the car. Left-click on the Add Component tool
again, but this time left-click on the driver part and left-click on the Open
button.

8. The driver will be yellow, showing that is it the part you are
working on – the screen should look something like the one
at right. You will orient the driver relative to the body. When
you first add a part, Pro/E goes into automatic constraint
mode, which means if you select two surfaces on two
different parts, Pro/E will try to figure out how to orient them
to each other automatically.
9. First, zoom in on the driver. (Scroll
wheel to zoom in or out; MMB to rotate
the view; [Shift] +MMB to move the view
left/right or up/down.) You're going to
line up the base of the driver with the
hole in the body that you made for the
driver. First, just move the cursor
around over the driver. As you move it
around, you should see different
surfaces highlighted in blue. Left-click
when the curved side of the driver's
base is highlighted (as shown at right).
The surface will turn red and it will have
an "Automatic" label.

10. The next surface you select will be

matched up to the surface you
selected on the driver. Zoom and
move the view around until you can
clearly see the driver's hole in the car
body. Move the cursor around as
before, and left-click when the
curved side of the hole is
highlighted (as shown at right).
Pro/E will assume you want to insert
the driver into the hole, and it will line them up that way, creating an
"Insert" constraint. But the driver may not actually be in the hole – it
may be above it, below it, or even partly overlapping the car body.
If you look at the Status, it will say "Partially Constrained". You
need one more constraint to fully match the driver up to the body.

11. The second constraint will be to match up the bottom

of the hole with the bottom of the driver. Move the
cursor around the hole, and left-click when the
bottom of the hole is highlighted. Then rotate the
view and move the cursor around the driver, and left-
click when the bottom of the driver is highlighted.
Pro/E will assume you want these two surfaces to
touch each other, creating a "Mate" constraint. The
driver is now fully constrained, and you can
left-click on the green check mark to finish
adding the driver to the assembly.

12. SAVE YOUR WORK! Your assembly should

now
look
like
this:
13. Now you will add the axles. Left-click on the Add Component tool again, and select the axle part.

14. The axle is probably not very close to the car body. You can zoom the view around to it, like you did
for the driver, but you can also move just the axle in the view window. Hold down the [Control] and
[Alt] keys, and right-drag the cursor. As you move the cursor, you will see the
Axle move. Move the axle close to one of the axle holes, and then release.
Zoom in on the axle and hole.

15. One feature of Pro/E is that you can orient parts so that they are free to move,
just like they would in the real assembly. In this case, you are going to constrain
the axle so it fits into the axle hole, but it can still spin around like a real axle
would.

16. left-click on the drop-down menu that currently says User-Defined, then left-
click on Pin (as shown at right). This will allow you to pin the axle into the axle
hole while still allowing it to spin.

17. Move the cursor

around over the axle
hole. Left-click when
the inside surface of
the hole is
highlighted in blue. It
will change to red, and
it will say "Axis
alignment". Then
move the cursor
around over the axle,
and left-click when
the outside surface of
the axle is highlighted. This will line up the axle with the hole.

18. The axle is probably sticking out too far on one

side, or may not even be in the hole at all.
That is because you need one more
constraint, to line up the end of the axle with
the side of the body. Left-click on the end of
the axle. It will turn yellow and say
"Translation". Then left-click on the side of
the car body. This will line up the end of the axle with the side
of the car. The only problem is we need the axle to stick out a
little, so we can attach a wheel to it. You can modify the
constraint you just made to do this. First left-click on the
Specify Constraint Alignments drop-down menu in the
dashboard, and select the Offset alignment. Then enter an
offset value of 0.375 inches in the text box next to it. This will
make the axle stick out 0.375 inches. The Status should now
say "Connection Definition Complete". This is called a "connection" instead of a
"constraint" because some motion is allowed between the parts. Left-click the green check mark to
finish adding this axle to the car.
19. Pro/E allows you to add the same part into an
assembly multiple times. To get the second axle
onto you car, just repeat the procedure on the
previous page. Your assembly should look like the
picture at right.

20. SAVE YOUR WORK!!

21. You will attach a wheel to an axle much like you

attached the driver to the body:
 left-click on the Add Component tool, and select the wheel part.
 left-click on the inside surface of the hole in the wheel, then left-click on the outside surface
of an exposed axle. This will align the hole in the wheel with the axle using an Insert constraint.
 left-click on the front surface of the wheel, and left-click on the end of
the axle. Depending on which way the wheel is facing, Pro/E will either try
to Mate these two surfaces (next to each other facing opposite ways) or
Align these two surfaces (next each other facing the same way). You
want the constraint to be Align, not Mate. If Pro/E chooses Mate, left-
click on the Mate drop-down menu and left-click on Align.
 left-click the green check mark to finish adding this wheel to the car.

22. Now you can do something to see the effect of pinning the axle
into the body instead of constraining it there. Left-click on the
Drag Packaged Components tool in the toolbar across the
top of the main window. Then left-click on the edge of the
wheel. You can now drag the cursor around the screen, and
the wheel and axle will spin! middle-click three times to exit this command. Toward the end of this
project, you will learn how to attach a "motor" to the axle so that it spins automatically.

23. Add the other three wheels the same

way you added the first one. (Once
you have added both wheels to an
axle, you can drag one wheel around,
and the other one will spin with it).
Your car should now look like this:

24. SAVE YOUR WORK!!

Task 14: Adding Color to an Assembly

1. Now to add color. No mention was made of different colors for the
different parts, but no one really likes the overall “gray” tone of the
assembly.

2. This is a good opportunity to introduce the concept of “parametric”

feature-based programs like Pro/E. The basic idea is that if you make
changes to a part, and that part is also in an assembly or drawing, then
the assembly or drawing will update automatically to reflect the changes
made.

3. Start with the car body. Open the body part.

4. In the main menu across the top of the screen, left-click on View >
Color and Appearance. The window at right will open.

5. left-click on a color shown in the top window. Then left-click on the

body part in the main window. Then left-click on the Apply button.
The body part will change to the color you have selected.

6. You can modify the appearance of the color you have selected using
the slider bars in the bottom half of the window. You can also modify
the color itself if you left-click on the color rectangle, and then adjust the
RGB slider bars in the window that opens. Make whatever adjustments
you like until you have the body looking the way you want it to. Then
left-click on the Close button in the Appearance window.

7. SAVE YOUR PART.

8. The changes you made to the body part have automatically updated
the assembly as well, which you can see if you left-click on Window >
car.asm to bring up the assembly window (if your assembly is not
open, open it instead).

9. Use this same procedure to color each of the parts. Note: when you
switch windows to a part that is already open, you must left-click on Window > Activate before you can
do any editing of that part.

10. Keep in mind that as you color a part that is repeated in an assembly, the update will then be reflected
in all the copies of that part (i.e. the axles and the wheels). If you change one wheel to black, all of
them in the assembly will be black – you don't have to color each wheel individually.

11. If all of this worked, your display should look something like
this:

12. SAVE YOUR WORK.

Task 15: Animating Your Car

1. Now you're going to animate the axles, so your car will look like it's cruising along. Switch to and
activate the car assembly window if you're not already looking at it. (Or open the assembly if it's not
already open.) Then left-click on the Applications Menu and then left-click on Mechanism. This
switches Pro/E to a different mode, which allows you to set motions for parts in an assembly. Note
that the tool bar along the right has changed.

2. You are going to attach a motor to each axle so they spin. Since you attached the wheels
to the axles, the wheels will spin with the axles. Left-click on the Define Servo Motor tool
in the toolbar at the right of the screen.

3. The Servo Motor Definition window at right opens, as well as the smaller
window below it that says "Select 1 Item". The item Pro/E is waiting for you
to select is the "Motion Axis", which is the axis that the spinning object will
rotate around. Motion axes are determined by how you assembled your
parts – parts that were assembled in ways that allow them to spin were
given motion axes. For your car, you only did this for the
axles, so you should see two motion axes labeled on your car,
as shown at right. Left-click on one of these Motion Axes.

4. The motor is now connected to the axle, but you must tell it how fast you
want it to spin. Left-click on the Profile tab in the Servo Motor Definition
window. The window will change to that shown at right. Left-click on the
Position drop-down menu and change it to Velocity. Where it says
"Magnitude", change the value of A from 0 to 90. This will make the
wheel rotate 90 degrees per second. Then left-click on the OK button.

5. You won't see the axle immediately begin to spin – you

will need to create an animation to do that. But first
you need to attach a motor to the other axle. Repeat
the steps above to do this. If you have attached a
motor correctly to each axle, you will see this orange
symbol on the Motion Axis for each axle:

6. To animate the motors, left-click on the Define Analysis tool. This will open up a
window on the right. All you need to do is left-click on the Run button. You will see your
car's wheels spin as Pro/E creates a series of snapshots of your car with the wheels at
different positions. When it is done, if you want to see the car from a different view, rotate
it around and run it again. For example, if you flip the car around, you will be able to see that the
wheels on both sides of the car are spinning. When you have the view you want, and you have run it
once, left-click on the OK button.
7. You can save your animation as a movie file. Left-click on the Replay Previously Run
Analyses tool. In the Playbacks window that opens, left-click on the Play Current
Result Set button (it looks the same as the tool shown at right). In the Animate window
that opens, left-click on the Capture button. You can use all of the default settings shown for the
movie – just left-click on the OK button. Pro/E may take a couple minutes to create the movie.
When it is done, you can run Windows Media Player and watch the movie – it will be in your toy car
folder.

8. Close all the side windows in Pro/E, and then SAVE YOUR WORK.
Task 16: EXTRA CREDIT (as time allows)

Here are some other things you can do if you get done early.

 You can use the Round Tool to smooth out the edges of
the Car Body. In the event that the rounds do not work,
you may need to go back to the original sketch of the Car
Body and change the areas that are too sharp for a round.

 Create one or more of the following additional parts, and add them to the car assembly (you may
need to add additional holes to the car body to attach some of these parts):

o an antenna
o a spoiler
o tailpipes
o headlights
o give the driver some hair, a hat