Abstract: The disclosed simulation environment, methods, and system support simultaneous design and analysis of assemblies with unified computer aided design (CAD) and finite element analysis (FEA). The system provides a simulation environment that is unified with the architecture of the assembly environment, which significantly reduces the amount of time it takes to set up structural simulations as compared to prior simulation tools. The system enables CAD designers to obtain accurate mechanical guidance such as strength and rigidity early and often in the design process, seeing the structural impact of CAD modifications at the sketch, part, and configuration level. Such guidance can be particularly helpful when CAD engineers are determining product fit and form, defining dimensions, and shaping the overall weight and volume of designs.

Abstract: A self-diagnosing resistance welding cable and method for monitoring the relative increase in cable resistance while a cable is in use, without disconnecting the cable. The cable incorporates a reference resistor in one of the terminals in thermal communication with the cable, such that a comparison in resistance variation between the cable and reference resistor cancels the effects of temperature variation on resistance change. The reference resistor is connected in series with the cable in an electrical test circuit. The test data is sampled each time the welding machine is cycled, and the data is updated and processed by a computer on a continuous basis. The system also monitors the actual temperature of the cable and the flow of coolant through the cable. Multiplexer circuits are used to monitor multiple welding cables with the same computer.