The Institute of Production Science at KIT focuses on application-oriented research of the production of tomorrow: from global, resilient production networks to the breathing factory with highly productive plants and innovative business models to quality assurance. Specifically, practical tools are developed for industry, which are then translated into entrepreneurial success.

BENTELER Group, a metal process specialist, produces safety-relevant products, systems, and services for the automotive, energy, and machinery industries worldwide.

BENTELER Automotive is a development partner of leading automotive manufacturers. With 19,000 employees and around 70 plants in over 20 countries, the division develops customized solutions: Components and modules for chassis, body, engine, and exhaust systems as well as innovative solutions for electric vehicles.

Automatic assembly and welding of a car axle from sheet metal parts

As part of a research project, an assembly line from BENTELER Automotive was to be analyzed. In this assembly line, a passenger car axle is assembled from sheet metal parts. The production of the sheet metal parts, i.e., pressing and punching, is not considered here; the focus is solely on the assembly and welding of the sheet metal parts.

The assembly line consists of 5 welding cells and one cell for laser cutting. The cells are connected by handling robots; the line also includes the supply of the sheet metal parts and the removal of the final product.

In each welding cell, a different number of sheet metal parts are welded into an assembly. This intermediate product is transferred to the following cell and then welded with further components to form a new assembly. With the help of rotary tables, processing, loading, and unloading partly take place simultaneously.

Assembly lines of such complexity cannot be planned manually

When planning such an assembly line, numerous requirements must be considered. The rotary tables and handling robots must be arranged in such a way that optimum accessibility is ensured, i.e., that the distances and thus the cycle times are as short as possible. Collisions must be avoided at all times. In addition, the processes must be coordinated in such a way that processing and loading/unloading can be carried out in parallel. Finally, the welding line must be supplied with the sheet metal parts and the end products must be removed.

In the past, such assembly lines were planned manually and with the help of Excel spreadsheets. However, such complex production systems cannot be modified or adapted in a short time; moreover, a realistic representation of the assembly line and its processes is missing.

To enable more precise planning of production systems and to reduce the time-to-market, it is necessary to use modern software for factory planning and simulation. The Institute of Production Science has chosen Visual Components for this purpose.

Professional software for factory planning and simulation

At Visual Components, we are proud to be recognized as one of the world’s leading providers of 3D factory design and simulation solutions. Our software includes an extensive library of predefined factory components, empowering planners to design, plan, and simulate production facilities efficiently. Users can create digital twins of everything from individual machines and production lines to entire factories. These digital twins are essential tools that facilitate meticulous planning, optimize production processes, and enable virtual commissioning, ensuring that our customers are well-prepared for real-world implementation.

Based in Espoo, Finland, our solutions have a global footprint and are utilized across a diverse range of industries, including industrial machinery, automotive, packaging, and logistics. Our software is available in various versions that cater not only to large corporations but also to smaller enterprises through both purchase and rental options. This flexibility helps businesses of all sizes leverage our advanced simulation capabilities.

Furthermore, we offer particularly attractive conditions for educational institutions, supporting the next generation of engineers and industry professionals in gaining hands-on experience with industry-leading simulation technology.

Numerous CAD interfaces and a comprehensive catalog of factory components

The models of the components to be welded can be imported into Visual Components in native CAD format or as JT or STEP files. The data of numerous robots from all leading manufacturers, including detailed kinematics, are available in the library, the eCatalog of Visual Components. In total, our eCatalog contains more than 3,000 predefined components, such as machines, conveyors, and racks which can be used out-of-the-box to create factory models. If a component should not be available in the eCatalog, e.g., a special robot gripper, it can simply be modeled in Visual Components, including its kinematic properties, and then used by any robot.

Visual Components very accurately represents the components and processes, including all details. BENTELER Automotive is enthusiastic about the many possibilities that Visual Components offers for factory planning.

Mr. Louis Schäfer, M.Sc., academic assistant at the Institute of Production Science

The stations can be linked as desired by simple drag-and-drop

All stations of the welding system were set up in Visual Components. The modular structure facilitates future modifications because new concepts of the welding system can easily be set up and quickly tested and optimized via simulation. It is also possible to extend the model into a digital twin after the physical welding line has been built. Such a digital twin behaves exactly like the real system. A digital twin saves a lot of time and costs in development, optimization, and commissioning.

Validation of robot programs in terms of reachability and axis values

According to Mr. Schäfer, the Institute of Production Science also intends to use Visual Components for the validation of robot programs in terms of reachability and axis values. The modularization allows new versions of the production line to be set up accurately in a short time. Other problems can also be solved via simulation, e.g., the identification of bottlenecks in the production flow or the evaluation of differences between automatic and manual handling. A digital twin is also being considered, i.e., the integration of real process data into the model.

In summary, Mr. Schäfer states that Visual Components offers enormous potential for a wide variety of simulation-related tasks. The user-friendly system allows a detailed analysis, as one can represent even very complex issues. In addition, working with Visual Components is a lot of fun. The user forum provides a lot of support: In case of questions, helpful solutions are quickly provided by the large user community.

About Visual Components

Founded by a team of simulation experts and amassing over 20 years in business, Visual Components is one of the pioneers of the 3D manufacturing simulation industry. The organization is a trusted technology partner to a number of leading brands, offering machine builders, system integrators, and manufacturers a simple, quick, and cost-effective solution to design and simulate production processes and offline robot programming (OLP) technology for fast, accurate, and error-free programming of industrial robots.

Want to learn more about the benefits of our solutions for your business? Contact us today!

The post BENTELER rolls out the production technology of tomorrow with the help of Visual Components appeared first on Visual Components.

Automobile manufacturers are outsourcing ever larger parts of their production to suppliers. Due to the increasing variety of models, suppliers are faced with the challenge of processing even smaller batch sizes efficiently and economically. Many manufacturers are turning to flexible manufacturing cells, which can process rapidly changing orders autonomously and produce parts such as transmission housings and steering knuckles around the clock, largely without personnel. They are complemented by measuring, assembly, and cleaning applications that complete the mechanical machining process.

FFG Europe & Americas unites major players from the German, Italian, Swiss and American machine tool industry with a broad range of milling, turning, grinding, and gear manufacturing technology, designs individual automation concepts and integrates machines with peripheral equipment for assembly or measurement. In this case study, we’ll show you how MAG’s Factory Automation department used Visual Components to design and optimize a flexible manufacturing system for unmanned or reduced-manning production.

Utilizing the eCatalog and reusable components for fast and accurate layout design

MAG’s first step was to create a layout of the cell, which requires careful precision with flexible manufacturing systems. It was crucial that all systems interlock seamlessly and that the entire material flow, from the delivery of the pallets to their onward transport to the next production station, takes place without any delay. This was especially challenging since different workpieces have different processing times.

Using a combination of custom components and components included in the eCatalog, MAG was able to model the cell with relatively little effort. For robot models, MAG utilized the Visual Components eCatalog, which contains more than 1,400 robots, including their kinematics, axis limits, accelerations and positional accuracy. For designing their custom components, MAG found the geometric and kinematic properties of their machine tools could be easily reused from existing CAD data.

Marcel Deess, Project Manager Digital Factory / Automation at MAG, who was responsible for the project, reported, “The CAD models of the workpieces in almost all cases are provided as 3D models, in STEP or IGES format or as native data. With Visual Components, there are no problems with importing CAD models. We also have experience with other simulation tools, but these seem much more complicated to us; people often think they come from the 80s. The Visual Components software, on the other hand, is very logical to use.”

The CAD models of the workpieces in almost all cases are provided as 3D models, in STEP or IGES format or as native data. With Visual Components, there are no problems with importing CAD models.

Marcel Deess, Project Manager Digital Factory / Automation at MAG

Validating the layout and workflow with simulation

Once the simulation model was created, MAG was able to dimension the length, height and position of the portal supporting the robot exactly in such a way that the robot could move to all desired positions within a short time, taking into account its axis limits, without collisions between robot, pallet, and machine.

MAG designed and optimized the arrangement and dimensions of the manufacturing system as well as the offline programming of the robot. MAG used Visual Components to simulate the entire production process and the smooth cooperation between AGV, robot, and machine tool. Utilizing the simulation model, non-productive times were minimized and issues such as robot accessibility and collision avoidance could be clarified.

Once the simulation model was completed, MAG exported a virtual reality model of the cell, as well as 3D PDFs and videos showing the simulated production process from all possible angles. They also used Visual Components to generate statistics and tables, as well as 2D drawings documenting the arrangement of the machine, robot and portal. Data for controlling the robot could also be transferred directly from Visual Components.

The completed cell

The cell MAG designed consisted of a SPECHT® 600 machining center and a KUKA Quantec robot equipped with a SIEMENS Vision MV 400 camera. There were also Autonomous Guided Vehicles (AGVs) transporting workpieces to and from the production system.

The workpieces are initially fed by intelligent, autonomous vehicles (KUKA KMP 1500), which supply the production system with the workpieces fixed on pallets in perfect timing and controlled by a manufacturing control system. These AGVs, which are controlled via WIFI, can move freely and without the need for conventional lane guidance or navigation elements. Using their laser scanners, the AGVs are able to avoid obstacles and achieve a positioning accuracy of just a few millimeters.

A KUKA Quantec robot with 6 axes is suspended overhead from a portal in front of the SPECHT® 600 machining center; a 7th axis, the linear axis along the portal, is also managed by the KR C4 controller. The robot is equipped with a SIEMENS Vision MV 400 camera, which enables the gripper of the robot to be positioned exactly with respect to the pallet with the workpiece. In this way, the robot can grip the workpiece pallets and feed them to the machining center with its pallet changer. The pallet changer then swivels 180° into the working area to load the machine tool.

In addition to loading and unloading the machine tool, the KUKA Quantec robot can perform tasks such as chip control, removal of chip pockets, and general cleaning tasks on the machined workpiece. The robot can also perform activities such as chamfering and deburring while the machine tool is already machining the next workpiece. And, with the camera attached to the robot arm, permanent quality control can be carried out with regard to the completeness of the holes drilled in the workpiece.

Winning more projects while saving time and money

When asked about the impact Visual Components had on this project, Marcel pointed out both the bottom line and selling benefits.

“In any case, because the simulation saved us a lot of time and money!” said Marcel.

“And, the simulation was not only very well received internally, e.g. by our sales department, but the customers are also enthusiastic when they can see “their” plant at an early planning stage. With Visual Components, they can for example change the position and parameters of a robot in order to optimize the system exactly according to their needs. This not only avoids costly planning errors, but also supports us in the quotation phase and helps us to sell more successfully.”

Because the project was so successful, it was also exhibited at the AMB 2018 trade show. In addition to the real manufacturing cell, the “digital twin” modeled with Visual Components, the simulation, and its results were presented on screens. Customers and trade show visitors liked the fact that process and system simulations ensure maximum transparency right from the planning phase.

With Visual Components, they can for example change the position and parameters of a robot in order to optimize the system exactly according to their needs. This not only avoids costly planning errors, but also supports us in the quotation phase and helps us to sell more successfully.

Marcel Deess, Project Manager Digital Factory / Automation at MAG

Using simulation to achieve flexible and intelligent production

MAG and Visual Components show how the production of the future can be closer to the customer, more flexible, and more intelligent. With Visual Components 3D manufacturing simulation software, the many parameters of a flexible manufacturing system can be adjusted for high total productivity, and decisive factors such as non-productive times, cycle times, layout topology, automation types, and machine up-time, can all be optimized.

About FFG Europe & Americas

FFG Europe & Americas unites major players from the German, Italian, Swiss and American machine tool industry with a broad range of milling, turning, grinding, and gear manufacturing technology, and the knowhow of the renowned machine tool brands VDF Boehringer, Hessapp, IMAS, Jobs, MAG, Meccanodora, Modul, Morara, Pfiffner, Rambaudi, Sachman, Sigma, SMS, Tacchella and Witzig & Frank.

At FFG, the activities of DIGITAL FACTORY and INDUSTRY 4.0 are combined in the new DIGITAL FRIENDS brand.

The post Optimizing flexible manufacturing systems with Visual Components at MAG appeared first on Visual Components.

In this case study, we’ll review a project they recently completed to drive sales of their lean manufacturing products, using the Visual Components Experience app.

About Virtual Manufacturing

“Our goal is to improve the customer’s production system,” explained William Falkenström, a consultant with the Assembly and Production Flow team at Virtual Manufacturing. “This can range from corporate cultural transformation to robotic simulation and programming.

The Swedish-based company employs about 70 workers and consists of four divisions: Industrial Management, Assembly & Production Flow, Robotics & Automation, and Lean Manufacturing Products (LMP).

Virtual Manufacturing uses simulation frequently in client engagements. Whether the project is to design a new robot cell or optimize a business process, 3D manufacturing simulation software plays an essential part in their consulting toolkit.

“We believe that in order to bring value in production, we need to be working in a 3D environment to increase understanding and communicate concepts,” said William.

Virtual Manufacturing doesn’t just use this technology for client engagements; they also use it to market their own solutions. William was recently involved in a project to improve communication and sales of shooter wagons, a product distributed by the LMP division. LMP, which manufactures and sells customer specific solutions for lean production systems, wanted the ability to present a 3D simulation of their shooter wagons from their mobile devices.

We believe that in order to bring value in production, we need to be working in a 3D environment to increase understanding and communicate concepts.

William Falkenström, Consultant with the Assembly and Production Flow team at Virtual Manufacturing

About the Project

William and his team were asked to create a simulation that demonstrated the functions and benefits of shooter wagons. It needed to be easy to understand and help their users – the LMP sales team – to communicate the benefits of this material handling solution to prospective customers.

Visual Components had just released Visual Components Experience, a mobile app that allows users to play, navigate, and explore simulations from their Android and iOS enabled devices. After an evaluation of the Visual Components Experience app, William and his team decided it met the needs of their users, and proceeded to create a demonstrator.

“Visual Components Experience makes it so much more fun and informative to show potential customers a 3D animation of the product, and how it moves and functions without building a real-world prototype,” said William. “It’s easy to create, show, and navigate the 3D animation, and it’s a very convenient alternative if you don’t have your laptop.

“Due to our experience in flow simulation and the capabilities of Visual Components, it was a no-brainer for us to use this software to create this product demonstrator.”

William and his team used Visual Components to create a demonstrator that showed the shooter wagons in a simple material-handling example.

Visual Components Experience makes it so much more fun and informative to show potential customers a 3D animation of the product, and how it moves and functions without building a real-world prototype. It’s easy to create, show, and navigate the 3D animation, and it’s a very convenient alternative if you don’t have your laptop.

William Falkenström, Consultant with the Assembly and Production Flow team at Virtual Manufacturing

About Shooter Wagons

Shooter wagons are a type of gravity-flow rack, combining storage and material handling in one system. They operate via a first-in, first-out racking order, meaning boxes move to the forefront only after the preceding one is removed. Shooter wagons are cost efficient and help companies to maximize space and efficiency while saving time, space, and manpower. They’re ideal for lean manufacturing environments and used in many applications, including material handling, storage, picking, and assembly lines.

Shooter wagons are a viable material handling solution based on several properties they exhibit:

• They’re easy to dock.
• They automatically pass off full boxes and receive empty boxes after docking.
• Compared to manual solutions, shooter wagons load and unload much faster.
• And lastly, these wagons are inexpensive and simple to maintain compared to pneumatic and electric systems.

Shooter wagons are a type of karakuri device, meaning they’re mechanically powered and don’t require electric, pneumatic, or hydraulic power to operate. They use gravity to process boxes.

“Shooter wagons are an ideal solution for any business looking to enhance productivity, improve workplace safety and save money,” explained William. “While they’re a simple and cost-effective solution, they’re not very well understood. This was a driving reason to use simulation, to show how they work.”

Due to our experience in flow simulation and the capabilities of Visual Components, it was a no-brainer for us to use this software to create this product demonstrator.

William Falkenström, Consultant with the Assembly and Production Flow team at Virtual Manufacturing

The Shooter Wagon Animation

To illustrate the functions and benefits of shooter wagons, William and his team created an animation to demonstrate the mechanics and ingenuity of the karakuri devices. The animation, which you can download here, demonstrates the shooter wagon concept in a simple material-handling example:

“In the demo, the material handler prepares the kit in boxes and places them on the gravity roller tracks on the top level of the shooter,” explained William. “These are basically angled tracks that allow the boxes to slide down using gravity.”

“When the shooter is full, it is transported to the production area, either manually or by an automated guided vehicle (AGV).”

At production, the shooter trolley is docked at the material shelf. Upon docking, the shooter automatically gives the prepared kit boxes to production while receiving empty ones. After the exchange, the shooter trolley goes back to the kitting area to be filled again.

In addition to demonstrating the concept, the animation provides a very detailed visualization of the inner workings of the shooter wagons.

“You’ll notice that when the boxes hit a mechanical stop, they’re waiting to be transported down a level,” said William. “The weight of a box at this mechanical stop is used to signal a raise of the tilt-elevator up one level. When the tilt is raised, it hits a mechanical switch, allowing the box to slide in. The weight of the box is heavier than the counterweight, and the tilt shifts downward.”

When the wagon comes together with the material shelf in production, a mechanical sprint is lifted, allowing boxes to flow between the gravity rollers of the shooter and the shelf. The exchange is performed automatically, using nothing but gravity.

Project Outcomes and Benefits

The LMP sales team now has a tool to more clearly and convincingly present the functions and benefits of shooter wagons. With the Visual Components Experience app, they have the ability to present interactive and 3D animations of their offerings, right from their mobile devices, wherever they are. They’ve since created more demonstrators, such as this palletizing animation, which show shooter wagons in difference contexts.

“It is helping LMP to profile itself as using market leading demo tools and technology,” said William. “This can be done during customer visits but also fairs, conferences, and trade shows. Other suppliers are opening catalogues and print brochures to showcase their products. LMP is now able to show a detailed animation of how the shooter wagons work in a manufacturing environment. It’s easy to see which method is more effective and impactful for the customer.”

The post Virtual Manufacturing Project Case Study: Driving Sales with 3D Simulation appeared first on Visual Components.