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Advanced Wire Forming & Sheet Metal Stamping Simulation Platform
  1. case
  2. Advanced Wire Forming & Sheet Metal Stamping Simulation Platform

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Advanced Wire Forming & Sheet Metal Stamping Simulation Platform

blackthorn-vision
Manufacturing
Industrial Automation
Information Technology

Current Production Challenges

The client faces challenges in efficiently designing, validating, and optimizing programs for their high-volume production machines. Traditional methods rely on costly trial-and-error on physical machines, leading to potential damage, downtime, and inaccurate productivity estimations. Complex wire bending calculations and the need to account for numerous parameters make program creation and modification time-consuming and prone to errors. Lack of a robust simulation environment hinders proactive identification and resolution of potential collisions and interferences.

About the Client

A well-established engineering firm specializing in the design and production of automated solutions for wire forming and sheet metal stamping, with a 50+ year history.

Project Goals

  • Develop a 3D simulation platform to accurately model the behavior of wire bending and sheet metal stamping machines.
  • Enable users to create, modify, and validate machine programs virtually, reducing reliance on physical machine testing.
  • Provide accurate estimations of machine productivity and cycle times at the design stage.
  • Implement automatic interference/collision detection and self-correction capabilities to minimize downtime.
  • Streamline the program creation process, making it more intuitive and efficient for operators.

System Functionality

  • Real-time 3D visualization of machine operation and production line processes.
  • Simulation of machining cycle times with user-defined speed parameters.
  • Library of pre-built components for rapid simulation setup.
  • Automatic interference and collision detection with diagnostic and correction guidance.
  • G-code generation from simulated program grids.
  • Intuitive user interface with flexible controls, undo/redo functionality, and customizable data views.
  • Data import/export capabilities for seamless communication with machine HMIs.
  • Accurate wire bending calculations based on geometric parameters.
  • Program feasibility validation through simulation of machine parts and tools.

Technology Stack

.NET Core
C#
WPF
Telerik UI Controls
Open Cascade Technology (OCCT)

System Integrations

  • Machine HMIs (data exchange)
  • Potential integration with existing .PRG file parsing systems

Quality Attributes

  • High accuracy in 3D simulation and collision detection.
  • Responsive and intuitive user interface.
  • Scalability to support complex machine configurations and production lines.
  • Robust error handling and data validation.
  • Maintainability and extensibility for future feature additions.

Expected Business Benefits

The implementation of this simulation platform is expected to significantly reduce production errors, minimize machine downtime, and improve overall manufacturing productivity. By enabling virtual program validation, the client can avoid costly trial-and-error on physical machines, leading to substantial cost savings and faster time-to-market. The simplified operator interface and automated diagnostic capabilities will empower operators to resolve issues quickly and efficiently, reducing human error and improving overall operational efficiency. Accurate productivity estimations will enable better production planning and resource allocation.

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