Adding Intelligence to Automation
There have been rate-limiting factors affecting engineers since the introduction of CAD. The segregation of engineering and manufacturing functions and the software- rather than solutions-driven approach to design and manufacture have led to lost production time and large scale inefficiency.
Large software manufacturers have benefitted from this software-led approach, enjoying low perceived risk of purchase brought about by brand recognition and a powerful sales presence in the market. This is now changing. End users have recognised that the commoditised approach gives rise to another type of risk; lower fitness-for-purpose. With increasingly demanding and complex challenges brought about by hostile market conditions, this is becoming a critical concern. Now a more intelligent, joined up approach is required.
Smaller providers, with innovation as a core value proposition, are at the vanguard of this new philosophy. They have the advantage of being able to move quickly and look more closely at the specific challenge of each client. One example is ac&e, a UK-based provider with US and EU offices and high profile clients worldwide. ac&e have instigated a culture change within the firm; leading with service and solutions, rather than software.
While they are well established in the development of simulation software for automated manufacturing, drawing upon experience in the field of computer simulation of engineering design and manufacturing systems, ac&e are driven by the needs of the client rather than target unit sales. By using software to bring together targeted applications-orientated simulation and off-line programming solutions that add intelligence to automation, they enable clients to look at their whole system in a new light. When fully integrated into the manufacturing process, this enables a joined-up approach where the system ‘teaches’ both the design engineer and the manufacturing engineer a smarter way of working together. While the software plays a fundamental role, it is the solution that excites both provider and client.
One example is with a major steel cutting and fabrication client using ac&e’s StruCIM® environment. The client can now automate beam and plate cutting for structural steel applications, using robotically controlled cutting systems. The solution is automated, user friendly and easily integrated into operations, enabling improved production throughput and consistency of cuts, reduced scrap, reduced cycle time and minimised production floor space.
Engineering models can quickly be converted to welding instructions and sent directly to robotic workcells for fast and accurate welds, with the system capable of learning from the factory floor and feeding this back into the software, leading to reduced errors and improved profitability. This synergy of robotics software and hardware has provided the client with an outstanding package of benefits including anticipated increased throughput of 300% over hand welding, improved weld quality with continuous welds and reduced consumable cost. Design and welding engineers are now working together in a manner not previously possible.
Director of ac&e, Yash Khandhia, sees an exciting future for this approach:
“The skills and competencies of the partnership approach have come together to provide a powerful synergy. We looked at the problem and worked with the client and our robotics partners to develop a solution that would grow with the organisation, enabling it to adapt through time and increase profitability. We can see an exciting future for this approach.”
For further information on ac&e call +1 888 634 6020