TPT November 2011

91 / 108

November 2011 89 ›
Software
Correction of bending machines
WITH the launch of the new software version
4.7, Aicon’s optical tube measuring system
TubeInspect will be extended by a practical
function: now the operator has the possibility
to simulate the bending process considering
individual correction values, and to verify
their effect on accuracy to gauge by means
of a virtual gauge check.
With the help of high resolution digital
cameras, TubeInspect determines the tube
geometry within seconds, and thus proves
accuracy to gauge. Beyond that, the system
shows in detail which bending points deviate
from the desired values, and suggests
correction values. These correction values
can be transmitted directly to the bending
machine, whereby TubeInspect allows the
connection to up to 100 benders.
However, sometimes the correction
values suggested by TubeInspect cannot
be transferred one-to-one, for example if
they led to collisions at the bending machine
or if corrections are suggested at parts which
cannot be affected because of solid bending
tools. Now the new simulation module comes
into play: When TubeInspect evaluates a
measured tube as a bad part and suggests
correction values, the operator can adapt
them at his own discretion. After all, only
he knows the actual circumstances and
characteristics of his bending machine. By
doing so, the operator does not take any risk
because from now on TubeInspect simulates
the results of the changes and shows with a
virtual gauge check if this bending process
could actually produce a good part. Just
when the right settings are found, another
real bending test will take place. Therefore,
in the future, fewer bending tests will be
necessary, which makes the setup process
even leaner.
Aicon 3D Systems GmbH – Germany
Email:
Website:
RAMP – Tube
shop control
and workflow
management
IN the field of tube processing the use
of CNC-controlled machines has become
wide-spread. Machines for cutting, flame-
cutting, bevelling, bending and flange-
welding can be used more efficiently with
CNC-systems. But software can be used to
control more than a single machine. In fact,
to fully utilise the full potential of modern
CNC-controlled machines, an integrated
workshop control system is essential.
Inefficient flow of material or workload
planning, which results in either bottlenecks
in fabrication or idle times at the machines,
cannot be solved with the purchase of new
machines alone. The machines need to
be connected, the flow of material needs
to be balanced so that each machine and
work place has both the materials and the
required data for the next work order at
all times. The machine should never have
to stand idle while operators wait for new
pipes to be delivered or calculate and enter
the CNC data manually. Nor should the
machines receive more work orders than
they can handle.
To coordinate all the tasks required for
efficient production, a workshop control
system, like 3R software solutions RAMP
(Resource Activity Material Planning) can
be used.
Tasks that can be handled with RAMP
include, but are not limited to:
• Balancing/nesting: the software
automatically creates work packages
for daily production, based on schedule,
material availability, machine capacities,
etc. Machines and work stations receive
neither more work orders than they can
handle, nor less, making optimal use of
the daily capacity.
• Cutting and tooling optimisation: RAMP
automatically calculates the cutting/
flame-cutting order that will result in the
most efficient use of materials, and the
least amount of scrap. In addition the
work packages created by RAMP take
the tooling on bending machines into
consideration, so that tooling changes
can be minimised.
• Material handling/transportation: ideally
machines should never have to wait
for the next tube to arrive, but should
work continuously without interruption.
In a RAMP-controlled, fully automated
pipe shop, the operator of the band-
saw or flame-cutting machine can see
the upcoming orders, and can request
the required material from the pipe
rack ahead of time. A fully automated
transport system retrieves the requested
tubes and automatically delivers them to
the machine, so the operator never has
to interrupt his work.
• Status tracking and change manage-
ment: with computers at every
workplace, it becomes easy not only to
give each worker up-to-date work orders
in a paperless environment, but it also
becomes possible to track the fabrication
status for each spool or component. If
the engineer had to make changes after
releasing the drawing for fabrication, it
is possible to update the work orders
immediately. This reduces the risk that a
spool has already been fabricated by the
time the changed information arrives in
the workshop.
Getting CNC-controlled machines to
increase workshop efficiency is a good
first start. But if there are underlying
problems, it requires intelligent coordination
and integration of your machines to solve
them. Therefore you should never see your
machines as independent from each other,
but as interdependent components of a
greater system. A system that 3R software
solutions’ RAMP can control for you.
3R software solutions – Germany
Website: