Encore Automation Develops Unique Robotic Cells for Auto Applications with Dassault Systèmes’ DELMIA

Robotics Used to Simulate and Optimize Processes

DELMIA Robotics was recently selected by Encore Automation (Auburn Hills, Michigan) as its simulation tool used in the development of sophisticated robotic systems for the automotive industry including a paint quality inspection system and a polyurethane (PUR) foam application system.

“Without simulation, it would be nearly impossible to verify that the robots can perform so many functions within the target cycle times and physical parameters,” said Encore Automation Proposal Manager, Curt White. “With DELMIA V5 Robotics, we can clearly illustrate to our customers via 3D animations that the cells will, indeed, perform exactly or even better than intended.” White added that many of Encore Automation’s engineers had previously worked with the DELMIA IGRIP UltraPaint solution and as their robotic lines continue to become more multi-task oriented, found that DELMIA Robotics solution would be the best way to address their future needs.

Encore Automation’s paint quality inspection system automates what has historically been a manual process by using robots and vision technology to measure paint thickness as well as examine general paint uniformity and overall appearance. Each robot is equipped with up to three inspection tools on its end-of-arm device.  There is a tool for implementing film build thickness measurement using PELT® (pulse echo layer thickness) technology and a separate tool for paint appearance that relies upon wave scan technology.  Encore is currently in the process of adding color match determination with X-Rite’s Car Flash unit.  A laser-positioning sensor will determine where the robot needs to locate in order to gather the various measurements.

The Encore Automation PUR foam system, which is used to fill automotive body and pillar cavities with polyurethane material to meet Noise, Vibration and Harshness (NVH) targets, has been designed to help achieve lower costs and increase throughput in the foam application process.   The end-of-arm tooling includes both a laser and a dispense gun.  The laser is used to accurately locate the body position and then transmit the position offsets to the robots. The dispense gun then automatically positions the 12 mm spray nozzle within the 13 mm body panel hole to spray the PUR foam.

DELMIA Robotics is an integrated solution that will enable Encore Automation to design, simulate, optimize, and program robotic workcells in a 3D digital factory environment.  Additionally, V5 Robotics can capture and reuse best practices, leverage programming knowledge and automate the repetitive work of robot programming, helping to reduce cost, design and manufacturing time, and accelerating time-to-market.

Nakayama Corporation Innovates Product Development Process with Dassault Systemes’ PLM Solutions

Shortened Time to Market and Streamlined Design Processes

IBM and Dassault Systèmes recently announced that Nakayama Corporation (Nakayama), a leading manufacturer of metal pipe products for automobile and industrial machinery, has innovated its product development process with DS’s CATIA and ENOVIA SmarTeam, shortening time to market.

“We were looking for an industry-recognized, fully scaleable solution with the possibility of adding new functionality as necessary. Selecting 3D PLM solutions from DS, a recognized innovation partner, we have been able to fulfil these criteria and to streamline across the whole enterprise system, from concept design to manufacturing, and to sales," says Tsuyoshi Ishikawa, senior managing director, Nakayama Corporation. Nakayama aims to fully digitalize its manufacturing process with further utilization of CATIA and ENOVIA SmarTeam and become its industry’s top global manufacturer for all three of its key product lines.

“Since deploying DS’s PLM solutions, Nakayama has achieved results rapidly, with its well-run project and a clear vision,” explains Nikos Calfacacos, general manager, Dassault Systèmes. “This is a perfect example of the benefits that SMBs can gain from PLM solutions, which provide a rapid return on investment while helping companies to become more competitive in the global market.” DS’s solutions were implemented by Toyotsu Syscom, DS’s local business partner.
 
In 2005, Nakayama’s R&D project was adopted by the New Energy and Industrial Technology Development Organization (NEDO), meaning that Nakayama urgently needed to deploy a solution to upgrade and migrate existing 2D design materials to 3D.  Nakayama deployed DS’s CATIA simultaneously throughout three company departments (pipe products, forming machine, roll).  From product concept to manufacturing, Nakayama streamlined its development processes in product and equipment design, and facilitated reverse engineering with measuring tools, saving time and resources.

DS’s CATIA (for designing the virtual product) supports the use of existing 2D data and newly designed 3D data, allowing a seamless upgrade; ENOVIA SmarTeam (for collaborative product data management) enables immediate collection and accurate reuse of this data.

About Nakayama
Nakayama Corporation is a Japanese leading maker of metal pipe products which was established 40 years ago.  It headquartered in Kariya city in Aichi, and has continued to provide innovative products in the market.  Nakayama has good reputation in its superior technology and its R&D project has been adopted by New Energy and Industrial Technology Development Organization NEDO in 2005 as its granted project.

Dassault Systèmes Bags Major Larsen &Toubro Contract

Expanding PLM Solution to Include Integrated Design and Project Management Tools 

Dassault Systèmes recently announced it has secured a major order from Larsen & Toubro Limited.  The technology-driven engineering and construction giant will adopt cutting edge integrated PLM solutions from DS for its heavy engineering division. DS’s solutions will integrate Larsen & Toubro’s stand-alone design automation and project management tools, increasing efficiency and savings potential across the division. 

“L&T believes that product and process innovation are at the core of the company’s ability to compete in the global marketplace. The DS solutions will help give an enhanced focus on value creation and process simplification,” explains Mr. M. V. Kotwal, Director and Senior Executive Vice President Heavy Engineering, Larsen & Toubro.  “Working closely with DS fits well with our enhanced thrust in the manufacturing sector. DS’s PLM solutions allow users to create a collaborative workplace that breaks down the barriers between engineering and design functions, accelerating the product development process and bringing about a new level of decision support, innovation and collaboration,” continues Mr. V. K. Magapu, Chief Executive, L&T Infotech and Member of the L&T Board.  DS’s end-to-end PLM solution will be implemented by L&T’s IT arm - L&T Infotech. 
 
“Larsen & Toubro operates at the upper end of the technology spectrum and has been at the forefront of introducing new processes, products and materials into the manufacturing sector for over six decades. The company has embraced a long term PLM strategy as critical to maintaining a competitive advantage. As part of its business transformation drive, L&T has extended this to include the collaborative intelligence capabilities of our ENOVIA solutions throughout the product delivery process with customers, partners and suppliers,” says Bruno Latchague, EVP, Dassault Systèmes.  L&T will apply DS’s solutions to processes for the shipbuilding business segment.  The deployment includes:

• CATIA, for designing the virtual product,
• ENOVIA VPLM, 3D collaborative virtual lifecycle management for highly complex products, resource and manufacturing processes, and
• ENOVIA MatrixOne, collaborative product development business processes for enterprises. 

This customer win is the first end-to-end implementation of a recently established partnership between Infotech Limited and DS.  Infotech Limited is a wholly-owned subsiderary of Larsen & Toubro Limited and has signed an agreement with DS to provide consulting, development and implementation services around DS’s end-to-end PLM portfolio.

About L&T Infotech
Larsen & Toubro Infotech Limited (L&T Infotech), one of the fastest growing IT Services companies,  is ranked by NASSCOM as the 10th largest software & services exporter from India in the year 2006. It is part of $ 4.5+ billion Larsen & Toubro Limited (L&T), India’s largest technology-driven engineering organization.  A full-services IT firm with a blue-chip client roster, it offers comprehensive, end-to-end software solutions and services in the following industry verticals:

• Banking & Securities
• Insurance
• Energy & Petrochemicals
• Manufacturing (Automotive & Construction Equipment; Semiconductor and Electronics (Hi-tech); Industrial Products; Consumer Packaged Goods; Utilities & Process)
• Product Engineering Services (Communications & Embedded Systems).

L&T Infotech delivers business solutions to its customers, leveraging its substantial domain experience and depth in technologies like SAP, Oracle (including PeopleSoft/JD Edwards/Siebel), Microsoft, EAI, and DW/BI.  In addition to application development and maintenance services (ADM), L&T Infotech has strong capabilities in infrastructure management (IMS), independent verification and validation testing (IV&V) services, end-to-end engineering services and embedded system solutions.

L&T Infotech’s vision is to provide world-class service to clients in its areas of focus, providing solutions that are based on business and technology insights.