Although digitalization and modern machines have largely replaced traditional methods, the manufacturing process still starts with a flat sheet metal plate - from a CAD perspective with unfoldings from the 3D model. Ideally, these provide data that NC programs understand in order to enable seamless control of the machines in production. The philosophy of SPI GmbH starts a little earlier: Parameters are initially recorded centrally and flow into the calculation of the processing of parts and assemblies depending on the output target. It all depends on what is to be manufactured where and under what conditions.

As a link between design and production, SPI SheetMetal solutions are the ideal complement to the respective CAD base systems. The available interfaces and the option of preparing DXF files with production-relevant information ensure optimum connection to existing CAM and offline programming systems. With a corresponding SPI interface, it is possible to read in material and bending process information and to guarantee the production radii and bending factors resulting from the bending process during design.

Export formats for various output destinations

For example, a GEO file is optionally generated for direct use in TruTops Classic and TruTops Boost, which contains bending, laser, punching and other production information. The data transferred by SPI is recognized and the corresponding processing patterns are assigned. All bending information used for the component (opening angle, radius, bending tool combination, bending technique) is transferred and is immediately available for NC code generation. The unfolding geometry can also be transferred to an XML file. In addition to the deformations contained in the model, this contains the unwinding geometry, information on bends and bending lines, bending angle, bending radius (shortening and position), engravings and tool information (ID number, position, orientation), units of measurement - especially for lengths and angles - as well as user-defined attributes. SPI also supports output targets via DXF or STEP data. For example, the DXF format generated for the BySoft 7 CAM software provides information on bending tools, bending angles, production radii and shortening values. As a software developer, SPI can supply data for other output targets if required.

So far everything is under control. But what about calculating the costs? Setting the course in product development is crucial: up to 80 percent of the manufacturing costs of products are determined here. And unfortunately, serious mistakes are repeatedly made in the calculation: offers are rejected by customers due to excessive prices or manufacturers do not accept orders because the profit, however calculated, would be too low. Rough calculations are more common than you might think and often form a barely reliable basis for pricing.

Many variables play a role in the calculation: wage and non-wage labor costs, machine costs, purchase prices, storage costs, packaging and shipping costs, specific surcharges - the list goes on and on. However, such factors can be systematized. 3D CAD models can be analyzed and also linked with information on materials, machines including hourly rates and tools with production parameters from technology databases. Such data can be transferred to ERP systems and their calculation tools, for example, which use this information to calculate real costs and prices.

Rule-based calculation

SPI offers various other calculation solutions. With an individually definable set of rules, even complex calculations can be carried out transparently. Actual cost prices or lower price limits are determined based on rules. Adjustable parameters make it possible to create a wide variety of calculations for different product types. Rules can be defined for the machines used and incorporated into the calculation. As a logical extension, an online configurator is available, which the customer can use to determine the price themselves. Another solution, which enables customers to upload data and calculate individual prices, is also available as a portal and web store solution.

New to the portfolio is the SheetMetal Calculator, which is directly integrated into SPI's existing sheet metal application. The calculation scheme is defined on a company-specific basis. The designer calculates the costs of his product in real time based on rules. Based on the evaluation, he can develop alternatives and calculate how costs would turn out if, for example, he opted for a different material. Cheaper component variants and even production locations can be taken into account. All of the company's production equipment, tools, cutting values, material information and calculation bases are stored in technology databases. The designer can call up a calculation for his part at any time with a click. The calculation result is clearly displayed without further input or a system change. The user can compare calculations or use other calculation bases. Real costing linked to the respective project can therefore be implemented immediately.

Christian Burdorf, SPI / ag

Blechexpo: Hall 1, Stand 1007