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RobotStudio Case Study: Benteler Automobiltechnik

Benteler has a small pipe business area for which they produce fuel lines and coolant lines made of aluminum for Porsche and other car manufacturers. One of the problems in production was that when Benteler added new products, production had too much downtime.

  • ABB
    ABB is a global leader in power and automation technologies. Their solutions improve the efficiency, productivity and quality of their customers’ operations while minimizing environmental impact.
  • Automotive
  • Maintenance
  • Benteler International AG is active in business divisions Automotive, Steel Pipes and Distribution and employs 28,000 people at 170 locations in 38 countries.

  • ABB presented RobotStudio as the solution. Engineers can use RobotStudio for offline programming using real-time data to test alternatives without shutting down production. Using RobotStudio, engineers can simulate real-world situations to identify problems with a new robot design. If problems exist, they can be addressed before the tool is actually made of steel and iron. RobotStudio is also used to create macros and to model welding, gluing, and image processing procedures.

  • Asset Status Tracking, Downtime, Fuel Levels, Maintenance Requirements, Production Efficiency
  • Mature (technology has been on the market for > 5 years)
  • Impact #1
    [Process Optimization - Real Time Asset Tracking]
    The location of individuals and assets can be identified in near real-time and integrated into process simulations.
    Impact #2
    [Efficiency Improvement - Production Uptime]
    Simulation and debugging of production processes related to new tools are possible without shutting down production.
    Impact #3
    [Efficiency Improvement - Installation]
    Technicians are able to query instruments remotely during commissioning to confirm device functionality.
  • Digital Twin
    The digital twin is a digital replica of a living or non-living physical entity. Digital twin refers to a digital replica of potential and actual physical assets (physical twin), processes, people, places, systems and devices that can be used for various purposes. The digital representation provides both the elements and the dynamics of how an object operates throughout its lifecycle. Definitions of digital twin technology emphasize two important characteristics. Firstly, each definition emphasizes the connection between the physical model and the corresponding virtual model. Secondly, this connection is established by generating real-time data using sensors to provide an evolving perspective into the current status of the physical object. The concept of the digital twin can be compared to other concepts such as cross-reality environments or co-spaces and mirror models, which aim to, by and large, synchronise part of the physical world with its cyber representation.
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