CAD Software Development

SPI develops the Tube Design software for the machine tool provider TRUMPF: a CAD program that facilitates profile design for products manufactured with TruLaser Tube machines, or TruLaser machines with RotoLas units. The software specializes in the programming of tube cutting machines for processing tubes and profiles. The programming system is based on extensive technological knowledge. This allows it to, for example, analyze cutting geometries and calculate contours. The program performs complex tasks such as corner processing of rectangular profiles automatically. Bend connections are created with ease. Complex tube designs can be cut and assembled in high-quality thanks to the intelligent connection technology. Numerous automatic functions for the intersection of tubes facilitate design and programming. The ergonomic and efficient operation ensures a high level of user-friendliness.

TruTops Bend, TruTops Punch, TruTops Tube and other software modules of the TruTops series are trademarks of the TRUMPF company and are protected accordingly.

Several manufacturing locations with centralised construction, heterogeneous machinery as well as the opening of a central cutting centre for southern Germany presented the Bader Group with a technical challenge that was solved with the help of SPI.

When Bader opened a new cutting centre at the company’s headquarters in Senden, equipped with brand new automated punching and laser machines and a central raw material warehouse, programming with the existing OEM systems proved to be a bottleneck. Existing CAD parts had to redesigned for production in different sites. This, of course, could not remain a permanent state of affairs.

To provide the required process information and control the machines, Bader decided for SPI SheetMetal in conjunction with WiCAM’s PN4000 programming system. 19 SPI software licenses are in use today, an extension is already planned. The SPI sheet metal unfolding software ensures that the CAD data is provided with cutting and machining data and transferred to the programming system as an XML file that includes all information relevant for the manufacturing process The software also delivers GEO data that can be used in other Bader production sites without needing additional adjustments for the machines used there.

The next challenge was the heterogeneity of the machine park across the different production sites: it includes machines from Amada, EHT, Hämmerle, Salvagnini, and Trumpf.

“Our goal was to be able to manufacture every product at every location,” explains the Head of Industrial Engineering. “When we design parts here at the headquarters, the designer should not care whether the part will be manufactured in Germany or in Hungary. However, the different sites have different machines with different deduction values, so production location is certainly not unimportant.”

The Data Editor that is integrated into the SPI solution allows to manage and retrieve different material and bending tool combinations. It takes just the press of a button to create the necessary flat patterns with machine-specific deduction values for the various production sites.

An important further step for process automation is the introduction of the SPI solution for ensuring a manufacturable rebuilding of parts that took place in the summer of 2018. Regardless of how a part has been constructed, even if it contains false internal radii, inaccurate reliefs or bending lines, the SPI software will analyse the data and create not only a GEO or XML file but also a production-ready STEP file. This file includes all process information, correct reliefs, punching, and stamping data. The result is a virtual prototype that shows the part as it would be manufactured, including the accurate production radii. Potential collisions in the bending process can be easily detected and fixed in time.

Further examples of how SPI has implemented special customer requirements in the sheet metal processing industry can be found under References.