Radek Fáborský

The entire welding line production process begins with a 3D conceptual layout and a time analysis (production cycle) in the Process Designer environment. The conceptual layout is created by the designer of the welding line. It contains the layout of all the equipment that is needed for the production of a given part.

The next step is virtual verification and optimization of the conceptual layout in the Process Simulate software. The output is a procedurally 100% layout in a 3D environment, on the basis of which a real welding line is built. The output is also off-line programs of robots placed in the line. At the same time, the functionality and collision-free condition of all devices in the line is virtually verified.

The basis for virtual commissioning (ViBN) is the creation of a PLC program which, after debugging, actually controls the entire welding line. In other words, the PLC program defines when and how the given device or robot should work in the line. In the past, the PLC programmer devoted himself to the optimization of PLC programs only after the construction of the real line. At present, this activity is carried out virtually using ViBN technology before the actual construction, which means significant time savings during project implementation.

The result of the entire process is a welding line completely created and optimized in the 3D environment of a single software. Even before the actual construction of the line, it is possible to monitor or correct the complete design, off-line and PLC programs in real time, and thus verify the process correctness of the welding line.