Designing large scale automation and robotic systems using Solid Edge

Precision Robotics and Automation Ltd (PARI) is a leading developer of automation and robotic systems globally. Their customers in the automotive sector include established giants like Ford, Chrysler, PSA, Daimler-Benz, Tata Motors, Mahindra, and new significant players like VinFast. PARI designs, manufactures and installs complete, automated systems including multi-station lines for machining and assembly of powertrain components and assemblies.

PARI has been a major user of Solid Edge for 15 years with 160 licenses deployed at their headquarters near Pune in India. Typical automation solutions deployed by PARI incorporate a wide variety of robots, actuators and sensors and other mechatronic items. These systems can comprise over 25,000 unique components.

Integrating robots into automated manufacturing lines

Mangesh Kale, Managing Director of PARI describes their design process. “If a six-axis robot is required for a specific application then we use robots from major suppliers like FANUC, ABB and Kuka, or other makes specified by the customer. We typically receive 3D models from these manufacturers and we integrate these into our automation system designs. However, many applications demand gantry type robots that we design and manufacture ourselves. In a typical solution, about 60% of the design is using standardized commodities of PARI. However, custom parts are typically 40% of the design. For example, the gripper sub-assembly for any material handling solution is typically a custom design. This design meets specific application needs to handle components at different stages in the machining or assembly process. The customization required for assembly processes is even higher. We find that Solid Edge is a very powerful and flexible solution for designing these sub-systems.”

High productivity for design tasks is critical for PARI’s success as Mangesh explains. “The engineering content of the systems that we design is very high. High productivity for the 250 plus mechanical engineers that we employ is critical for the profitability of any project. This coupled with the fact that our labor market has a demographically lower age of engineers means that we need a fast learning curve for the CAD solution. Solid Edge 3D design meets these requirements very well.” PARI are supported in their use of Solid Edge by local Siemens channel partner 3D Engineering.

Siemens applications for beam analysis and process simulation

Another area where Solid Edge helps is in stress analysis of critical components. “Some of our gantry robots operate on a beam up to 8m in length. We use the beam analysis capabilities of Solid Edge Simulation to ensure that we optimize the beam section and support system for a specific application. We can ensure that the maximum beam deflection will meet our design criteria. This in turn ensures the accuracy and reliability of system for our customers.”

PARI is also using Siemens Process Simulate software to optimize the cycle times of the systems they design. Process Simulate is also used to program the PLCs and robots that are integral parts of their systems. “Right now, we are working closely with Siemens to optimize the integration between Solid Edge and Process Simulate” says Mangesh. 

PARI’s relationship with Siemens goes even deeper: “Many of the industrial control systems that we integrate into our manufacturing lines are supplied by Siemens.” says Mangesh. And PARI are extending their expertise to designing assembly systems for the batteries and electric motors used in electric vehicles. This must be a good move for PARI, delivering the systems that will support the rapid growth in manufacturing of electric vehicles globally.