In this article, we explore a real-world case study that highlights how the implementation of advanced tube processing technologies, such as the Lasertube, tube benders, and wire benders, combined with sophisticated programming and integration software, has significantly streamlined the production process while reducing both time and material usage in the construction of a bicycle shelter. This project serves as an excellent example of how contractors and designers can leverage modern tube and wire processing systems to enhance the efficiency of structural fabrication and tubular frame production.
This particular project involved the redesign and optimization of a bicycle shelter originally conceived with traditional manufacturing methods. The shelter’s frame was initially composed of tubes of varying diameters, metal wires, and sheet metal components. Under standard conditions, the conventional production process would take between 6 to 8 weeks, with 2 days dedicated solely to the assembly of components. This lengthy assembly phase was largely due to the extensive use of welding jigs, which required precise preparation, placement, and welding by skilled operators. Despite the expertise of the workers, the complexity of the structure often led to limitations in achieving high precision in the final assembly.
By adopting the latest tube processing technologies from BLM GROUP, the entire production process underwent a comprehensive re-engineering. This transformation not only simplified the workflow but also resulted in significant improvements in efficiency. Specifically, the new approach led to a 50% reduction in labor requirements, a 52% decrease in production time, a 26% cut in production costs, and a 20% reduction in material expenses.
To achieve these impressive results, several innovative techniques were employed. One of the key strategies involved simplifying connections through the strategic use of joints, pass-through holes, hooks, and custom cut-and-bend parts. These connections ensured precise alignment of components, making assembly and welding easier and enhancing the overall precision of the structure. Laser cutting played a critical role in creating these joints with exceptional accuracy. The ArTube software, specifically designed for Lasertube programming, provided a comprehensive library of joints and connections that could be easily applied to the CAD models of the components, streamlining the design and production processes.
Another major advancement was the replacement of complex sheet metal elements, which required cutting, bending, and welding, with simpler tubular designs. Initially, these support elements were fabricated using multiple machines—a sheet metal cutting system (either laser or otherwise), a press brake, and a welding machine. With the introduction of the Lasertube system, these multifaceted elements were replaced by a single component derived from a laser-cut and bent tube. This change not only reduced the number of machines needed but also introduced simple markings for precise positioning during assembly, simplifying the subsequent welding process.
Material savings were another significant outcome of this project. By incorporating slots and teeth into the transverse support tubes, the design accommodated bent tubes and rods that hold the bicycles. This approach not only facilitated easier assembly and welding but also minimized material usage by shortening the lengths of the rods. The reduction in material consumption was further enhanced by the application of All-In-One technology, which compensated for the deformation effects of tube bending by strategically adjusting the cutting geometries, thereby eliminating waste and enabling the production of laser-cut and bent tube parts directly from the start.
This project exemplifies how embracing modern tube and wire processing technologies can revolutionize traditional manufacturing practices. It showcases the potential for contractors and designers to achieve greater efficiency, precision, and cost-effectiveness in their projects. For those interested in learning more about the All-In-One technology or the capabilities of BLM GROUP’s Lasertube systems, there are additional resources available that delve deeper into these innovations.
As industries continue to evolve, the integration of advanced software and machinery is proving essential for maintaining competitiveness and sustainability. The bicycle shelter project is just one instance demonstrating the transformative power of these technologies, setting a precedent for future applications in construction and beyond.
To learn more about how these advancements can be tailored to fit specific needs, feel free to reach out for further information.
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