In this article, we explore a practical case study that highlights how the implementation of advanced tube processing technologies, such as the BLM GROUP’s Lasertube, tube benders, and wire benders, alongside integrated programming and production management software, has transformed the fabrication process of a bicycle shelter. This project exemplifies how contractors and designers can leverage modern tube and wire processing systems to enhance efficiency in constructing structural frames and tubular assemblies.
The case revolves around a shelter designed for bicycle parking, featuring a frame constructed from tubes of varying diameters, metal wires, and sheet metal components. Under traditional manufacturing practices, this structure would typically take between 6 to 8 weeks to complete, with 2 days dedicated solely to component assembly. This lengthy assembly phase is largely due to the reliance on numerous welding jigs, requiring meticulous preparation, placement, and welding by skilled operators. Despite the expertise of the workforce, the precision of the final assembly remains constrained by the inherent complexity of the design.
However, by embracing BLM GROUP’s advanced machinery and software solutions, the entire production process was streamlined through comprehensive re-engineering. This transformation led to a remarkable 50% reduction in labor requirements, a 52% decrease in production time, a 26% cut in production expenses, and a 20% saving in material costs.
One of the key innovations involved simplifying connections within the frame by utilizing joints, pass-through holes, hooks, and custom-cut-and-bent parts. These techniques ensured precise alignment of components, facilitating assembly and welding while enhancing overall structural accuracy. For instance, laser cutting was instrumental in creating intricate joints with exceptional precision, while ArTube, the specialized Lasertube programming software, offered a versatile library of pre-designed joints that could be easily integrated into the CAD models.
Another significant advancement was replacing complex sheet metal elements—previously fabricated through cutting, bending, and welding—with simpler tubular components. This change not only reduced the need for multiple machines but also improved the ease of assembly and welding. By introducing just two small reference points, accurate positioning during assembly became straightforward, further streamlining the fabrication process.
Furthermore, the adoption of All-In-One technology proved pivotal in minimizing material wastage. By strategically adjusting the geometry of laser cuts to account for the deformation caused by bending, this technology eliminated unnecessary waste and enabled the creation of laser-cut and bent tube parts directly from the start. This approach not only simplified the design but also contributed to a more sustainable production process.
For a deeper understanding of All-In-One technology and its impact on reducing material consumption, consider watching our video showcasing the fabrication of the bike shelter using Lasertube and benders. This video provides visual insights into how these technologies work together to optimize production.
In conclusion, the integration of advanced tube processing systems and software has revolutionized the fabrication of the bicycle shelter, offering a blueprint for future projects. It underscores the importance of embracing modern tools to enhance efficiency, reduce costs, and improve precision in structural manufacturing.
To learn more about how BLM GROUP’s solutions can transform your projects, don’t hesitate to reach out for additional information. Experience the difference today!
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