Reducing onsite virtual commissioning time by 30 percent and overall costs by 20 percent

Prioritizing automation

Founded in 1993, Estun Automation Company Limited (Estun) is a pioneer in the fields of motion control, industrial robotics and complete solutions in China. With three decades of advanced robotics and innovation experience, Estun is a recognized and respected international brand, adhering to the corporate mission that “everyone enjoys automation.” Estun operates in 64 countries and regions, providing customers with immediate, convenient and complete business services.

Addressing high demands and hardware limitations

Although selling industrial robots and automation products is a main focal point, Estun also focuses on other advantageous industries. This includes lithium batteries, photovoltaics and new energy, specifically providing automated production lines for these types of manufacturing companies.

For example, the company aids in producing and deploying robots developed for the lithium battery industry that are suitable for various types of large cylindrical and prismatic battery cell module assembly lines. These robots enable higher efficiency during energy storage battery and power battery production, which several leading lithium battery enterprises in China recognize and favor.

However, there are nuanced complexities in battery manufacturing, from chemical composition to mechanical design, that complicate the manufacturing process. Estun understood that the only way to address these manufacturing intricacies was by using a customized manufacturing solution. The high demand for battery-related products has surpassed the capabilities of traditional hardware equipment, which typically relies on on-site production line debugging. If manufacturers like Estun rely on traditional hardware equipment, the costs can become too high and the production cycle difficult to control, making it hard to adapt to competitive market demands.

To overcome those challenges, Estun turned to Siemens Digital Industries Software as their digital manufacturing partner, and its Tecnomatix® portfolio, which is part of the Siemens Xcelerator business platform of software, hardware and services.

Leveraging Tecnomatix to transform R&D processes

Estun began using the virtual commissioning capabilities of Siemens industrial simulation software Process Simulate in the Tecnomatix portfolio to drive the company’s research and design (R&D) process transformation. The company can use Process Simulate to improve their manufacturing efficiency and flexibility while benefiting from high quality standards.

Estun uses Process Simulate in a digital environment for designing, validating and optimizing mechanical, robotic and automation systems for lithium battery and photovoltaic manufacturing automated production. This enables line commissioning with maximum independence from hardware equipment, resulting in virtually zero burden on corporate inventory and a significant improvement in the efficient use of corporate capital without the risk of damaging expensive hardware assets. Using Process Simulate supports offline programming of more than 30 brands of industrial robots globally, including ABB, Fanuc, KUKA and Yaskawa. The Estun controller was added to this list of supported controllers to enable the manufacturer to integrate its robots using Process Simulate.

Using Siemens simulation and virtual commissioning technology, Estun engineers can create a comprehensive digital twin in Process Simulate for production equipment and manufacturing processes. This includes cell and module conveyors and fixtures, and robots working with turntables to pick and place parts. The digital twin provides a visualization of the whole process while helping engineers automatically check for mechanical interferences and prevent multiple problems during the system’s physical deployment.

“Using Process Simulate combined with Estun virtual robot controllers, process principles and model libraries, we leverage a digital twin solution to reduce the delivery cycle while improving product quality,” says Xiaolei Chang, general manager for digital business at Estun.

Advancing product quality and cost

The Estun and Siemens collaboration is comprehensive. The company not only uses Process Simulate for virtual debugging but also jointly developed an offline programming (OLP) package and realistic controller simulation (RCS) module for industrial robots, which integrate Estun robot models (3D model libraries, OLP interfaces, etc.) with Process Simulate software. With this integration, the company can accurately simulate robot motion sequences and automatically generate robot programs. They can download these programs to the robot’s physical controller to control the hardware devices, providing a more efficient and effective user experience (UX) for Estun’s customers.

Using offline programming technology, Estun can eliminate the production line’s robot interference, realize the production line’s efficiency and flexibility and reduce malfunction and loss risks. In parallel, using internet of things (IoT) technology, the company can achieve data collection and analysis, providing data support for continued production line optimization and upgrade.

“The joint development of the Estun robot OLP package and the RCS module is a crucial step for Estun to enter the global robotics and automation market,” says Chang. “We are happy to partner with Siemens in that journey and expect the partnership to be long-lasting.”

Alexander Greenberg, director of advanced robotics at Siemens, explains that since the beginning of 2023, Siemens has been working closely with Estun to develop an OLP package for their industrial robots. This collaboration empowers intelligent manufacturing by transforming the production line planning and debugging process.

“By leveraging the power of 3D simulation and virtual commissioning, combined with the offline programming package, we continually develop and improve,” says Greenberg. “As we continue to work closely with Estun, we are confident that our partnership will drive further innovation and deliver even more advanced automation solutions that meet the expanding needs of our customers in the rapidly evolving market.”

Since Estun’s corporate values put the customer at the center of all company decisions, it realized the need to accelerate automation equipment deliveries for manufacturing lithium batteries and photovoltaics. Estun used digitalization to transform its traditional operations and shorten the cycle of production line development and debugging. Adopting digitalization enabled Estun to accelerate production and ensure quality. More importantly, it helps Estun quickly recoup capital, reduce the high cost of on-site production line development and debugging and realize immediate control of the production process.

“By leveraging Tecnomatix Process Simulate, we reduced commissioning time by 30 percent and overall costs by 20 percent, benefiting our customers with shorter production periods and enhanced efficiency,” says Jonas Xu, project manager of digital business at Estun.

Embracing digital transformation

In a strategic embrace of digital transformation, Estun seamlessly integrated processes and communications across various departments. This interconnected approach facilitates the proactive analysis of intricate facets such as production line design, manufacturing processes and the control logic and code governing automation equipment. By fostering this holistic connectivity, Estun positions itself to promptly implement timely adjustments and optimizations, ensuring a precision-driven, on-site debugging process. This not only enhances operational efficiency but also expedites the product launch process, allowing Estun to stay ahead in the dynamic landscape of intelligent manufacturing.

“Using Tecnomatix Process Simulate, we leveraged 3D simulation and offline programming to reduce commissioning time and costs,” says Xu. “Our collaboration with Siemens fuels innovation, ensuring tailored automation solutions for evolving market needs.”

This commitment to interconnectedness and digital prowess remains rooted in Estun’s overarching mission, “Everyone enjoys automation.” By consistently delivering exceptional results to their customers, Estun strives to provide even more advanced solutions that effectively address evolving client needs in a rapidly changing market.

“Using Tecnomatix Process Simulate propels us forward, shaping agile production lines that outpace competition,” says Chang. “In this competitive industry, innovation is not just a choice; it is our strategic advantage.”

The ongoing synergy between Estun’s dedication to digital innovation and its customer-centric approach underscores its pivotal role in shaping the future of automation, solidifying its position as a reliable partner in the journey toward intelligent manufacturing excellence.