Reducing onsite virtual commissioning time by 70 percent

Facilitating complex production challenges

Founded in 1999 and headquartered in Zur Yigal, Israel, Polygon Technologies (Polygon) is a leading robotic engineering firm that specializes in a range of automation and robotics technologies for products including services from concept and specifications definition to development and production.

Polygon develops advanced robotic automation solutions that help businesses streamline their processes, reduce costs and improve productivity. Serving industries such as automotive, aerospace, electronics and industrial manufacturing, Polygon has built a reputation for delivering high-performance robotic systems tailored to complex production challenges. With the help of Siemens Digital Industries Software’s Process Simulate in the Tecnomatix® portfolio, Polygon’s latest innovation, Wirebot, is transforming the complex process of wire harness assembly for electrical cabinets.

“Using Process Simulate, WireBot is able to simulate complex wiring scenarios before actual production, eliminating errors and ensuring smoother operations,” says Omer Einav, chief executive officer (CEO) of Polygon.

Overcoming the challenges of complex wire routing

One of the major challenges in robotics has been handling flexible components such as gaskets, fibers and electrical wires. Traditional robotic systems have struggled with these materials, leading to repeated development failures. In conventional electrical panel assembly, wiring is done manually, making the process time-consuming and prone to errors. Polygon Technologies recognized this gap and set out to develop a robotic solution, Wirebot, that could perform wiring tasks with greater speed and precision than human operators. The potential market for just the field of control and electrical panels for facilities and systems is estimated at $250 billion annually because this level of efficiency is helpful for any organization seeking to optimize production.

“By integrating Process Simulate with the WireBot system, we provide customers with cost-effective component arrangements during the design phase, which not only enhances wiring efficiency but also saves time and boosts overall productivity,” says Einav.

Beyond speed, the system ensures precise and optimized wiring, leading to significant material savings. Compared to traditional manual methods, it reduces copper waste, allowing large organizations to cut raw material costs for control and electrical panels by about 10 percent in addition to lowering labor expenses and improving overall reliability.

Developing Polygon’s robotic wiring system required replicating human dexterity in groundbreaking areas such as haptic and tactile feedback, artificial vision, dual-arm coordination and advanced information processing. The Wirebot solution integrates robotics, digital twin technology and artificial intelligence (AI) driven optimization. By creating a digital model of the wiring process and leveraging advanced algorithms, Polygon developed a system capable of automating complex wiring tasks with unprecedented accuracy.

Robotic wire processing for electrical automation

Although Polygon specializes in a wide range of automation solutions, they have started to focus on creating an efficient wiring solution in electrical control panels, a domain where demand is growing. The market for these systems, valued at $5.6 billion in 2022, is projected to reach $9 billion by 2030. Polygon faced multiple challenges in developing their Wirebot solution, notably in optimizing workflow automation, minimizing material waste, preventing equipment damage and enhancing real-time process monitoring and control.

To overcome those challenges, Polygon turned to Siemens as their digital manufacturing partner and its Process Simulate, which is part of the Siemens Xcelerator business platform of software, hardware and services.

Powering robotic wire processing

By using Process Simulate, Polygon Technologies developed a high-fidelity digital twin of the Wirebot system. This innovative approach enabled them to virtually validate robotic movements, delivering precise and collision-free routing. Additionally, by optimizing cycle times and production efficiency in a virtual environment, they minimized costly onsite adjustments and improved first-time-right execution.

“By leveraging Process Simulate, the WireBot automated wiring system can determine the optimal routing path while offline, reducing production time and conserving wiring materials,” says Einav.

“Using Process Simulate enables WireBot to predict potential issues in the design phase, reducing the risk of delays and improving the quality of the final product.”

Polygon leveraged Process Simulate, which played a critical role in developing Wirebot. The virtual commissioning software enabled the creation of a digital twin of Wirebot, allowing for virtual process validation and optimization. By simulating complex wiring scenarios prior to production, Polygon identified optimal wiring paths, reduced material waste and improved the reliability of robotic operations without risking damage. Consequently, Polygon was able to analyze cycle times, which resulted in more efficient wiring sequences and layouts, further enhancing productivity.

Driving efficiency and reducing downtime

The implementation of Process Simulate led to significant advancements in Wirebot’s performance. Production cycle time was reduced by 30 percent, allowing for faster output without sacrificing quality. Wire positioning accuracy improved, minimizing errors and rework.

Furthermore, Wirebot was seamlessly integrated into existing manufacturing workflows, enhancing overall operational efficiency. These improvements have positioned Polygon as a leading innovator in automated wire harness assembly, driving both cost savings and enhanced productivity.

Following the success of Wirebot, Polygon continues to explore new ways to use Process Simulate. By embracing virtual commissioning and digital twin technology, Siemens and Polygon are redefining the future of robotic automation. Their commitment to innovation enables manufacturers to achieve new levels of precision, efficiency and scalability in their operations.