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Robotic Simulation

Robotic Simulation

Robotic Simulation

Robotic Simulation

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Seamless Automation with Expert Robotics Simulation for BIW Assembly Lines

Optimise faster production, enhanced quality, and cost savings with expert robotic simulation and layout planning services for automotive manufacturing. We analyse and refine every detail to ensure seamless automation and efficiency. With over 29+ years of experience in engineering for the automotive industry, we help you mitigate risks and maximise productivity.

Certifications
Certifications
Certifications
Certifications
Certifications
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Robotic Simulation in Automotive Manufacturing

Automotive manufacturers leverage robotic simulation in BIW assembly to optimise efficiency, safety, and precision. It streamlines robotic work cells, validates layouts, estimates cycle times, and enhances multi-robot line balancing. We, at Sphinx Worldbiz, a globally recognised leader in digital manufacturing, with three decades of expertise in the industry bring the best-in-class solution for automating your production lines. From planning to virtual commissioning, we deliver cost-effective, high-performance solutions that integrate multiple vehicle models within a single plant.

Our Robotic Simulation Excellence

Delivering cutting-edge process simulation solutions tailored to global OEM standards.

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29+ Years in the Business

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5+ Years in Germany

Delivery Centres in Noida, Pune & Germany

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150+ Customers Globally

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20+ OEM Standards

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500,000+ Hours of Work Experience

Benefits of Robotic Simulation Driven by Sphinx Advantage

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Accelerated Product Introduction

Speeds up new product deployment with precise planning.

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Process Assurance

Validates processes before implementation for seamless execution.

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Optimisation

Enhances cycle times, robot reach, and overall efficiency.

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Collaboration

Bridges design, digital manufacturing, and shop floor teams.

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Cost Savings

Reduces errors and prevents costly rework.

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Improved Efficiency

Optimises robot movements for faster cycles and higher output.

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Enhanced Quality

Detects and resolves errors early for flawless production.

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Risk Prevention

Anticipates and eliminates potential production risks and flaws before deployment, ensuring smooth and error-free operations.

Our Services

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Concept and Process Planning with Lean Assessment

We begin with a process overview and material flow analysis, calculating cycle times based on production targets. Our team assesses joining technologies, robot utilisation, and 2D layouts for feasibility and space optimisation. With a strong focus on lean assessment, process validation, and productivity enhancement, we help BIW assembly lines maximise efficiency and safety.

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Robotic Cell Design and Feasibility

Our services include building robotic cells in a 3D environment, evaluating panel orientation feasibility, and defining material flow. We also verify metal joining and assembly procedures and develop equipment pre-BOMs, ensuring robot reachability.

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Detailed Robotic Simulation

We create detailed work cell layouts with a strong focus on operator safety and ergonomics. Tooling validation is a key part of this phase, as is the avoidance of joint locks or singularities. We conduct comprehensive risk and safety assessments, designing work cells that are easy to maintain. Simulation ensures that robots can perform all desired tasks efficiently and that cycle times are optimised.

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Offline Robot Programming

This includes creating collision-free paths, calculating and optimising cycle times, and ensuring robots are interlocked properly. We prepare detailed sequences of operations and use Real-Time Controllers (RCS) to verify robot behaviour, addressing any jerky motion or unnecessary waiting. This ensures all robots and equipment work in synchronisation while adhering to interlocks and I/O signals within the required cycle time.

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Simulation Cells Calibration Using POD Data/Robot Backups

We ensure precise cell alignment using POD data or robot backups while reconstructing objects based on point cloud scanned data for enhanced accuracy and efficiency.

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Event-Based Simulation and Virtual Commissioning (VC)

We build Virtual Commissioning environments using Process Simulate, utilising CEE facilities. We apply sensor conditions, build logic blocks, and monitor signals within the simulation environment. This enables the validation of robot logic conditions, including all required I/O instructions, to ensure that the system behaves as intended in a real-world scenario.

Know More About Our Robotic Simulation and Layout Planning For a High Performing BIW Assembly Line!

Our Digital Manufacturing Process

We extend our scope of services beyond robotic simulation and offer a complete suite of Digital Manufacturing Engineering Services

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Process Engineering

Leverage our domain expertise for process validation, equipment selection and material routing to optimise cycle time.

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Digital Plant Layout

Build on our expertise to create 3D plant layouts, design work cells and exploit NextGen technologies to streamline plant logistics

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Process Simulation

We undertake ergonomics simulations for human factors and maximize throughput leveraging robotic simulations

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Virtual Manufacturing

Capitalise on our virtual commissioning experience in digital environments to optimise performance and costs

Key Project Elements We Handle

Flexible Line Design

For different vehicle models and variants.

Materials Handling

For steel, aluminium, and composite joining technologies.

Integration of New Lines

Integration of New Lines into existing systems.

Complete Assembly Lines

Including underbody, side panel, framing, closures, and finish lines. We specialise in Pilot Lines, Low Capacity, and Mass Production Lines ensuring uniquely tailored solutions.

Our Technical Expertise and Capabilities

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BIW Assembly

Our team has deep expertise in BIW assembly processes, including welding, material handling, and other robotic operations. We can simulate and optimise the assembly of underbody, closures, inner framing, and outer framing components.

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Joining Methodologies

We have a comprehensive understanding of various joining methods used in weld body shops such as stud welding, clinching, spot welding, MIG welding, robotic sealing, and roller hemming. We also perform clinching, riveting, grinding, polishing, and painting. 

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Software Proficiency

We use various software tools including Process Designer, Process Simulate, Robcad, Delmia V5, and Autodesk AutoCad 2024.

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Process Designer
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ROB CAD
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PS on eMServer
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Process Simulation
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Delmia V5
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AutoDesk AutoCAD

Robot Programming

kuka
fanuc
abb
comau
yaskawa
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Simulation Types

We offer robotics assembly process simulation, line simulation using Process Simulate CEE, ergo simulation studies, time-motion studies, plant material flow simulation in Delmia V5, tandem press simulation, and virtual commissioning cell building.

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Plant Layout

We can help determine optimal plant layouts, considering floor space constraints, and validate the placement of equipment like fences, floor tracks, and light screens. We collaborate with plant layout teams to optimise the location of plant BOMs.

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Tooling Validation

We can validate tooling designs to ensure suitability for all robot tasks, including gun and gripper access, payload, reachability, and clearance. This includes multiple design iterations until an optimised design is achieved.

Engineering BIW Success Story For You 

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Highly Experienced Team

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Dedicated Project Support

Cost-Effective Solutions

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Global Reach

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Adaptability and Flexibility

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Multi-Skilled Professionals

Our Clients

Our broad portfolio enables us to handle any project with expert services, scalable delivery models, and top engineers who’ve solved critical challenges for global line builders.

Online and Offline Robot Programming Services

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Offshore

Our offshore teams deliver high-quality solutions with minimal onsite dependency and maintain high productivity.

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Onshore

We also offer onsite deputation of our experts for projects requiring close collaboration. Our engineers can work directly at client locations to ensure real-time coordination, faster issue resolution, and smooth project execution.

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Hybrid

We also offer a combination of the best of both models by developing dedicated Offshore Development Centres (ODCs) depending on customer needs to enhance flexible, scalable, and efficient solutions.

Our Testimonials

Let’s hear what some of our clients have to say about us. 

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Sphinx Worlbiz is Your One-Stop-Shop for All Your Robotic Simulation and Digital Manufacturing Engineering Solutions.

FAQ

At Sphinx Worldbiz, we offer robotic simulation services for creating virtual environments to simulate the behaviour, performance, and interactions of robots. These simulations help in testing, optimising, and validating robotic systems before physical implementation in an automotive manufacturing setup.

At Sphinx Worldbiz our robotics applications include the following:

• Material handling and packaging
• Welding (Spot, MIG, STUD)
• Cutting, Clinching, Riveting, Grinding & Polishing
• Painting, Roller Hemming

At Sphinx Worldbiz, we ensure to provide the following benefits with our services:

• Cost Reduction: Simulations reduce the need for physical prototypes and testing
• Time Savings: Faster design iterations and validation
• Risk Mitigation: Identify potential issues and optimise performance early in the development process
• Training and Optimisation: Train operators and optimise robot operations in a safe virtual environment

Sphinx Worldbiz specialises in the following BIW simulation services:

• Specialised in robotics assembly process simulation
• Line sim technometrix- (Process Simulate "CEE")
• Ergo simulation study
• Time- motion simulation study
• Plant material flow simulation in MRS (delmia v5)
• Tandem press simulation
• Virtual commissioning cell build

We, at Sphinx Worldbiz use the following software for robotic simulation:

• DELMIA V5
• PROCESS DESIGNER
• PROCESS SIMULATE
• ROBCAD

Yes, we have EMServer facilities available at Sphinx Worldbiz Limited.

Our other relevant areas of services are as follows:

• PROCESS PLANNING
• 2D & 3D LAYOUT BUILDING
• E-PLAN
• P-PLAN
• FIXTURE DESIGN

No, we are currently in the development phase for this area, but we can prepare the robotic cell for VC testing.

We, at Sphinx Worldbiz use the following software for layout building:

• AUTO-CAD
• MICROSTATION
• FACTORY-CAD

Yes, we can do the simulation starting from SL-01 to SL-5.

KUKA, FANUC, ABB, COMAU, YASHKAWA, KAWASHAKI

Yes, our team can perform online robot programming on KUKA, FANUC, ABB, COMAU, YASHKAWA, and KAWASAKI robots.

Yes, we have experience of press line simulation.

Yes, we do have experience in battery pack assembly simulation.

Not expertise specific to paint shop, but if it's a small job for paint robot reach study & OLP we can execute

Yes, we can, based on job requirement and in the shortest time.

Our team of Simulation Experts consists of 40+ engineers including (layout & process planning + robotic simulation + online robot teaching)

Yes, we have a prototyping manufacturing facility available.

Mr. Avishkar Surana, Director (Marketing). His email address is: a.surana@sphinxworldbiz.com