Process Modeling logic for Custom BIW Cell (Imported Geometry)

Process Modeling
1

Hello everyone,

I am a student currently working on my Bachelor’s Thesis project (POLYTEHNIC UNIVERSITY OF BUCHAREST, FACULTY OF INDUSTRIAL ENGINEERING AND ROBOTICS). My goal is to recreate a complex BIW (Body in White) Welding Cell simulation based on a real-world reference.

Context: I am rebuilding this cell based on this video: https://www.youtube.com/watch?v=48m_RvzMCcM

The Challenge: I have successfully imported and configured my own CAD geometry (Robot 7th Axis, Custom Linear Rail, Custom Lifters/Positioners). However, I am completely stuck on the Process Modeling phase. I do not understand how to make my custom imported geometry work with the Process Flow. I don’t want to replace my models with standard eCatalog components (like generic conveyors or feeders) because I need the specific components of my design.

My Layout & Workflow (See attached screenshots):

  1. Inputs/Outputs: 3 separate entry points for BiW parts, 1 exit point.

  2. Handling: 3 Handling Robots pick parts from 4 linear positioners and place them onto the central line.

  3. Process Station 1 (Lift & Weld):

    • A set of 4 synchronized linear positioners (custom modeled) must receive the parts.

    • Logic: They LIFT the assembly → Spot Welding Robots weld it → They LOWER the assembly onto a central shuttle.

  4. Transport: Custom Linear Rail (Shuttle) transports the assembly to the next zone.

  5. Process Station 2:

    • Another set of 4 Positioners LIFTS the part from the shuttle → More welding → LOWERS it back.

  6. Exit: Shuttle moves to exit.

My Questions:

  1. Custom Geometry as Process Node: Since I am not using eCatalog parts, what Behaviors (Transport Node, Process Executor, etc.) do I absolutely need to add to my custom CAD to make it recognized by the Process Flow?

  2. The “4-Legged” Station: How do I treat the 4 separate positioners as a single logical station for the simulation? I need the part to sit on all 4 of them, but logically be processed as one unit.

  3. Complex Sequence: How do I program the Transfer → Lift → Weld → Lower → Transfer sequence in Process Modeling?

I have attached screenshots of my current layout below.

Any guidance, tutorials, or examples of setting up Process Flow on purely custom geometry

would be incredibly helpful for my graduation project.

Thank you in advance!

LAYOUT CELULA - ENGLISH
LAYOUT CELULA - ENGLISH1640×901 16.9 KB

314
3141278×871 258 KB

Poza de sus celula
Poza de sus celula1137×922 160 KB

CELULA MANIPULARE SUDARE BiW GP225.vcmx (11.0 MB)

2

Good morning,
Here’s some advise to help you in start.
1. Modeling a process node:
It requires Transport Node, Process Executor, Component Container and preferably Statistics behaviors, as well as setting the references between them. I recommend checking the Machine Wizard command from Modeling Wizards, as it sets up these behaviors in your component with fewer clicks.
2. 4-legged station
Model the 4 legs as one link in one component. If they are always synchronized, there is no reason to control them separately in the simulation.
To easily command the axis up/down from a process, you should check IO-Controls wizard from the Modeling wizards: it creates the signals and logic script to drive a joint up and down. You can then use Send Signal and Wait Signal statements to command the positioner.
3. The sequence
I would model the transport linear rail so that the moving link contains the behaviors of process nodes. Then it’s easy to use the Move Joint statement from the process to transport the parts in the correct position
Then each of the 4-leg positioners would also have the process node behaviors in the moving link, and would call the spot welding program with a Run Robot Routine statement.
The process flow would be something like this: shuttle → positioner 1 → shuttle → positioner 2 → etc.

I hope this helps you to start.

2 Likes
3

Thank you for your advice. I’ll get to work on it later today and I’ll come back with results.