Solutions

Our innovative software systems realise complex automation tasks in milling, grinding, cladding, coating, and additive manufacturing. For particularly demanding challenges, we integrate 3D scanners and process sensors into standard industrial machines and robots.
With our application modules, components can be automatically processed according to their individual shape or wear conditions. This allows our customers to repair, for example, engine or turbomachinery components and to customise components with AM. They also repair tools, deburr cast workpieces, machine AM components, and much more.

BCT solutions are modular and can therefore be combined to create automated processes and process chains.

OpenSCAN: In-process laser line scanning and scan data preparation
OpenFIT: Best-fit machining based on probe data and 3D scan data
OpenDED: NC path generation for DED based on CAD and 3D scan data for additive and hybrid processes; automatic DED process for rotary components
OpenDATA: In-process sensor data acquisition, spatially resolved display, and evaluation
OpenARMS (Open Adaptive Repair and Manufacturing Software): Application-specific automation solutions for adaptive machining

BCT solutions are open to industry-standard CAD and CAM formats, sensors, and controllers, and support both Cartesian machines and industrial robots. For the development of applications, we have several 3D printers, a 5-axis machining centre, a robot cell with an 8-axis robot available, as well as various 3D line scanners and process sensors.

OpenSCAN

Capturing component geometry using laser line scanning

To consider for individually shaped components or special clamping situations during automated processing, deviations from the nominal shape (CAD) and nominal position must first be determined. In the simplest case, this is done by tactile measurement with touch-trigger probes. However, if the task requires a large number of measurement points, laser line scanning is more suitable. This method measures the distances of a laser line projected onto the component to the sensor, point by point. Therefore, laser line scanning delivers a huge number of measurement points in a short time. OpenSCAN allows you to conveniently define scan paths and display the scan results. Special compensations increase the overall accuracy of the measurements and ensure that scans taken from different directions result in a consistent point cloud.

Measurement of components in machines or with the robots
Short measurement times with high resolution
Capturing component geometries for various applications

OpenFIT

Precise Alignment of Components

By taking into account inaccurate component positions in the fixtures, OpenFIT ensures that all NC machining operations are carried out at the planned positions. Allowances on forged, cast, or 3D-printed blanks are taken into account, and finished part geometries are “fitted” into the blanks. OpenFIT operates independently of CAM systems. It takes over existing NC programs and adapts them, taking into account the machines/robots and fixtures used.
The integrated module for tactile measurement records the position of the components within the machine. The necessary data exchange with the controller takes place automatically. Alternatively, the required information can also be extracted from scan data (virtual measurement). Based on the results, OpenFIT minimizes deviations between the target and actual positions, thereby optimizing the orientation of the machining operations.

Key points:

No lengthy, manual alignment process
Reduced fixture requirements (cost reduction)
Control over machining allowance
Seamless integration into the process flow
No need to recalculate NC programs using CAM

OpenDED

Automated Directed Energy Deposition

Automated DED opens up a wide range of possibilities for part manufacturing and repair. Standard components can be adapted to specific requirements by adding functional elements, and worn areas can be filled.

OpenDED offers customised path strategies for the welding process (laser welding with powder or wire, arc welding, EHLA), including special approach and retraction movements. Welds can be performed on CAD-described or scanned base surfaces. The construction of rotationally symmetrical components is simplified by specialised strategies that optimally utilise the system’s rotation axes.

After CAD import or scanning of the substrate geometry and definition of the desired target geometry, the required build volume is determined and filled with weld paths. Different strategies allow the process to be adapted to specific requirements. The build direction and orientation of the welding head can be specified. The build of rotationally symmetrical components on systems with rotary axes requires only a minimum of start/stop operations. The underlying system description, including kinematics, allows motion sequences to be simulated.

Key points:

Path generation for AM welding (on flat substrates as well as on scanned surfaces)
Strategies for Cartesian machines
Optimised strategies for the build of rotating parts on systems with rotary axes
Path simulation including machine/robot

OpenDATA

Spatially resolved acquisition of process data

Processes can only be improved based on sufficient information about the relevant process data. In a milling process, vibrations and milling forces, rotational speeds, and feed rates can be measured. In additive processing, a wide range of parameters, from laser power to melt pool temperature, can be recorded to draw conclusions about the process behaviour.

OpenDATA answers the question of which process data was measured at which location on the component. The spatial resolution thus allows for quick and practical insight into the respective process and provides reliable information for optimisation or monitoring.

Key points:

Precise assignment of measured values to the location on the component
Support for a wide variety of sensors
Clear display of spatially resolved measuring values

OpenARMS

Automatic machining of individually shaped components

The actual shape of components often deviates from the nominal geometry. The reasons for this are varied, such as inaccurate manufacturing of raw parts or individual wear in repair applications. In any case, such individually shaped components pose a challenge for serial machining.

BCT offers specialised software solutions for such adaptive machining tasks under the OpenARMS (Open Adaptive Repair and Manufacturing Software) product group.

First, the actual situation is captured using the integrated measuring module for contact probes or laser line scanning with OpenSCAN, or using external measurement/scan data. This enables the application-specific geometric adaptation of the nominal NC programs. The connection of OpenARMS to the machines or robots makes adaptive machining in series possible. OpenARMS thus combines the ideal CAD/CAM descriptions with the real, individually shaped components.

Key points:

Integrated capturing of component shape and position, tactile or optical
Suitable for additive and subtractive manufacturing processes
Automatic, serial adaptive machining through direct connection to NC systems
Elimination of tedious manual alignment processes
Reduced fixture requirements –> cost reduction
Reduction in scrap
Minimising manual rework.

The principle of adaptive machining

Only taking the respective component shape and clamping situation into account makes automatic machining of individually shaped components possible. But for this, adaptive machining requires knowledge of the nominal and the current, real-world situation.

Nominal: Component geometry (CAD model) and NC program (CAM) (1/2).
Import via interfaces.
Real: Actual position and geometry (3) captured tactile or optical.
Adaptation: Adapting NC machining to the real-world situation
Result: NC programs adapted to the actual position and component geometry (4).

System Integration

Everything from a Single Source

Systems for adaptive machining, whether additive or subtractive, always consist of a combination of measurement and system technology. To ensure a seamless exchange of status information and data between the components, OpenARMS is directly connected to the respective systems. This allows the sending of measurement programs, the receiving of measurement results, and the transmission and execution of customised NC programs. In addition to the software, BCT also supplies the appropriate sensors for capturing the actual geometry, the clamping elements, and the complete system hardware, including NC machines/robots, ensuring smooth operation of the systems.

Key Points:

Delivery of the complete system from a single source
Seamless integration of different components
Mapping of complex process sequences