Case Study

Stretching the limits of innovation

Roschiwal + Partner

Innovative engineering service provider delivers high value to customers – reduced costs, modular construction, superior product output and enhanced production

Extensive service portfolio

Approximately 100 engineers at Roschiwal + Partner, an engineering service provider, have comprehensive experience in designing machine tools and leveraging transmission, assembly and test bench techniques. They also excel at designing special machines for wood, paper and foils. These engineers provide design services for aerospace companies, for product development and for the manufacturing optimization of industrial products, such as pumps, cylinders and huge telescopes.

As part of its service portfolio, the company provides idea generation, concept development, engineering, composition, finite element modeling (FEM) calculation and prototype delivery services for its customers. However, not every customer makes use of the company’s full range of services. In some instances, the company provides its customers with single design packages that are described in-depth and professionally realized in ideal structures. In other cases, the company executes cost-reducing product revisions that include new machine concepts, processes and modules.

When FEM calculations are required for product development and risk analyses, the company can perform failure modes and effects analysis (FMEA). If customers want to release their engineering groups from routine work, Roschiwal’s Romanian subsidiary can perform 3D modeling of carry-over parts. Roschiwal is highly trusted by its customers. In fact,many well known industrial customers derive their NC programs directly from the models that Roschiwal delivers – without inspection of the related drawings.

CAD systems as tools

Sabine Roschiwal, the company’s commercial director, notes that for this kind of close cooperation, an engineering service provider needs to have the same CAD infrastructure as its particular customer. Roschiwal points out that for his firm, in practical terms, this means that the CAD infrastructure should include one of the world’s leading CAD systems that exactly matches the customer’s current version in use, as well as add-ons and a standard parts pool.

Roschiwal describes the company’s working environment: “Every colleague is proficient in several leading systems, knows various engineering methods and often inserts this valuable know-how in external projects.”

“However, a CAD system is still only a tool for us,” adds Guenther Denuel, technical director of the company. “Its utilization may not be mixed up with the real work.Our customers get solutions, not just work force.”

The company’s projects are predominantly realized in-house. The ability to exchange information between colleagues who are experts of different domains, a creative work environment and the CAD infrastructure combine to maximize company expertise for every customer project.

The ascent of NX

Sometimes new tools establish new solutions. A good example is NX™ software, the digital product development suite provided by Siemens PLM Software. Roschiwal + Partner began to implement NX in 1998 when a well-known machine tool manufacturer was looking to support the development of a modular milling machine concept. One of the first German engineering companies, the firm had selected NX because of its master model concept, on-request parametrics, many special features and their related benefits.

“By now, we noticed the (NX) system’s unstoppable ascent in our most important customer industry,” says Denuel. Several current projects demonstrate NX’s high performance in practice.While working with a customer, Roschiwal + Partner recently realized a design concept for the efficient preproduction of cast machine beds. Various machine configurations are based on the same casting bed, which is milled from the requested configuration solely during NC processing. Up to 70 percent of these configurations contain common parts. To define the NC processing, the casting part (modeled in NX) is linked to the needed finished part, which also is engineered with NX. This process enables the company to turn identical basic components into the requested machine bed in no time.

Another example of NX’s efficiency is demonstrated by a completely different project, which was required to apply an existing safety closure principle to oil tube fittings. In this instance, a cable pull operates along the tubes to close and disconnect the fittings to prevent tube leakage. A problem involving the constriction of the tube section was resolved with the design of a ball that is perforated in the same diameter as the tube section. In case of emergency, the ball can be turned into a complete closure by the cable pull.

To facilitate this design solution, the original parts had to be modified and transferred on further fitting models with different inch-long sections. These designs were created in NX and scaled with the system’s new synchronous technology. This approach facilitates direct geometry editing, which involves scrolling and turning the surfaces without the constraints of history and parametrics; it also facilitates controlling the model by dimensions or by values. After scaling without parametrics, all dimensions exist in new variants that can be modified more easily. All drawing information is directly included into the master model.

As a service provider, Roschiwal + Partner knows extremely complex, parameter-driven systems by heart. Its cooperative work with a well known printing machine manufacturer demonstrates its capabilities. The manufacturer’s huge plants require complex kinematics that consist of parametric-built series and modules. Roschiwal engineers leverage the NX suite’s exceptional module functionality to quickly and contextually perform their design work by starting the structure and subsequently picking the requested module.

Roschiwal + Partner are also enthusiastic about another key NX function: the system’s direct modeling capabilities. Direct modeling enables engineers to perform layout creation without the need to concentrate on design method, parametrics or module engineering. It also facilitates drafting and the presentation of ideas and concepts. “This is a completely new CAD functionality, which strengthens our core competency of permanently creating new ideas,” says Denuel.

Once a customer accepts an idea, new models are designed according to established guidelines. However, concept modeling enables engineers to finalize their work much faster. Essential questions are already answered, all required information is available, and modification is significantly easier when compared to the old method. Innovation barriers are notably reduced as well. The company’s engineers are positively impressed by new functions like the drilling module (which enables complex processes to be easily grouped) and geometric search. With NX’s geometric search, technical and economical aims can be more effectively satisfied. Geometric search facilitates part re-use, which reduces purchasing and manufacturing costs while relieving engineers from routine work that has already been done by a colleague.

Successful cooperation

Roschiwal + Partner generates up to 80 percent of its revenue from machine and plant engineering customers. In the last decade, NX became standard in this industry. At Roschiwal, more than 30 percent of approximately 250 projects per year are realized with NX – and the trend is still increasing. None of the company’s innovative engineers regrets this fact. Engineers note that NX suite’s technical features are inspiring and Siemens PLM Software’s support is excellent. “We are very pleased with the solution’s value in terms of speed and quality,” says Denuel. “In the last years, we’ve established an excellent relationship with the team.”

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