3-Roller Bending (deprecated)

Note: See the deprecation notice regarding this process above at Machines.

aPriori uses the formulas below to determine costs associated with this bending process (used for plate rolling).

Accounting Calculations

Labor Time = Cycle Time * Machine Labor Time Standard

Labor time is the product of the following

  • Cycle time (see Cycle Time Calculation)

  • Machine labor time standard (specified as a machine property). This value reflects the amount of time spent by machine operators in between machine cycles, including time performing maintenance and cleaning tasks as well as time pausing between tasks. The amount is expressed as a cycle time multiplier.

Labor Cost = (Labor Time / 3600) * Labor Rate

Labor cost is a function of the following:

  • Labor time (see formula above)

  • Labor rate: this is the product of the following:

    • Machine property Labor Rate
    • Cost model variable laborRateAdjustmentFactor (1 in starting point Digital Factories)
    • Machine property Work Center Labor Rate Factor (1 in starting point Digital Factories)

Amortized Batch Setup = Machine Setup Time * Labor Rate

Amortized batch setup is a function of the following:

  • Machine setup time (specified as a machine property)

  • Labor rate: this is the product of the following:

    • Machine property Labor Rate
    • Cost model variable laborRateAdjustmentFactor (1 in starting point Digital Factories)
    • Machine property Work Center Labor Rate Factor (1 in starting point Digital Factories)

Cycle Time Calculation

Cycle Time = Load Time +Unload Time +
Rolling Time + Inspection Time

Cycle time depends on the following:

  • Load time (obtained from lookup table; see below; increases with part mass, which increases with material density)

  • Unload time (obtained from lookup table; see below; increases with part mass, which increases with material density)

  • Rolling time (see formula below)

  • Inspection time (see formula below)

Rolling Time = (Sheet Width *
Number of Passes) / Rolling Rate

Rolling time depends on the following:

  • Sheet width (obtained from GCD extraction)

  • Number of passes (linear function using the ratio of bend diameter to part thickness—the ratio must be less than 20; number of passes capped at 10)

  • Rolling rate (specified as a machine property)

Number of Passes = Linear function using ratio of Bend Diameter to Part Thickness (Diameter Thickness Ratio must be less than 20. Number of Passes capped at 10.)

Inspection Time = (Load Time + Unload Time + Rolling Time) *
Hourly Inspection Rate

Inspection time depends on the following:

  • Load time (obtained from lookup; see below; increases with part mass, which increases with material density)

  • Unload time (obtained from lookup table; see below; increases with part mass, which increases with material density)

  • Rolling time (see formula above)

  • Hourly inspection rate (based on plant variable inspectionMinPerHour)

Load and unload times by part mass are contained in the lookup table rollingHandling.