Plant Stationary Equipment BM Calculation for Scrap-Optimized Plate Nesting
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Solution Overview
Problem
The manual BM calculation for plant stationary equipment leads to inaccuracies, increased scrap rates, and higher costs due to the lack of an automated system for optimizing material purchasing and cutting plans.
Innovation Solution
An automated BM calculation method using a strength calculation program to extract data, convert it into a usable format, and execute a BM calculation program to optimize cutting and fabrication plans, minimizing scrap and reducing labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual BM calculation is used for stationary equipment, then flexibility in processing is maintained, but calculation accuracy decreases and scrap rate increases
Solution Approach 1:
The patent replaces manual BM calculation (mechanical human operation) with an automated computer-based calculation system. The system extracts data from strength calculation programs, processes it through algorithms, and generates optimized BM results automatically, eliminating manual errors while maintaining high flexibility through programmable parameters and configurable calculation rules.
2Measurement precision
If automated BM calculation is implemented, then calculation accuracy improves, but system complexity increases
Solution Approach 1:
The patent introduces an intermediary data processing layer that bridges strength calculation programs and BM generation. This intermediary system standardizes data extraction, performs automated calculations using configurable parameters, and generates results in a unified format, thereby managing system complexity through modular architecture while delivering accurate BM calculations.
Solution Approach 2:
The automated BM calculation system is designed with universal functionality to handle multiple stationary equipment types (pressure vessels, towers, tanks, heat exchangers, reactors) through a single integrated platform. The system uses configurable parameters and standardized data structures that can adapt to different equipment configurations without requiring separate specialized systems for each equipment type.
3Loss of substance
If manual BM calculation is used, then implementation simplicity is maintained, but material utilization efficiency decreases
Solution Approach 1:
The patent utilizes parameter changes in the automated calculation system to optimize material utilization. By dynamically adjusting calculation parameters such as cutting patterns, plate sizes, and fabrication margins based on equipment geometry and material properties, the system minimizes scrap generation while maximizing material usage efficiency across different stationary equipment types.
4Loss of substance
If automated BM calculation with optimization is implemented, then material utilization improves, but calculation time increases
Solution Approach 1:
The patent applies preliminary action by pre-configuring optimization parameters, cutting patterns, and material specifications in the automated system before actual BM calculation. The system pre-processes geometry data, pre-determines optimal plate sizes based on standard inventories, and pre-configures fabrication margins, thereby reducing actual calculation time while maintaining scrap minimization benefits.
Data Source
AI summary
The present disclosure relates to a bill of material (BM) automatic calculation method for plant stationary equipment, and more particularly, to a BM automatic calculation method for plant stationary equipment capable of automatically calculating BM data for purchasing a plate required quantity required for manufacturing stationary equipment through cutting plan and optimization deployment in order to manufacture stationary equipment using data extracted from a strength calculation program of the plant stationary equipment prepared in a plant engineering step. The present disclosure has an advantage of greatly reducing the labor force by automatically calculating the cutting plan drawing, the nesting plan drawing, and required BM of the plate of the stationary machine which has been manually performed in the related art.