Belt-drive systems engineering toolkit
Legacy modernization of mathematically complex applications
Client
NDA
US
Team
11 specialists
Timeline
January 2019 – ongoing
Engagement
6 years
Project summary
VB6 to .NET migration – belt-drive systems engineering precision without risks associated with aging software. We transformed a mathematically complex toolkit (VB6, VBA) to deliver a cross-platform .NET application – instantly minimizing licensing costs for 75% of users.
Stop wasting a sum of up to 80% on maintaining outdated systems.
Services:
Overview
Project overview
We joined the project to empower a manufacturer of industrial belt-drive systems and fluid power solutions. They work with leaders in automotive, agriculture, forestry, construction, mining, and other complex industries to improve the efficiency and safety of operations.
- Their focus: the design and manufacturing of durable motion & power solutions
- Their product: a specialized engineering toolkit for designing and analyzing complex belt-drive systems
Our company was approached to modernize and extend a portfolio of mathematically complex applications. They caused multiple issues from maintenance to security.
Learn about the details from this case study.
Project goals
Project goals
Eliminate risks
Future-proof toolkit
Preserve accuracy
Cut costs
Enable growth
Expand capabilities
The problem
Critical calculations, aging foundation
An unsupported VB6 framework
A fragmented VBA codebase
A limited WinForms functionality
MATLAB & AutoCAD dependencies
Data corruption
Security vulnerabilities
Intermittent crashes
Progress loss
Complicated troubleshooting
Complicated maintenance
A rising licensing cost
Limited growth
Our solution
Same logic, better execution
Modern applications
Unified workflows
Reliable calculations
Lower dependency
Cross-platform capabilities
New functionality
Key features
One toolkit to cover every task
The platform is basically an application with multiple specialized modules that serves internal needs:
- There are 6 modules that support the specification and engineering of complex belt-drive systems, which are being distributed across multiple major sectors
- 2 of 6 modules are public – external users might perform own calculations and order custom solutions
It provides:
- A comprehensive design guidance
- A complete product catalog
- Project creation
- Derivatives creation
- Design calculations
- PDF reports
Along with:
- User and permission management
- Version control
- Automatic updates
- Automatic backups
Design modules
1. 2-point belt drive system design tool to review potential solutions for defined and existing industrial drives.
2. Multi-point belt drive system design tool to calculate belt tension, belt length, shaft load, and more.
3. A module to design motorcycle and scooter drives.
4. A module to analyze the layouts of accessory belt drives.
5. A module to analyze the layout of synchronous belt drives. In particular:
Belt-tensioner interaction
Installation conditions
Tolerance stack-up
Thermal behavior
6. A module to design teeth profiles. It helps:
To forward generate profiles from hob to pulley
To backward generate profiles from hob to pulley
Wrap mold into rack
Un-wrap rack into mold
Mobile functionality
2-point drive design module, which allows to quickly:
Select products
Specify details
Consider service and equipment as well as other important conditions
Create reports
2. Premises’ management, which users to quickly:
Add/merge/edit premises
Add drives
Review distributors
Search co-workers
3. Tensioning calculation – by using this tool, the user can run tensioning calculation in three different modes:
4. RPM calculation – by using this tool, the user can measure belt RPM.
5. Sound meter – by using this tool, the user can measure noise levels in decibels.
6. Distance meter – by using this tool, the user can calculate geometric parameters.
Main challenges
The behind the scenes
Algorithm precision
Some algorithms had to be rewritten to a modern language with precision to prevent regression issues.
Outdated logic
Some algorithms had to be rebuilt all over from scratch and had us involving additional engineers.
Cross-platform architecture
To ensure easy maintenance, we shared a common business logic across platforms:
Essential functions are extracted to common data libraries
As changes are introduced, those functions are being automatically included across platforms
Essential functions are extracted to common data libraries
As changes are introduced, those functions are being automatically included across platforms
Custom calculations
In collaboration with the client company’s product engineers, we implemented industry-specific calculations. By leveraging our expertise in applying computer vision, we enabled the end-user to conduct drive calculations by using Apple ARKit.
Our approach
Module-by-module, modernized
VB6 modernization
We migrated VB6 applications to the .NET framework.
VBA modernization
We reworked VBA functionality into maintainable modern applications.
WinForms to .NET migration
We rebuilt WinForms modules on the .NET foundation.
MATLAB & AutoCAD migration
We recreated dependent functionality to minimize third-party needs.
We provided:
Discovery
Analysis
Modernization
Migration
Unit testing
Automated testing
Refactoring
Rebuilding
Performance optimization
Software development
User training
Technical support
Business outcomes
The payoff of leaving legacy behind
75%
of users pay lower licensing costs
Fewer
crashes forget about runtime error
Lower
burden of troubleshooting and maintenance
Faster
training with consistent, unified workflows
Before
The client was dependent on unsupported, aging technologies, fragmented applications, limited functionality, and expensive third-party tools.
After
The client now enjoys a modernized .NET toolkit, consolidated applications, expanded functionality, and lower third-party dependency.
Tools & technology
Backend
- C#
- .NET 6
- .NET 7
- ASP.NET Web API
- Wout Ware CadLib
Frontend
- WPF
- MVVM Light
- MahApps.Metro
- Blazor
- Xamarin
Infra & DevOps
- Visual Studio 2022
- TFS
- TestFlight
Project timeline & team
Project manager
Business analyst
Technical lead
CV engineer
Software developers
QA engineer
UI/UX designer
Technical writer
Total duration:
6 years and going
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