visual references

Projects

BMW - Shipping Protection Conveyor

Basic Info:
  • Control equipment for Slat Line Conveyor to convey completely assembled cars
  • Spartanburg plant

Equipment:
  • 1 x S7 416F-3F
  • SEW-Movidrive technology for the conveyor equipment
  • 2 x WinCC Operator Panels with IPC477D

BMW - Rework Inspection Conveyor

Basic Info:
  • Control equipment for Slat Line Conveyor to convey completely assembled cars
  • Spartanburg plant

Equipment:
  • 1 x S7 416F-3F
  • SEW-Movidrive technology for the conveyor equipment
  • 3 x WinCC (TIA portal) Operator Panels with IPC477D and IPC677D

BMW – Increase of production capability in Final Assembly at Plant Spartanburg

Basic Info:
  • Increase of production capability of TILT and Heavy-EMS line
  • Expansion of existing TILT line through change of line topology and adding more work takts
  • Implementation of four additional Associate Belt Conveyors into existing TILT and Heavy-EMS lines
  • Modifications on existing Heavy-EMS to achieve more flexibility in production

BMW - AGV systems for FrontEnd and Cockpit lines

Basic Info:
  • Control equipment for AGV systems for two FrontEnd assembly lines
  • Control equipment for AGV systems for two Cockpit assembly lines
  • Spartanburg plant, total of approx. 130 AGV’s

Equipment (per AGV system):
  • 1 x S7-416F
  • Wireless LAN
  • 1 x WinCC (TIA portal) Operator Panel with IPC477D

BMW - IDENT System

Basic Info:
  • Identification system for final assembly hall
  • Spartanburg plant

Equipment:
  • 1 x S7-417-5H
  • Profinet connection to all final assembly lines
  • Profinet connection to MES/ERP production system

Automated guided vehicle (AGV) system - front-end assembly, BMW China Shenyang plant

Basic info:

  • Control equipment for AGV system for front-end assembly line
  • Shenyang Tiexi plant, 1 x AGV system line with 16 x AGVs

AGV control equipment:

  • 1 x S7-416F
  • free WLAN
  • B+R operating consoles with Zenon, Profinet and Pilz pssu peripherals

AGVs:

  • ET200S CPU IM151-8F, Safety CPU, linked by free WLAN to the AGV system's control equipment

AGV system and conveyor equipment for engine assembly at Leipzig plant

Basic info:
  • Control equipment for conveyor facilities for delivery and pre-assembly of engines to the AGV system, AGV system control equipment for 13 x AGVs
  • AGV system path with clocked and progressive assembly sections
  • Leipzig plant - 1 x AGV system line with ca. 13 x AGVs;
Equipment:
  • 1 x S7-319F; free WLAN
  • SEW-Movimot technology for the conveyor equipment
  • MP377 operator consoles
  • AGVs with ET200S CPU IM151-8F
  • Safety CPU, linked by free WLAN to the AGV system's control equipment

BMW - Tilt telpher at Spartanburg plant (United States)

Basic info:
  • Control equipment for a Tilt telpher used in swiveling assembly
Equipment:
  • 2 x Siemens S7-416 (1 x F-CPU)
  • 39 x cabs with Siemens S7-IM151 cab control systems, linked via iWLAN and Leaky Wave, SEW Movipro drives

BMW - BMW i3 "marriage" at Leipzig plant

Basic info:
  • Control equipment for "marriage" (joining the body to the drive train) for the new i03 Electromobile
  • application of a new adhesive technology
Equipment:
  • 4 x gantry automation units
  • 2 x transfer units with SEW safety equipment (DFS/DCS)
  • 1 x S7 control system with CPU416F and 3 x S7 units with CPU319F
  • 9 x Zenon visualization systems with PC677C
  • installations linked to the quality, technology and logistic assembly control systems
  • interfaces to IPM and SAP

BMW - Undercarriage, body frame, and doors at Leipzig plant

Basic info:
  • Plant engineering area
  • complete electrical planning, i.e. hardware construction, software planning and design, switchgear cabinet construction, robot programming
  • supply, assembly, installation, and commissioning of the complete control equipment for facilities such as "Clean, glue and join dashboard", "Undercarriage", "Undercarriage midsection", "Clean, glue and join entire undercarriage", "Clean, glue, and join entire body-in-white 1 and body-in-white", "Clean, glue and join lefthand/righthand doors", and "Measure in-line"
Equipment:
  • 9 x Siemens S7-400 control systems with CPU 416F
  • 56 x operator consoles with Zenon visualization system
  • 9 x visualization systems with Zenon on PC627
  • 22 x ABB IRC5 industrial robots
  • interface to BMW's IPS control system

BMW - Capacity ramp-up in Shenyang (China)

Basic info:
  • Increasing the production capacity of the trim line, heavy-duty telpher, power train, "marriage" and door line
  • equipping a traverse conveying section with 2 x new workstations in the trim line
  • enlarging the line with another stationary lifting and turning station
  • speed and cycle-time optimization in the power-train and marriage sections
  • 3 x new suspension tackles and cycle-time optimization in the telpher section
  • equipping all heavy-duty suspension tackles with battery chargers; software changes (concerning trim line) with respect to line synchronizations
  • evaluation of skid positions with absolute-value sensors in order to minimize the risk of crushing and prevent pile-ups

Fendt/AGCO - 4 conveyor systems at the Marktoberdorf and Bäumenheim (Bavaria) plants

Basic info:
  • Control equipment for 4 separate conveyor facilities
  • Marktoberdorf plant - 2 automated guided vehicle (AGV) lines with ca. 60 AGVs
  • integration of hydraulic hoists, elevating platforms, and turntables
  • loads of about 18 metric tons must be handled
  • Bäumenheim plant - AGV line with ca. 50 AGVs for manufacturing and fitting out tractor cabs
  • conveying equipment for transporting away the completed cabs for shipping
Equipment:
  • 1 x S7-414F
  • open WLAN
  • SEW Movidrive technology
  • MP277 operator consoles
  • AGV system with ET200S and CPU IM151-8
  • 1 x telpher for assembling cabs with 5 x heavy-duty transport units, including conveyor equipment, for delivering the cabs
  • IM151-8 control systems for the transport units
  • SEW Movidrive with functional safety
  • overload evaluation via safety programmable logic controller (PLC)
  • 1 x S7-317F for the control and conveying equipment
  • WLAN with RCoax, Movimot drive
  • MP277 operator consoles

AUDI - Heavy-duty telpher at Györ plant (Hungary)

Basic info:
  • Heavy-duty and floor-mounted telpher with completely new SEW conceptual design respectively SEW electric-vehicle control systems
  • total of 92 x cabs
Equipment:
  • 1 x S7 control system each, with CPU416-F PN/DP and fail-safe functions
  • PROFINET
  • 22 x Siemens MP377 panels
  • panel PCs with WinCC flexible.

MAN - Cutting and marking installation for PA tubing at Munich plant

Basic info:
  • Redesign and construction of a new (respectively replacement of an old) cutting and marking installation for all plastic truck tubing
  • improved functionality
  • 8-10 dispenser units and cutting lines (various diameters)
  • collaboration as general contractor with promark automation GmbH & Co. KG
Equipment:
  • 1 x S7-300 with CPU 317
  • visualization by means of industrial-grade PCs using GraphPic
  • labeling of tubing by means of data from PC (Oracle-DB) with special inkjet printers
  • installation linked to the MAN control system Legato

BMW - Munich and Regensburg plants

Basic info:
  • Shell construction area
  • complete electrical planning, switchgear cabinet construction, programming of robots; supply, assembly, installation and commissioning of entire control equipment for facilities such as "Weld inner panel", "Glue skin", "Bead inner panel and skin", "Weld/glue sidewall"
  • quality control by camera
Equipment:
  • 5 x Siemens S7-400 control systems with CPU 416F
  • 20 x operator consoles with Zenon visualization system
  • 37 x ABB IRC5 industrial robots

BMW - Regensburg plant

Basic info:
  • Plant/Shell construction area
  • complete electrical planning, switchgear cabinet construction, programming of robots
  • supply, assembly, installation and commissioning of entire control equipment for facilities such as "Weld inner panel", "Glue skin", "Bead inner panel and skin", "Weld/glue sidewall", "Weld and glue sidewall"
  • quality control by camera
Equipment:
  • In-line measuring units for L7 doors and tailgates
  • 7 x Siemens S7-400 control systems with CPU 416F
  • 30 x operating units with Zenon visualization system
  • 42 x ABB IRC5 industrial robots

BMW - Flexible stud-welding cells at Munich plant

Basic info:
  • Control and monitoring of stud-welding units with Nelson and Tucker stud-welding technology
  • complete electrical planning, software development, and commissioning
Equipment:
  • 2 x Siemens S7-400 control systems (CPU 416F-PN)
  • 2 x Zenon visualization systems on PC627
  • 6 x ABB IRC5 industrial robots (cooperating robots with ABB Multimove and Safemove)

BMW – PL7 side frame in Dingolfing plant

Basic info:
  • Project in the area of automotive body assembly (Model F34)
  • programmable control systems for facilities such as "side frame - inside", "side frame - outside", "side frame - middle", or "weld, handle, join, and transport side frame"
  • hardware and software planning, construction of switchgear cubicles, erection, installation, and commissioning.
Equipment:
  • 7 Siemens S7-400 control systems with CPU 416F
  • 27 operating units with Zenon visualization system - in part on a PC627

BMW – Module fabrication and management of storage-battery cells, Munich, plant on Hufelandstrasse

Basic info:
  • Controls for "laser welding", "plasma cleaning", "support gluing", "Tox pressing spindles", and the "resistance and high-voltage insulation measurements"
  • complete electrical planning, software development, commissioning

Equipment:
  • one S7-400 control system
  • one Zenon visualization system on a PC627
  • three operating units; six ABB IRC5 industrial robots
  • linkage to BMW's IPS coordinating control system

Magna Cosma Europe - B-pillar for Opel Zafira at Bopfingen plant

Basic info:
  • Complete electrical planning, switchgear cabinet construction, programming of robots
  • supply, assembly, installation and commissioning of entire control equipment.
Equipment:
  • Siemens S7-400 control system with CPU 416-2DP
  • Pilz safety control system with Safety Bus-p
  • visualization system with WinCC flexible on MP-377 touch panel
  • 3 x Kuka industrial robots
  • Matuschek welding-power control systems
  • link to corporate network via Profibus

Magna Cosma Europe - MQB assembly line at Bopfingen plant

Basic info:
  • Complete hardware and software planning
  • switchgear cabinet construction, programming 2 x Kuka industrial robots and the control system
  • commissioning
Equipment:
  • Bushing inserting center with Kistler servo pressure cylinder
  • SEMA milling center
  • DMC-code camera systems and corresponding label printers

Magna Cosma Europe - VW MQB rear-axle mounting at Bopfingen plant

Basic info:
  • Complete electrical planning
Equipment:
  • 2 x S7-400 control units
  • 8 x visualization systems with WinCC flexible on PC627 and MP-277 touch panel
  • Feldbus or Profibus interfaces to the installations and devices
  • Kuka industrial robots for MIG/MAG welding
  • SKS-MIG/MAG welding control system
  • Markator embossing and marking systems

BRP AGV assembly line for Spyder and Skidoo (Valcourt, Canada)

Basic Info:

- Control equipment for an AGV assembly line in work cycle and line production

- AGV system with a total of 67 AGVs

- Adjustable rates of flow in the production of diverse types

Control equipment:

  • 1 x S7 417-5 H
  • WLAN
  • Operator panel with IPC 477D

AGVs:

  • ET200S CPU IM151-8F, Safety CPU, connected via WLAN to the AGV control technology

BRP AGV assembly line for Quads/Can-AM (Juarez, Mexico)

Basic Info:

  • Control equipment for an AGV assembly line
  • AGV system with a total of 44 AGVs (expansion to 72 AGVs, end of 2018)

Control equipment:

  • Siemens S7 414
  • WLAN
  • Operator panel with IPC 477D

AGVs:

  • ET200S CPU IM151-8F, Safety CPU, connected via WLAN to the AGV control technology

BRP AGV Pilot-assembly line for motors (Gunskirchen, Austria)

Basic Info:

  • Control equipment for an AGV assembly line
  • AGV system with a total of 8 AGVs
Control equipment:
  • Siemens S7 412
  • WLAN
  • Operator panel with IPC 477D

AGVs:

  • ET200S CPU IM151-8F, Safety CPU, connected via WLAN to the AGV control technology

BRP FTS assembly line for motors (Gunskirchen, Austria)

Basic Info:

  • Control equipment for an AGV assembly line
  • AGV system with a total of 26 AGVs

Control equipment:

  • Siemens S7 412
  • WLAN
  • Operator panel with IPC 477D

AGVs:

  • ET200S CPU IM151-8F, Safety CPU, connected via WLAN to the AGV control technology

Dual Strand Conveyor (Plant Spartanburg/USA)

Basic Info:

  • Control equipment for lead time buffer (take-over after paint) and three assembly lines
  • approx. 240 drives, dual strand conveyors, lifters, lifter tables, rotary tables
  • High speed door, different interfaces e.g.: to the plant MES, handling devices, automatic stations
  • 30 Control panels

Equipment:

  • 3 x S7-416F
  • ET200SP Remote IO Panels
  • SEW-Movidrive technology for the conveyor equipment and lifter
  • Operator panel IPC477D and IPC677D with WinCC (TIA Portal),
  • BMW TMO V1 Standard

BMW Exhaust systems conveyor (Plant Munich)

Basic Info:

  • Control equipment for conveyor-system to transport containers loaded with exhaust systems
  • The construction consists 44 conveyor elements, four lifting stations, eight high speed doors, two automatic fire doors
  • 13 Operator panels

Equipment:

  • S7-1518F-4PN/DP, ET200SP, RFID data system technology
  • SEW Movidrive und Movifit MC/FC classic and technology execution
  • Operator panel with Siemens IPC 677D and IPC 477D with WinCC Professional
  • Profinet with Profisafe
  • BMW TMO V3 Standard

BMW AGV axle assembly line, hall 140 (Plant Munich)

Basic Info:

  • 3 autarkic AGV lines with a total of 130 vehicles
  • Control equipment for 3 AGV assembly lines
  • Take-over to an electrified monorail system via lifter

Control equipment:

  • 3 x S7-1518F-4PN/DP
  • 21 Operator panels IPC 677D with Euchner Electronic-Key-System
  • Lifter with SEW Movidrive, with absolute encoder
  • BMW TMO V3 Standard

AGVs:

  • ET200S CPU IM151-8F, Safety CPU, connected via WLAN to the AGV control technology

Free parametrization of ea. work tact via WINCC Professional

BMW Exhaust systems conveyor assembly handling device (Plant Munich)

Basic Info:

  • Control equipment for conveyor to transport exhaust systems and an assembly handling device
  • BMW plant Munich, construction consists 4 conveyor elements, 1 handling device, 1 operator panel

Equipment:

  • S7-1516F-PN/DP, ET200SP, hand scanner
  • SEW Movifit MC classic execution
  • Operator panels with Siemens IPC 677D with WinCC Professional
  • Profinet with Profisafe

BMW Traverse construction (Plant Munich)

Basic Info:

  • 3 seperate assembly/disassembly constructions:
    assemblybar assembly, paintbar disassembly, assemblybar disassembly
  • Assemblybars are set on a station and are disassembled after assembly process with a second construction. Third construction disassembly paintbar after assembly of the assemblybar. Constructions consists of longitudinal conveyors, robots, power screwdriver and lift tables for conveying and assembling construction components.

Equipment:

  • S7-1518F-4PN/DP, ET200SP
  • SEW Movidrive with servo- and asynchronous traction motors
  • Kuka robots, corded electric screwdrivers
  • Operator panels with Siemens IPC 677D with WinCC Professional
  • Profinet with Profisafe
  • BMW TMO V3 Standard

AUDI Doors EMS ML 1 / 2 (Plant Ingolstadt)

Basic Info:

  • Control equipment for 2 EMS-conveyor constructions to transport doors
  • Construction consists of eight lifting stations, 4 fast action doors (roller shutter), two fire protection doors and 36 operator panels, total length: >2000 m

Equipment:

  • S7-Classic CPU 319F-3PN/DP, ET200S, RFID data system technology
  • SEW Movidrive B with technology execution
  • Operator panels with Siemens MP377 with WinCC flexible
  • Profinet with Profisafe

AUDI Cockpit EMS ML 1 / 2 (Plant Ingolstadt)

Basic Info:
  • Control equipment for 2 EMSs of the Cockpit pre-assembly and conveyor technology for delivering to the assembly line
  • Process technology is realized using 2 additional PLC’s
  • Vehicles with hub- und rotation axles
  • 16 Operator panels
  • Total length (EMS) 600 m

Equipment:

  • S7-Classic, CPU 319F-3PN/DP, ET200S, RFID data system technology
  • EMS-carriers with Rofa vehicle control system RCU 750, linked to Vahle SMS rail (Ethernet/Profinet)
  • SEW motors, ET200Pro motor control system, Movidrive (lifter)
  • Operator panels with Siemens MP377 with WinCC flexible
  • Profinet with Profisafe

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