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Conversion front end and cockpit preassembly (AGVS), BMW USA

Date: 2023 to 2024
Contracting entity: DS AUTOMOTION GmbH
End customer/site of installation: BMW Spartanburg (USA)

Project description:

  • Entire electric planning (hardware construction, software project planning)
  • Control cabinet construction
  • Supply of new subdistribution boards and human interfaces
  • Assembly and installation
  • Software and commissioning
  • Disassembly of the existing system

In the course of an expansion of the final assembly, the existing plant had to be moved and expanded. The AGVS was moved in several steps and expanded according to construction progress. In addition, the general contractor also delivered other vehicles that we provided. New cabinets were built and installed to meet the increased power requirements, visualization was created on new panels, and the software was adapted and put into operation according to the step and course guidance. Our scope included the complete disassembly and reassembly of electrical components.

Technologies (excerpt):

S7-1500 with CPU 1518F – PN/DP | OC visualization with WinCC-TIA on Beckhoff CP3224 | OP visualization with WinCC-TIA on Beckhoff CP3224 | Vahle technology version | SEW drives | Siemens ET200SP and ET200Pro I/O modules

AGVS for a high-voltage battery assembly (new battery production plant)

Date: Projects from 2020 to 2024
Contracting entity: DS AUTOMOTION GmbH
End customer/site of installation: BMW Dingolfing (W2.20)

Project description:

  • Entire electric planning (hardware construction, software project planning)
  • Control cabinet construction
  • Provision of control technology
  • Assembly and installation
  • Project-dependent: virtual commissioning, physical system start-up

Technologies (excerpt):

2 pieces S7-1500 with CPU 1518F – PN/DP | OC visualization and OP visualization with WinCC TIA V14 on Siemens PC-677D and Beckhoff CP3224-2003-0020 | 11 pieces access points for Wi-Fi coverage (communication with vehicles) | 68 pieces vehicles for the transport and assembly of the high-voltage storage systems | 64 pieces vehicles with lifting and swiveling unit for the transport and assembly of the high-voltage storage systems

Process description:

The central control system developed by Kocher for the automated guided vehicle system (AVGS) carries out not only the data management with the hall control system of the end customer (from order data preview to error messages), but also all process-relevant orders of the vehicles via robot cells and manual processing stations. With its own Wi-Fi structure, it is the centerpiece of the workflow and controls the process throughout the entire production line for all station control points. 

Entries can be made via a visualization interface to adjust parameters, select/deselect processes, and display processes, vehicle positions, interface overviews, and error messages. In addition to the standard process sequences, emergency strategy concepts are implemented according to individual requirements.

Fendt MOD MO25F01: expansion of an AGVS for integrating hybrid assembly stations for the additional production of e-tractors

Date: 2023 to 2024
Contracting entity: DS AUTOMOTION GmbH
End customer/site of installation: AGCO Fendt – Marktoberdorf

Project description:

  • Entire electric planning (hardware construction, software project planning)
  • Extension of control cabinet construction
  • Provision of control technology for the extension works
  • Assembly and installation
  • System commissioning

Technologies (excerpt):

S7-414F-3PN/DP | 4 pieces MP277 10" TOUCH | 10 pieces access points for Wi-Fi coverage (communication with vehicles) | 30 pieces vehicles for transport and setup of the tractors (combustion engines and e-tractors)

Process description:

The assembly line was adapted for the integration of the new electric vehicle (E124P series) into the final assembly of tractors in Marktoberdorf. The automated guided vehicle system (AGVS) ejects the vehicles with bodies for electric tractors from the existing production line so that high-voltage assembly and testing processes can be carried out in a new, separate hall area before they are returned to the production line.

The central control system developed by Kocher for the AVGS carries out not only the data management with the hall control system of the end customer (order data to error messages), but also all process-relevant orders of the vehicles through the processing stations. With its own Wi-Fi communication, it is the centerpiece of the workflow and controls the process throughout the entire production line for all station control points.

Entries can be made via a visualization interface to adjust parameters, select/deselect processes, and display processes, vehicle positions, interface overviews, and error messages. In addition to the standard process sequences, emergency strategy concepts are implemented according to individual requirements.