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BMW DGF BA07: AGVS for a High-Voltage Battery Assembly (New Battery Production Plant)

Date: 2020 to 2023
Contracting entity: DS AUTOMOTION GmbH – Linz /Austria
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
  • System commissioning

Technologies (excerpt):

  • 1 piece S7-1500 with CPU 1518F – PN/ DP
  • 2 pieces OC visualization with WinCC TIA V14 on Staudinger 0C-9-22-677D-V04/ EKS
  • 2 pieces OP visualization with WinCC TIA on Staudinger OP-9-22-477E-V04/ EKS
  • 8 pieces access points for Wi-Fi coverage (communication with vehicles)
  • 5 pieces Loop 1 vehicles for the transport and assembly of the high-voltage storage systems (HVS)
  • 19 pieces Loop 2 vehicles (exclusively manual workstations) with lifting and swiveling unit for the transport and assembly of the high-voltage storage units

Process description:

The central control system developed by Kocher for the automated guided vehicle system (AGVS) carries out not only the data management with the hall master control system of the end customer (from order data preview to error messages), but also all process-relevant orders of the vehicles through the robot cells and manual processing stations.

The master controller with its own Wi-Fi communication is the heart of the entire plant workflow.

It controls and monitors the process from the transmission of order data (marriage) throughout the production line at all station controls.

The production line is designed for the output of 30 HVS per hour and is divided into two areas.

Loop 1 with 65 vehicles and a mix of manual and automatic stations.

Loop 2 with 19 vehicles and manual stations only. These vehicles are equipped with a lifting and swiveling unit, which, after preselection for each station, enables targeted alignment and an ergonomic working position.

In a transfer station, the workpiece carriers with the partial body of the HVS are transferred alternately/step by step between Loop 1/2. The order data is transferred from the source vehicle to the new target vehicle in each case, so that communication between the vehicles and the stations is ensured for a reliable process. 

A visualization interface allows, for example, input for the adjustment of parameters, HVS ident numbers, process dial-in/dial-out. All processes, positions of the vehicles and the on-board swivel devices, interface overviews to station and vehicle controls, and error messages are displayed.

In addition to the standard process sequences, emergency strategy concepts are implemented according to customer requirements.