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Battery EMS (BMW USA)

Date: 2022 to 2023
Contracting entity: ICT
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, control cabinets, and human interfaces
  • Assembly and installation
  • Software and commissioning
  • Disassembly of old chargers

The final work on the production cars is carried out in an existing finishing line. To ensure that the 12VDC battery does not run down, it is possible to use external chargers to maintain the capacity or recharge the battery. The existing system had to be adapted due to a new vehicle type. In the course of this work, the battery-charging concept was completely revised. Due to a new EMS system that was installed above the production line, the battery chargers could be delivered to the worker in sync with the car. A new control system was installed, which communicates with the carriers via a CAN bus and tracks them with millimeter precision using a barcode positioning system. The track (approx. 300 m) includes several switches and a repair track with maintenance jack. After successful implementation, the old battery technology was dismantled. 

Technologies (excerpt):

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

Type integration marriage line

Date: 2022 to 2023
Contracting entity: MBN Maschinenbaubetriebe Neugersdorf GmbH
End customer/site of installation: BMW Spartanburg (USA)

Project description:

  • Electric planning (hardware and software project planning)
  • Disassembly and installation
  • Software and commissioning
  • Robot programming
  • Disassembly of a system

Due to the discontinuation of a model and the introduction of a new type, the marriage had to be adjusted in the final assembly. As one of the existing systems was no longer needed, it was removed from the control system and uninstalled. In return, a new type was integrated into the remaining systems. This resulted in completely new procedures for the robots, screwdrivers, and in the process, among other things. Over the course of the years, the existing systems had been incorporated with a wide variety of standards and technologies and had to be individually adapted.

Technologies (excerpt):

S7-1500 with CPU 1518F – PN/DP | S7-400 | WinCC TIA with PCs, TPs | Various robots