Systems and Solutions for the Automotive Industry

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Systems and Solutions for the Automotive Industry
Opel Gear Works uses Solutions for Powertrain-Transline Simatic WinCC for Painting Truck Cabs

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4th Edition July 2|2005

Body Conveyor System at DaimlerChrysler:

Fast Problem Solving Directly On Site

2

CONTENTS

Volkswagen presented the first Profinet applications for automobile production at the Hanover Fair

P. Koerber

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8
The Simatic WinCC system offers a comfortable overview of the current painting process

Publicis CPZ

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The mobile operator panel enables reliable local system control

3 EDITORIAL
TRENDS

12 14

Conveyor systems

Fast Problem Solving Directly On Site
Body conveyor system at DaimlerChrysler Gear production

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Profinet in practice

Impressive Performance
Volkswagen and Siemens demonstrate two Profinet applications at the Hanover Fair 2005

Power Solution for Powertrain
Opel Austria builds six-speed gear with Solutions for Powertrain-Transline Wheel assembly systems with WinCC

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CASE STUDIES

Consistently proactive
Ghyselinck chooses PC-based automation solution with WinCC Integrated production

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Process visualization

Optimum from the prime coat
Cab painting for Volvo trucks Production of vehicle seats

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Perfectly Integrated

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Two New Lines Just-in-time

Body-in-white production line for the Citroën C3 platform controlled and visualized with Simatic Vehicle testing systems

Johnson Controls in Geel (Belgium)

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RAMA For Even More “Pleasure of Driving”

Siemens develops chassis adjustment benches for BMW

Title photo: DaimlerChrysler, Conveyor bridge Photo by: W. Geyer

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EDITORIAL

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Profinet – a highlight in Hanover
One of the highlights at this year’s Hanover Fair for Industry was definitely the Volkswagen AG stand in Hall 17 at which the company gave some insight into the production for their new model, the new VW Passat. VW spotlighted the quality of production and gave a few key suppliers – including Siemens – the opportunity to present the capability of their products and systems for the production of the new Passat. On the VW stand, we were one of the first manufacturers at all to present Profinet applications, one of which had integrated safety technology which has been demanded by the AIDA Consortium. It was no coincidence that Profinet was at the center of attention because the rumor has spread throughout the branch that Profinet has the best chance of becoming the future fieldbus standard for the automotive industry. Our goal is to introduce Profinet uniformly as the central fieldbus system in all units as the PNO, a manufacturer neutral body, propagates. We hope that the branch has learned its lesson from the “fieldbus war” of the 1990s which considerably hindered technological development. Because system manufacturers and users are dependent on a common “backbone” in which the best system wins in technological competition. Profinet becomes the backbone of an even more consistently implemented Totally Integrated Automation – with extensive diagnostic possibilities through all system levels and interfaces to management level or ERP systems. The overwhelming response we have received at the fair confirms that we are on the right track.

W. Geyer

The body-in-white production for the Citroën C3 is equipped with Totally Integrated Automation

18 TELEGRAM
Loch GmbH, Ergolding Volvo Truck, Brisbane, Australia Kührer Papst Industrieautomation (KPI) GmbH, Benningen Rausch GmbH & Co. KG, Haan Nimak Automatisierte Schweißtechnik GmbH, Wissen Opel Azambuja, Portugal

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23 DIALOGUE

PSA Group

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Ralf-Michael Franke Head of the Industrial Automation Systems Division

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TRENDS
Profinet in practice

Volkswagen and Siemens demonstrate two Profinet applications at the Hanover Fair 2005

Impressive Performance
With two systems, the Volkswagen AG and Siemens Automation and Drives jointly demonstrated at the Hanover Fair 2005 what possibilities the use of Profinet holds for the automotive industry. On show in Hall 17: a fully mobile fastening system equpped with Wireless LAN and a live producing radiator line with integrated safety based on Profinet IO.
The Automation Initiative of the German Automotive Industry (AIDA) relies on Profinet with integrated personal safety

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utomation in the automotive industry – and not only there – is due to change paradigms. At a joint press conference during the SPS/IPC/Drives in Nuremberg 2004 the four German leading

automobile manufacturers Audi, BMW, DaimlerChrysler and Volkswagen who have joined forces in the AIDA interest group (Automation Initiative of the German Automotive Industry) declared that they want

to use Profinet with integrated personal safety in future where the overall economical and technical conditions allow. Of interest to the automotive industry as well as to other branches are the new possibilities for effective data archiving which are becoming increasingly important for quality assurance and process documentation in addition to the greatly increased transmission performance in comparison with conventional bus systems. Other advantages are the real-time capability and clock synchronicity which enables extremely demanding motion control applications on a common Profinet bus by means of IRT (Isochronous Real Time) technology. At the HMI 2005 in Hanover Siemens and the Volkswagen AG demonstrated the first live applications of production plants in the automotive industry equipped with Profinet. The presented concepts have been developed in close cooperation with the planning departments at VW Wolfsburg and Hanover. Under the motto “Automation live” the Volkswagen AG stand in Hall 17 presented what is already technically possible today and will soon be part of regular production. During the fair the professional visitors were able to see two production installations of the automotive industry automated with Profinet in action: one plant for automatic complete production of radiators and a mobile fastening system for assembly. ■

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Automatic radiator production
One of the plants with Profinet producing “live” at the Volkswagen AG stand in Hall 17 was a fully automatic production machine of radiators. This special machine is already successfully in use with almost identical mechanics and automation with Simotion and Profibus DP at VW in Hanover. In the plant on show a sheet rolling off a coil runs into the first section of the machine at 300 meters per minute. There the sheet is formed into fins and cut to a pre-defined length. The individual fins are then transported to the second section of the plant, the so-called corebuilder, by compressed air. There the fins are pressed together into the finished raw radiator package with the radiator tubes, which is subsequently given a frame. The plant has a capacity of up to three radiators per minute. This machine was in operation for 8 minutes every half hour at the fair and therefore produced about 300 raw radiators per day. These were transported daily to the VW factory in Hanover Stöcken where they were

Simatic CPU 416F-2

Drive Cliq

Switch cabinet
ET 200S ET 200S Servo motors

Sinamics CU 320 Simotion D435 Sinamics Active Line Module 16 Sinamics Motor Modules

Fin machine
ET 200S ET 200S IE/PB Link

Console Fin SN3

Core builder
Panel PC ET 200S ET 200S ET 200S ET 200S IE/PB Link

SN1 K100 1KF1 2KF1 2KF2 2KF3 1KF10 2KF10 2KF11

Coil locked SG5 Fin back locked Fin front locked

Light curtain

Servo motors

Light curtain

Emergency stop

Emergency stop Emergency stop

Absolute value encoder

Configuration of the Fin radiator machine with Profinet IO

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TRENDS
Profinet in practice

Mobile fastening system
soldered and assembled. Sixteen Sinamics S120 are used as a drive for the radiator production plant which drive a total 18 axes of the machine. Closed-loop control, motion control and drive control are taken over by the drive-based motion control system Simotion D435. The axis group communicates with the automation system via Profibus. The machine is equipped with Profinet with safety technology for communication The second live demonstration was a mobile fastening system which also communicates via Profinet and which includes a wireless LAN connection. This station which is already in use in a similar configuration – but without Profinet – at Volkswagen Emden in the final assembly of the powertrain of the Passat is an innovative system for ergonomic manual screw tightening in assembly. The new fastening system consists of a suspended assembly with up to two drive controllers from Atlas Copco, a Simatic S7-200, a panel PC, a Sinamics converter G110 and a Siemens gear motor. The entire communication between the components in the station and with the higher-level plant PLC and master control is handled by Profinet and a WLAN link by Scalance WLAN Access

Corebuilder of the Fin machine

with the distributed periphery. The individual safety-oriented Simatic ET 200S for the corebuilder, fin machine and switch cabinet communicate with the central plant PLC Simatic S7-416F2 via Profinet IO. The Simatic Panel PC 670 for HMI is also equipped with the Simatic PLC via Profinet. This plant proves that distributed plant configurations with integrated safety can be implemented based on Profinet IO and a high product quality and process reliability achieved. In the near future, also motion control functionality based on Profinet with IRT will be available.

In the tightening process itself the torque with the respective setpoints from the joint database is compared by the electromechanical nutrunner among other things

Tightening used to be done at VW in assembly by different fastening system – from handheld EC nutrunners to compressed air tools suspended from overhead rails and having to be pulled into the respective position by the workers. An assembly technique which demanded constant physical exertion and where the fastening procedures could only be documented worker-independently with a considerable effort.

Points or Client Modules and leak wave conductor is used. The drive controls from Atlas Copco which are connected via Industrial Ethernet are also integrated smoothly in the automation network. The new assembly station runs in an aluminum profile rail and is driven by a gear motor. The station moves in exact synchronization with the workpiece carrier mounted on a moving skid conveyor. At the end of the respective assembly step the fastening system automatically returns to its home position and is then positioned exactly parallel with the next workpiece. The exact position of the nufastening system is defined by a perforated rail code running parallel to the car-

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Cross-section of the rail

Rail

Configuration of the suspended assembly of the mobile fastening system

L1 L2 N PE L1 L2 N PE

Scalance Scalance W 788-1 W 788-1

Fastening control AC
Scalance W 744-1

Suspended assembly

Switch

Sinamics G110 Simatic Panel PC Switch
Sinamics G110 Simatic ET 200S

Simatic ET 200S

The powertrain for the new generation of the VW Passat are assembled at the mobile fastening system already installed at VW in Emden

Simatic Panel PC

Scalance W 744-1
Fastening control AC

rier profile which supply an absolute pathactual value. The energy supply is single-phase via Vahle busbars. The Sinamics G110 converter takes care of conversion into a threephase power supply for the three-phase current gear motor. The feeding is therefore implemented with little effort and lowmaintenance three-phase current motors can be used. The ET-200 of the fastening system communicates with the plant PLC via a radio line consisting of a leak wave conductor and Scalance W WLAN network components. The actual position of the moving platform is synchronized with that of the fastening system and the drive is controlled accordingly. In the fastening process itself several parameters are recorded by the electromechanical nutrunner (for example the torque) and compared with the respective nominal data from the joint database. When all joints at an assembly station have

been done correctly the fastening system automatically returns to its home position and is ready for the next assembly step. The data of every single joint is transferred to the central screw data server and buffered additionally in the PC of the fastening station. This data transfer also takes place wirelessly via the radio bridge of Scalance WLAN Access Point and leak wave conductor via the Profinet protocol. The Touch Panel PC of the assembly station receives the code number of the respective workpiece from the plant PLC via Profinet – Wireless LAN for every new work step and the appropriate assembly instructions are displayed. The mobile fastening system sets new standards in terms of ergonomics for workers and thus ensures better productivity, process safety and high flexibility in assembly line balancing. The new W-LAN

concept with leak wave conductor has proven its practical use in this demonstration installation. The Volkswagen AG is so impressed by the system that it has already ordered 80 units which are to be used in the Emden factory.

More information: www.profibus.com www.siemens.com/profinet

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CASE STUDY
Process visualization

Cab painting for Volvo trucks

Optimum from the prime coat
The driver cabs of Volvo trucks in Sweden have recently been getting their prime coat in one of the most modern paint shop plants in the world. The Swedish heavy truck manufacturer chose Totally Integrated Automation with Simatic WinCC as a control and automation system and are very pleased they did.

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he Volvo Truck Corporation is one of the world leaders for heavy trucks. The company has production and development sites in Sweden, Belgium, the USA and Brazil. The trucks for the European market are built in Gothenburg (Sweden) and Gent (Belgium) whereby the engines, gears and driver cabs are supplied by different factories in Sweden.

Cabin production for the whole of Europe
The Volvo factory in Umeå is Volvo’s only production site for truck cabs in Europe. In this factory in Northern Sweden, 250 miles away from the Polar Circle, the cabins for all Volvo models are built and then transported to the assembly works in Gothenburg and Gent. The Umeå factory also supplies CKD (completely knocked down) assembly kits for the cabs to factories in Asia, Africa, Australia and America.

The driver cabs are offered in numerous variants – from the comfortable sleeper with a miniature office for long distance haulage to the simple day cab. A modular system with standardized components is therefore used for the cabins which can be applied for many models. At present Volvo Umeå makes three cab series with a total of 11 different models. The cabs are fully prepared for installation in Umeå and then transported to the assembly works by rail. The production includes the complete metalworking, cab body construction, surface treatment, painting and final assembly. The whole production in Umeå is automated to a great extent with robots.

Publicis CPZ

Volvo

Robots developed by Dürr take over the application of the prime paintwork with a 100 % repetitive accuracy

Higher capacity due to new painting line …
The annual production was to be increased from 50,000 to 60,000 cabs with a capacity

extension. The most important investment here was a new painting plant for the prime paintwork of the driver cabs. Dürr Paint Systems in Stuttgart received the general contract for this. The new painting plant from Dürr consists of a cleaning system, a hand painting system EcoMacc, two airbrush systems for the interior painting with automatic door openers, two ESTA systems for the outside painting and two dryers. The plant is considered one of the most modern in the

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Control room level WinCC Clients WinCC archiving server

Schematic plant configuration of the new painting plant at Volvo, Umeå

Router WinCC Server

OSM

OSM

Redundant TCP/IP-Ring (Fiber optic/twisted pair) OLM S7-400F

Profibus with Profisafe

Robot control WinCC Clients

Robot control WinCC Clients
Publicis CPZ

ET 200S-F Control level

Profisafe Robot Application level Robot

Profisafe

The Simatic WinCC system offers a comfortable overview of the current painting process

world and meets the strictest environmental regulations regarding solvent emissions.

… with distributed control technology
Dürr suggested the Siemens AG to the Volvo Truck Corporation as the supplier for the automation and control technology. The Swedish auto manufacturer decided, after detailed evaluation, to accept Dürr’s suggestion and had its new painting line equipped with Simatic WinCC as a control system and failsafe Simatic S7-400F controllers and a distributed periphery. The system concept with WinCC as a process visualization system was designed and implemented in cooperation with the Siemens Paint Center and WinCC Competence Center in Stuttgart. The system concept of the WinCC-SCADA system with client-server structure and the distributed automation architecture with homogeneous programming and data storage ultimately proved superior to the PC-based single station systems previously used in the paint shop sector.

Painting control technology of the highest standard
The cabs entering the paint shop are registered via a mobile data system and logged

into the painting control system. According to the respectively identified cab the master Enterprise Resource Planning (ERP) system requests the appropriate painting data and outputs them to the corresponding painting controller. Volvo uses three different paints for the prime paintwork which depend on the shade of the final coat of paint. The painting control system receives the current quality data such as type, color, process data and alarms from the control level as a reply and passes them on to the ERP system so that a continuous record is available for tracing the individual body right into the ERP level. The data are also available locally through the archive server for long-term analyses. The WinCC server is designed redundantly with two servers. This server system is supplemented by an archive server for archiving the message data and value archives as well as an engineering station with which both WinCC and all controllers and the Micromaster drives are parameterized, loaded and saved. The backup and version management is user-friendly with Simatic A&D Data Management ADDM. As operating stations 11 WinCC Clients are integrated at the moment for the visualization and operation of the painting

process as well as the process and conveyor technology. The control level is equipped with ten Simatic-400Fs with which the whole painting plant is controlled. The communication is distributed on two TCP/IP networks: one network for linking the process data, another for visualization with integration in the factory network. At the control level Profibus with Profisafe technology is used in which safety-oriented functions such as light barrier, emergency stop switch, door position switches together with the standard control functions are linked decentrally. The communication with the superior ERP system takes place based on TCP/IP and Web Services. Volvo is very pleased with the user friendliness of the new control system. The capacity, availability and productivity have increased considerably in comparison with the old painting plant according to factory information. A second painting plant is being planned for the final painting at Volvo Umeå. ■

More information: www.siemens.com/wincc E-mail: [email protected]

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CASE STUDY
Production of vehicle seats

Johnson Controls in Geel (Belgium)

Two New Lines Just-in-time
What does an automotive supplier do when faced with the task of supplying twice as many car seats as before within a few months? He makes room, modernizes his production and installs a totally new production line. Johnson Controls in Geel in Belgium took the opportunity to introduce Totally Integrated Automation at the same time and bring its control up to the latest state-of-the-art.
Johnson Controls

The production data acquisition by RFID systems such as Moby E is now also a must for suppliers

Just-in-time to VW and Opel: Production of vehicle seats at Johnson Control, Geel

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ohnson Controls is above all a specialist for vehicle seats. One of the more than 500 just-in-time production sites of the company is Johnson Controls Automotive in Geel in Belgium. Here the company produces about 1,100 seats for the Opel Astra every day which are delivered to Antwerp, about 30 miles away, within three and a half hours of receiving the order. Added to this are another 900 seats for the VW Golf and Polo models which arrive at the VW factory in Brussels, 55 miles away, within a time window of six and a half hours. In order to cope with the order volumes of Opel and VW, Johnson Controls was faced with the task of doubling its production capacity and increasing its work staff by 50 percent. They therefore decided to modernize a 12 year old production line and to install a totally new line parallel to it. Of course the ongoing production in Geel could not be allowed to suffer as a result. Johnson Controls put their trust in two familiar partners: Ariadne Industrial Automation took over the project management whilst Siemens Automation and Drives was responsible for the automation system. A tight schedule had to be kept: the project start for the totally new production line for the VW seats was the beginning of 2003. It went into production in August 2003. Conversion of the Opel production line began in May 2003. Production here started on time on January 2, 2004. Ivan Vos, Project Manager at Ariadne, describes the procedure. “The critical phase was between Christmas and New Year. Production for the old Astra ended on December 23 and the line was completely dismantled. The new Opel line had to be

Johnson Controls

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MES-Level Clients 37x Workstation WinCC PC visualization Server WinCC PC visualization Workstation Clients 47x

Simatic S7-416 2DP

Simatic S7-412 2DP

Simatic S7-313 2DP

Simatic S7-416 2DP

Simatic S7-416 2DP

Ethernet

Screwdriver control Frequency converter Screwdriver control

OP17

OP17

ET 200eco Moby E

OP17

OP17

Profibus

Datatags Moby E ET 200S ET 200eco Moby E ET 200eco

Frequency converter ET 200eco ET 200S Moby E

Datatags

Schematic plant configuration at Johnson Controls, Geel

turning out 800 units a day by January 2 already – and that’s exactly what it did!”

Complete data in focus
The changeover from several independent applications to an integrated complete system was the major aim of both projects. Koen Vanharen of Johnson Controls explains: “Our customers get more demanding by the day and complete tracking is becoming more and more important. The problem was to pick up the different data such as those on the barcodes.” Ivan Vos adds: “Everything starts at the database level. Here the orders of both customers are registered and the information for every single seat such as the upholstery type is saved. That is the first decisive step.” A special feature was that the automation system also had to include the six suppliers working under the roof of Johnson Controls. Siemens suggested installing Simatic ET200 Eco modules at the suppliers thus providing the basis for Totally Integrated Automation which covers all the processes in Geel.

A Simatic S7-416 2DP was installed for controlling both the Opel and the VW line, supplemented by an S7-412 2DP for graphic visualization of the Andon signal system of the VW production line and an S7-414 2DP in the test area of the Opel line. The latter controls the automatic test process and stores the recorded data in a local SQL database the contents of which are transferred to the central process database of Johnson Controls at regular intervals. One example of the importance of an extensive data acquisition is the complete entry of the data which result from packing of the airbags which are recorded as safetyrelevant information. These can be consulted for example when an airbag fails to work properly because these data are kept for up to ten years after the model is discontinued.

Flexible solution with a future
Siemens implemented the communication with the different HMI Systems in the proven way with Ethernet. Readers for scanning the Moby tags on the seat are

positioned at different points along the production line. They are linked by Profibus as are the frequency converters and the servo controllers. Electronic tags are used in many places. There is a growing trend in the automotive branch to rely on the tags and process their information locally instead of communicating the whole data flow through the increasingly overloaded network. Koen Verharen stresses the flexibility of the whole system: “The system can be transferred easily to new customers. Every automotive customer demands a just-in-time or just-in-sequence delivery but since every seat has the same components, extensions are not a real problem.” For Siemens the double project at Johnson Controls in Geel was further proof that a highly flexible control system which combined existing technologies with Totally Integrated Automation can be implemented with Simatic. ■
More information: www.siemens.com/tia E-mail: [email protected]

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CASE STUDY
Conveyor systems

Body conveyor system at DaimlerChrysler

Fast Problem Solving Directly On Site
In the Sindelfingen works of DaimlerChrysler the buildings are closely grouped together. A new conveyor system links the body shop of, for instance, the CLS-class with the paintshop. This is an example of how intelligent control technology can contribute decisively towards improving the operating reliability and availability of the conveyor technology.

available. In this time the existing system had to be upgraded, the clients replaced by Simatic PC 670 with WinCC V6, the server converted and the system successively extended.

Computer calls service technicians
If a conveyor system comes to a halt there is normally reason for excitement. The fault is first signaled to the control center who then have to phone a service technician. The new conveyor system eliminates this time-consuming process and calls the technician directly by radio signal. This gives the technician concrete data about the fault that has occurred and he arrives on site well informed about the event and may already have the necessary spare part with him. Signal lamps mounted at head height show where the fault has occurred already from a distance.
All pictures: W. Geyer

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t is a room in which everything is constantly on the move. Body-in-whites file past end to end. They roll in on a glasspaneled steel bridge. Over 100 feet above the production line and an impressive 140 yards long it connects the body production with the paintshop. Up to 1,300 raw bodies roll in and empty body platforms out every day here on three lines. The bodies are specifically ordered and ultimately land optimally sorted in a two-tier buffer store. But the new conveyor system is not only a fascinating construction, it is also equipped with a new control system with Simatic 400.

Integration by specific upgrading
The eleven Simatic S7-400s comply with the inhouse standard of DaimlerChrysler which also prescribes WinCC frontends with ProAgent process diagnostics, ProTool, S7-Graph and S7-PDiag. The conveyor system is linked smoothly with the following buffer store with nine Simatic S7-400 controllers. Step 7, V5.2 was changed over to in the course of plant upgrading. All existing WinCC clients were replaced by Simatic Panel-PC 670 with Windows XP. From the order to commissioning of the conveyor system about 18 months were

Mobile operation for greater safety
One of the real innovations of the new conveyor system is the apparently modest hand-held operator panel. This is simply connected to one of the terminals distributed throughout the plant and allows operating statuses to be displayed as well as

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Existing clients FLP, upgraded

New clients bridge

Redundant server

Foreman’s office

Simatic Panel PC 670 Simatic S7-400

Simatic Panel PC 670 Simatic S7-400 DAKS Server

Factory network Industrial Ethernet

Hipath telephone system

DECT network

Schematic overview of the Ethernet link for the conveyor bridge The 140 yard long conveyor bridge transports the bodies into the paintshop at a height of more than 100 feet

operation of the respective plant section directly on site. Bojan Skufca, the man in charge at DaimlerChrysler in Sindelfingen for maintenance and repair of this conveyor systems, sees this as a clear safety advantage: “The situation is not normally visible from the stationary operator panels. The service technician therefore has to contact a second person who he calls to activate the necessary functions. With the mobile operator panel, the function can be controlled exactly where the situation can be assessed.” An additional advantage is that the whole system does not have to shut down in the event of a fault but only a limited segment is blocked. This guarantees the safety of the service technicians and the plant operation is disturbed as little as possible.

The mobile operator panel allows safe local plant control

Clear and comfortable plant overview with WinCC on a PC 670 Panel

The starter also takes care of monitoring the motor and automatically releases a warning to the controller when a settable limit value is exceeded. This allows preventive plant maintenance and proactive plant management.

Everything in good view
The whole plant is distinguished by a homogeneous control and visualization concept. Both at the control stand and in maintenance and directly on site, the current operating status of every single conveyor line can be viewed. Is it empty or is there a vehicle body on it? Is there an unexpected standstill? Also, the current operating data

Easier, more intelligent, better all round
Another advantage of the new conveyor system are the motor starters. Neither a circuit needs to be switched off nor any cables disconnected for servicing assignments. Instead the starter is simply removed from its holder and exchanged with a few actions.

for every single drive element can be called and critical operating statuses are visually highlighted. All in all the latest conveyor system at DaimlerChrysler in Sindelfingen is an example of how greater operational reliability and maximum availability can be achieved by the use of state-of-the-art control technology. ■

More information: www.siemens.com/simatic E-mail: [email protected]

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CASE STUDY
Gear production

Opel Austria Powertrain Gear Works Vienna-Aspern builds six-speed gear with Solutions for Powertrain

Power Solution for Powertrain
“Solutions for Powertrain-Transline” is a comprehensive solution for automation of mechanical processing lines. In a new gear production line at the Opel factory in Vienna the concept shows its advantages for plant owners and machine suppliers alike.
The new six-speed gear M20/32 of Opel Austria Powertrain is used for front-wheel drives with 2.2 liter engine capacity

T

he engine and gear factory Opel Austria Powertrain GmbH in ViennaAspern is specialized in drive components for small and medium-sized automobiles of the GM company such as the Opel Astra. A new production line for six-speed gears went into operation in 2004 which is planned for an output of 300,000 units in 2005. The production is to be boosted to 800,000 gears per year in threeshift operation in 2006. Altogether, sixspeed gears with 200 and 320 Newtonmeters in about 50 variations with 15 different transmissions are produced and mounted on 340 machines and systems. Production technologies are used which satisfy the highest standards regarding environmental compatibility, quality, costs and flexibility. These include for example dry turning and milling, laser welding or low pressure carburizating system with high pressure gas quenching. The machine park chain of the new production line is made up of 89 lathes, 37 grinders, 34 washing machines, 24 slotting and 24 test machines, 18 scrapers, 14 drills, 12 measuring machines, 10 roll mills, 6 broaching machines, 13 labeling machines and other special machines.

A top address as system supplier: Siemens
Opel Austria Powertrain planned the new six-speed gear production with Siemens as a fully integrated production plant based on “Solutions for Powertrain-Transline”. All

machines are equipped with Sinumerik their developments primarily with Siemens components and software. Siemens was the and Simatic control technology. A Manufirst address for us in this respect too,” facturing Execution System (MES) links the Seidl says. production and office environments and therefore guarantees among other things that remote maintenance and control are supThe gear production in the Vienna-Aspern works ported via the Internet. “The decision for the project was made three years ago. We examined the distribution of the machines of the respective manufacturers for the different controller providers, their mastery of the individual processes and of course the price/ performance ratio,” Dipl. Ing. (FH) Erwin Seidl, Head of Electrical Planning Gears at Opel Austria Powertrain explains. The decision in favor of Siemens fell after assessing the availability, response time to problems and local support. In addition the companies were evaluated on the question of whether they were at all able to provide such a large number of controllers or axes in the allotted time. “Apart from that, the processes running in metalworking machines are extremely complex. They reflect the knowhow of the different machine manufacturers who have made

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Another aspect in favor of Siemens was the extensive wealth of experience of the Siemens developers which represented an indispensable safety factor for Opel especially in the run-up phase.

Solutions for Powertrain-Transline
As a single source system provider, Siemens offers the automotive industry and its suppliers a comprehensive, homogeneous automation concept for the mechanical production and assembly for large series. Areas of application for Transline are for example transfer lines for the construction of engines and assembly lines for gear production. Basis for this are the product series Simatic, Sinumerik, Simodrive and Profibus and Profinet as bus systems. The solutions include standardized hardware concepts, homogeneous user interfaces and well-developed programming guidelines. On the basis of the Siemens standard, changes can be made at any time, the user can respond easily to model and design changes. Works management and Siemens experts work hand in hand during the whole integration process of the modules in a working system – support accompanies all development phases right into the operating phase, training and service included. And all this worldwide in line with the size of the Siemens A&D Division.

Partner for plant owners and machine manufacturers
Opel Austria Powertrain specified a works standard with a uniform user interface, homogeneity in the automation concept, standardized hardware, slim logistics and low staff training effort. Within this scope Solutions for Powertrain offered machine manufacturers enough freedom to apply their technological know-how to the automation platforms Sinumerik 840D and Simatic. The machine manufacturers were therefore able to concentrate on their specific technological domains and select the subsequent topics such as visualization and communication from the range of system modules. This consisted of the Simodrive family, the HMI systems, the open interfaces and the networking with superior or-

der and MES systems which enable integration in the existing company control landscape. Opel’s experience with local Siemens support was positive. Two Siemens technicians are always present at the factory. Dipl.-Ing. Seidl confirms that “these specialists operate with very exten-

sive know-how and great solution competence. We have only had good experience ■ with Siemens to date.”
More information: www.siemens.com/transline E-mail: [email protected]

Test bench in assembly

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All pictures: Opel AG

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CASE STUDY
Wheel assembly systems with WinCC

Ghyselinck chooses PC-based automation solution with WinCC

Consistently proactive
The Belgian company Ghyselinck N.V. is one of the world market leaders for automatic wheel assembly lines – a position which the company has achieved by uncompromisingly high quality and reliability coupled with innovative concepts. For many years the company has pursued a machine strategy which relies consistently on modularization and distributed structures. The new machine generation is now equipped with an automation solution based on the PC-based Simatic WinAC controller and is therefore perfectly prepared for the vertical integration in Supply Chain Management systems.

O

ver 35 years ago Willy Ghyselinck developed a machine with which tires could be mounted on different rim types. This idea was the beginning of the success story of the Ghyselinck N.V., today a manufacturer of fully automatic wheel assembly lines with an international reputation who includes almost all leading automobile manufacturers and their suppliers among its customers. One of the success factors – in addition to technically pathbreaking and innovative machine solutions – is certainly the unusual sales concept which Ghyselinck pursues consistently: the machines are installed at the customer’s within the scope of a leasing contract. This solution reduces investment expenses for the customer and gives Ghyselinck a decisive competitive edge – and at the same time protects the company’s many patents. Ghyselinck applies the highest standards to its solutions and makes no compromises in quality and reliability. The machines achieve an availability of 100 percent after being run in for 3 days.

In addition to the competitive price and the cost guarantee for the whole life cycle of the machine it is precisely this guaranteed quality which is a decisive factor for the customer and is also ensured by extensive support of the machines at the customer’s. Telediagnosis and telemaintenance have been part of the standard scope of delivery since the year 2000. By telemaintenance the Ghyselinck service engineers can get a clear

view of the problem immediately and intervene directly at the manufacturer site. Any faults can therefore be eliminated immediately and quickly without travel times and expenses – advantages which the company’s customers can appreciate.

Standardized and modular
The automatic assembly machines are compact and modular in design with a high degree of standardization. Every

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Industrial Ethernet

Station 1 IPC 670

Station 2 IPC 670 WIN CC V6 Options: - Proagent - User Archives - Win BDE WIN AC SLOT 416
PROCESS FIELD BUS

From distributed to PC-based
Another step was the decision in favor of a PC-based machine control a good 12 months ago. Especially in branches with a high logistic effort such as the automotive industry there is a clear tendency towards integrated Supply Chain Management. For this it must be possible to exchange machine data easily and reliably with the corresponding IT systems of the MES and ERP level. PC technology is used widely there and it was therefore logical to implement a PC-based machine control. Ghyselinck again relied on a solution with Siemens products because the two companies had been cooperating successfully for a long time as Willy Ghyselinck confirms. “Siemens is far more than just a name on the products. We value quality and availability highly and that is just what Siemens guarantees us with its products. Therefore we can also guarantee our customers maximum availability, reliability and quality.” The new machine generation is equipped with Simatic Win AC as a slot PLC in a Simatic Panel-PC 670. The slot PLCs are equipped with Profibus DP and DP/MPI interfaces as standard. Simatic WinCC V6.0 is used as a visualization system. This solution is extremely robust, immune to faults and reliable. With the integrated support possibilities via OPC server and ActiveX components for optimization, the “recipe management” of the different tire-rim combinations, for the archiving and for technical jobs such as data management or image processing the system is also very flexible and versatile in its application – an important aspect, Willy Ghyselinck stresses. “Our customers work with justin-time (JIT) systems and expect our machines to be integratable in the logistics processes without any problems. The data and information of our machines must be prepared and usable for optimization of the whole process – and our machine concept meets exactly these requirements. We are therefore a proactive components in our customers’ communication chain.” ■

PROCESS FIELD BUS

Profibus DP

Profibus DP

Camera system ET 200S ET 200S

Automation schematic of the Ghyselinck machines with Simatic WinCC

The new generation of wheel assembly systems from Ghyselinck is equipped with a PC-based automation solution based on Simatic WinAC

Pictures: Ghyselinck N.V.

module – for mounting the tires, checking the valves and uniformity and balancing and testing the wheels – fits in a standard container and can work totally independently in the assembly works and can be loaded with any tires and rims by an operator for example. The modules can also be combined easily in complete automatic assembly lines depending on the customer’s requirements. The changeover to distributed systems in the periph-

Ghyselinck N.V.

ery in the year 2000 was an important step for Ghyselinck with which the automation was also adapted to the modular concept. Since the introduction of Profibus DP and the distributed peripheral systems Simatic ET 200S there have not only been savings in time, space, wiring and complexity – the system also guarantees a higher availability of the whole assembly line through simplicity and stability.

More information: www.siemens.com/wincc E-mail: [email protected]

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TELEGRAM
This and other interesting applications can be found in detail under:

www.siemens.com/read-moveup

The Loch GmbH in Ergolding, Germany, has specialized in deep drilling machines. Customers for these machines are automobile manufacturers all over the world. The fully automatic, high-precision machines are equipped with control and safety technology from Siemens.

CNC Design has modernized a punching machine for manufacturing chassis parts which is used at Volvo Truck Australia, Brisbane. The project included the total replacement of the electrical control system as well as the rewiring of the machine. The Sinumerik SafetyIntegrated function was used at Volvo for the first time here.

Kührer Papst Industrieautomation (KPI) GmbH from Benningen, Germany, has equipped a core removal system for engine block casting with Windows CEbased Simatic Multi Panels as a close-to-the-machine HMI system for a leading German automobile manufacturer.

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Kührer

Fa. Loch GmbH

19

With the new, mobile HMI device Simatic MP 170, a wellknown manufacturer of deburring machines, Rausch GmbH & Co. KG (Haan, Germany), uses just one single, hand-held device instead of many distributed operating stations.

Instead of stationary Operator Panels at every single servo control module for its welding tongs, Nimak Automatisierte Schweißtechnik GmbH (Wissen, Germany) now uses one mobile operator panel with touch display for several units. The handling is a lot easier thanks to the touch operation on the graphic display.

W. Geyer

Opel in Portugal has set up an Andon system for quality assurance and material logistics. The microcontroller Simatic S7-200 passes on all switching commands to the master system network quickly and reliably via the Ethernet link CP 243-1.

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Opel AG

W. Geyer

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CASE STUDY
Integrated production

The body-in-white production of the Citroën C3 is equipped with Totally Integrated Automation

Body-in-white production line for the Citroën C3 platform controlled and visualized with Simatic

Perfectly Integrated
The PSA Peugeot Citroën Group uses Totally Integrated Automation for the automation and the Simatic WinCC control system in its new body shop for the Citroën C3 model. The total integration of the HMI systems in the Simatic control environment and the use of PDiag diagnostic software open up new perspectives for efficient plant monitoring.

T

he PSA Peugeot Citroën Group builds the Citroën C3, Citroën C3 Pluriel and Citroën Xsara models at their Villaverde factory in Madrid. For the production of the new small automobile series C3 and the multifunctional Citroën C3 Pluriel a new body-in-white production line was installed for which Siemens supplied the automation and control technology. For the automation, PSA Peugeot Citroën chose Totally Integrated Automation with Simatic S7-400 controllers, Simatic OP27 Operator Panels, Profibus DP as a field bus system and the distributed peripheral equipment Simatic ET 200. Simatic WinCC was installed as a master plant monitoring and control system.

Central diagnosis decisive
The most important feature in the automation concept of the new body shop for the Citroën C3, however, is the use of the S7Pdiag diagnostic software for the diagnostic management of all production stations in the central control under WinCC. In addition, ProAgent is used on the OP27 Operator panels for local fault diagnosis on the individual cells. Simatic WinCC in connection with ProAgent was chosen as an ideal HMI system for management and collection of all alarms from the production cells because it could be easily integrated in the plant’s automation structure.

In addition the graphic editor offers numerous possibilities for visual design of the production processes. Up to 20,000 tags can be processed. Finally all the alarms and the appropriate data can easily be updated automatically thanks to the integrated software in WinCC ProAgent. The operator can have the respective program segment of the PLC that triggered the alarm displayed or the appropriate S7 graph step sequence visualized in WinCC. The Head of Maintenance on the new production line Francisco Javier Tejedor explains: “We decided to use the WinCC software because the diagnostic functions of the plants were to be centrally grouped and

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the system had already been successfully tested in other factories of the PSA Peugeot Citroën Group. The ProAgent solution is used because it is the best link between the PLC diagnostics controlled by PDiag and the WinCC control system.”

Total communication
The biggest advantage of the integrated automation concept in the new body-in-white production is the communication between the programming software of the PLC (Step 7 and PDiag) and the process visualization

system (WinCC and ProAgent). This considerably simplifies the handling and programming becomes almost totally obsolete. The operator of the WinCC process visualization system has the whole area monitored on one screen and can concentrate of the diagnosis when a fault occurs. With a few mouseclicks he can switch from the view of the complete line to a single cell and even check the state of a sensor. In addition to the process views, the WinCC systems also has masks for the data management on which the communica-

Status diagrams can be called up in various degrees of detail on every operator panel

tion with the production software, the status of robots or welding sequences can be checked. All 40 Simatic S7-400 controllers in the plant are connected to the HMI systems via Industrial Ethernet. Because of the harsh conditions to which this network is exposed, Simatic Industrial Ethernet components have been used. To ensure the demanded high availability and reliability of the equipment in the rugged production environment, Simatic Panels PC 670 have been installed on the machines themselves in all areas to be monitored. A server collects all the data from the different areas. These PCs contain the programming software of the Simatic PLCs and the HMI devices. Changes to the devices can be entered directly online.

Exact error localization
Thanks to the alarm management by ProAgent and the display functions of WinCC which can be extended by “Graphic Designer” the system pinpoints the exact location of the error in the event of a fault regardless of whether it is process or hardware related and offers help texts for localization and elimination. Using the integrated WinCC alarm system in connection with ProAgent, the system informs the operator about the different process errors and creates an alarm archive which can be printed or exported to a file. Then the response time of the operating personnel in the event of fault will be shortened and downtimes on the production line minimized as a result. The large capacity of the message acquisition of the WinCC is extremely important for this task. This function also makes preventive maintenance work on the production line easier. Diagnostic data can be exported simply and therefore enable easy monitoring of the downtimes and error times. The Spanish version of WinCC 5.1 was installed under the Windows 2000 operating system. In this way both the visualization system and the programming software are embedded in the Spanish language environment. This makes possible extensions easier for the owner to handle and mini■ mizes training expenses.

PSA Group

Citroen

Schematic plant configuration of the new body shop (section)

Server + IL 40

Simatic PC 670

Industrial Ethernet (optical) OSM 6/2 TP OSM 6/2 TP OSM 6/2 TP

Simatic S7-300 Simatic S7-400

Simatic S7-400

More information: www.siemens.com/wincc E-mail: [email protected]

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CASE STUDY
Vehicle testing systems

Siemens develops chassis adjustment benches for BMW

RAMA For Even More “Pleasure of Driving”
Highly modern chassis measurements are essential to BMW for assuring their familiar sporty driving properties. Siemens supplies these systems for the adjustment which BMW uses in series production and new development in almost all its factories.

Assembly of the BMW Roadster Z4 in Spartanburg, USA

T

alk of “RAMA” at BMW rarely has anything to do with that common German margarine brand of the same name but usually with a chassis adjustment system, the “Reference Axis Geometry Measuring System”. This system takes over the chassis tuning and adjustment and contributes considerably to optimum driving properties. Still the adjustment process for a vehicle rolling off the assembly line has to be completed in about three minutes. In this time the vehicle is completely adjusted and the individual wheels are measured and adjusted accurately to a few angle minutes.

ment system which measures the contour of the tire and computes the position of the wheel in space. The automobile specialists at Siemens A&D PT 3 developed a system in which a Simatic S7-414-3 is responsible for controlling the servo drives, sensors, actuators and operator buttons among other things. A Windows XP measuring computer handles the test process logic, processing and displaying of measured values. This also provides the interface to the IT systems of BMW and handles the transfer of result data in XML format for example.

Company-wide application
In addition to their use in series production, BMW will be installing an additional chassis adjustment bench for the Analysis department in all its plants as well as in vehicle development on which more extensive measurements can be made on the chassis. A&D PT 3 has developed a new kind of measurement system for this which is based on a two-dimensional col-

High end test systems from Siemens
Siemens received an order from BMW to replace the existing chassis test benches in their factories in Munich and South Africa with state-of-the-art technology and to equip the Leipzig factory with new chassis adjustment benches. The heart of these chassis adjustment benches is a non-contact laser measure-

ored stripe projection and enables a much greater measuring accuracy. In addition, a measuring disc fixed directly to the wheel and printed with a special black and white code can determine the exact wheel position so that even a minimum drift can be detected and the measuring result corrected accordingly. The test benches with the standard functional scope for production in the Munich, Leipzig and South African plants have already been delivered as have the test benches with extended functions for the Munich, Leipzig, Regensburg, Dingolfing and South African plants as well as for the BMW Development Center. The new chassis adjustment benches are also planned for the production of the Z4 and X5 in Spartanburg, USA, and for the production of the ■ Mini in Oxford.

More information: www.siemens.com/testsystems-automotive E-mail: [email protected]

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BMW

DIALOGUE

23

infos
Further information about our concepts, solutions and systems in the automotive industry can be found at our Automotive internet portal. There you will also find your personal Siemens contact

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Publisher Siemens Aktiengesellschaft, Bereich Automation and Drives (A&D), Gleiwitzer Str. 555, 90475 Nuremberg, Germany www.siemens.com/automation Group Executive Management Helmut Gierse, Anton S. Huber, Alfred Ötsch Editorial Responsibility in Accordance with the German Press Law Peter Miodek Responsible for Technical Contents Thomas Schott In-house editorial staff: Kathrin Brämer [email protected] Jürgen Nolde [email protected] Concept Christian Leifels

www.siemens.com/automotive
If you want to know more about Siemens automation and drives technology, log on to our online information hub in the internet:

www.siemens.com/automation/newscenter

online
move up online
Under the address

Publishing House Publicis KommunikationsAgentur GmbH, GWA Corporate Publishing Zeitschriften P. O. Box 32 40, 91050 Erlangen Telephone +49 (0) 91 31 91 92-5 01 Telefax +49 (0) 91 31 91 92-5 94 [email protected] Editorial staff: Christoph Manegold Layout: Jürgen Streitenberger Copy editor: Sabine Zingelmann Jobnumber: 002100 ROE52 DTP: Döss Prepress, Nuremberg Printed by: Stürtz AG, Würzburg move up is published quarterly Circulation: 6000 ISSN 1610-7802 (Print) © 2005 by Siemens Aktiengesellschaft Munich and Berlin. All rights reserved by the publisher This edition was printed on environmentallyfriendly chlorine-free paper. The following products are registered trademarks of Siemens AG: DRIVE-CLiQ, ET200, MICROMASTER, MOBY, ProAgent, S7-300, S7-400, SIMATIC, SIMATIC Multi Panel, SIMATIC NET, SIMATIC Panel PC, SIMODRIVE, SIMOTION, SINAMICS, SINUMERIK, STEP 7, TOTALLY INTEGRATED AUTOMATION, WinAC, WinCC If trademarks, technical solutions or similar are not included in the list, it does not imply that they are not protected. The information provided in this magazine contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. IWI: TMOV Order No.: E20001-M4205-B100-X-7600

www. siemens.com/read-moveup
you can download the latest issue as a PDF file. The electronic archive also gives you access to all previously published issues. Furthermore, you will find a form in which you can write your suggestions and comments on the issue and the individual articles. Your feedback will be included in the next issue of moveup. Finally, you can also inform us of any changes to your subscription.

support
Folder: Wireless LAN With Leak Wave Conductor RCoax-Cable
With Scalance W from Simatic Net access points and clients are available which, with a large number of features, enable radio networks to be set up under harsh basic industrial conditions. Innovative processes such as rapid roaming and the leak wave conductor RCoax-Cable offer new potential to increase the reliability and efficiency in addition to the mobility. The new possibilities of wireless communication with rail-bound systems such as overhead monorail, moving pallets or high-rack stores are presented in detail in a new brochure. You can order the brochure through the Internet under the order number E20001A2909-P820-V1.

www.siemens.com/simatic-net

Company-wide automation – with PROFINET, the open Industrial Ethernet Standard

profinet
You see your future. You see ultraproductive engineering and seamless information everywhere for true operational excellence. You’ll get there with PROFINET. Based on Industrial Ethernet, PROFINET is open and the most comprehensive networking solution for all applications. PROFINET is the most advanced real-time architecture including high-performance motion control. PROFINET utilizes well-established IT standards and fully supports TCP/IP. PROFINET is integrated, company-wide communication – from management information systems down to the field level – and with full real-time capability. w w w. s i e m e n s . c o m / p ro f i n et

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