move upThe Magazine for Automation in the Automotive Industry

Volume 8, Number 1, 2009

Automotive technology from France

Innovation for Success

2 move up | 1-2009

p Editorial

p Cover

France 4 Quality, Profi tability, Growth

Renault, France

8 Test Rigs Fit for the FutureFaurecia Abgastechnik GmbH, Germany

p Process

Powertrain 12 Effi cient Integration

PSA Peugeot Citroën, France

p Technology

Conveyor Technology 14 A New Benchmark:

Modular Overhead Conveyor SystemElectric Overhead Conveyors

Sensor Technology 17 Perfect Recognition

BMW, USA

Switching Technology 20 Uninterrupted Supply

Volkswagen, Germany

22 In Brief

23 Dialogue

Together with Siemens, Renault developed a standardized solution for typical automation tasks in its manufacturing processes

Page 4

Together with Siemens, the automotive supplier Faurecia has modernized and reorganized its measurement and testing technology at its Fürth site

Page 8

Cost-effective and fl exible: a Volkswagen facility benefi ts from Sentron 3WL circuit breakers and a LDA busbar trunking system

Page 20

Ren

ault

Siem

ens

AG

Siem

ens

AG

C o n t e n t s m o v e u p | 1 - 2 0 0 9

Jürgen Nolde

Head of Vertical MarketManagement, Automotive

Siemens Industry

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E d i t o r i a l

Dear readers,

In these challenging times in particular, cost management and effi ciency become more important than ever, not only for produc-tion systems but also for automation and drive technology. We want you to rely on us as a partner for these areas too and to let us support you with our expertise and technological leadership as you set about strengthening your competitive position.With this in mind, cost-effectiveness is the key topic in this issue of move up. As part of an approach conceived during a coopera-tive project between Renault and Siemens, Renault is now benefi t-ting from a modern automation concept based on Profi net that has modular automation units for the entire Body Shop process; this results in a clear improvement in Renault’s productivity and cost structure. Automotive supplier Faurecia is making use of countless synergies thanks to a project that modernized its test rigs with the help of Siemens expertise. Even production pro-cesses in plants that are already established can be made more transparent using new code-reading concepts and a recently built gearbox production facility reduces total system costs. Busway systems also offer potential for further savings.We hope that this issue of move up provides you with some inspi-rations to develop more effi cient and fl exible production systems and we hope you enjoy reading it!

Yours,

4 move up | 1-2009

Ren

ault

C o v e r F r a n c e

Renault, France p

Quality, Profi tability, Growth

Consequently, the company invited three automa-tion suppliers to develop a concept that would incor-porate all automation and safety functions and use a standardized set of both hardware and software for all typical automation tasks encountered in Renault’s manufacturing processes. After careful evaluation, Renault decided that the concept presented by Siemens was the most innovative and effi cient ap-proach to this task. The leading technology provided by Totally Integrated Automation, with the Simatic control and HMI technology and the Safety Integrated

Renault’s Commitment 2009 was launched in 2006 and defi ned a growth plan aimed at estab-lishing Renault as Europe’s most profi table au-

tomaker. The plan focuses on three major targets of improvement: quality, profi tability and growth. In line with this commitment, Renault thoroughly as-sessed its manufacturing environments and equip-ment to determine areas of improvement. During this assessment, Renault recognized that a standardized concept for manufacturing automation would clearly contribute to achieving Commitment 2009 goals.

With a standardized solution based on Siemens technology for typical

automation tasks, Renault made a signifi cant step towards manufacturing

excellence as stated in the company’s Commitment 2009 growth plan.

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solution for manufacturing safety, offered the fl exi-bility, modularity, reliability and standardization that Renault was looking for. Moreover, the Safety Inte-grated concept is approved by French CETIM author-ities, giving further proof of the concept’s quality and capabilities. Finally, Siemens also provided the level of worldwide presence and support that Renault ex-pected from its supplier. This aided the global roll-out of the standardized solution throughout Renault facilities.

Improving performance

Following this decision, Renault and Siemens jointly launched the SCUBE (derived from S3: Standard Sys-tems Siemens) project. This concept represents the broad deployment of highly fl exible technology capa-bilities throughout the manufacturing and assembly processes and uses a set of pre-designed hardware and software solutions.

Strategic goals for SCUBE are cost reduction among automation components, spare parts, technical sup-port, training and repairs. Renault also wants to re-duce the required design and commissioning times of their manufacturing and automation equipment by reaching a goal of 50 to 80 percent pre-wired elec-trical components, up to 80 percent standard sub-routines for PLC programming and using more than 50 percent standardized HMI screens. An additional

target is to establish contractual commitments among OEMs and system engineering companies on reliabil-ity, maintainability, continuity and training, and other services by specifying a uniform automation architec-ture for all equipment.

Networking with Profi net

For its information and communication backbone, Renault chose the open Industrial Ethernet standard Profi net. At the machine and equipment levels, Profi net IO RT (Level 0) connects fi eld devices such as Simatic ET 200 systems, RFID components and drives. The Level 1 Profi net network transmits non-critical data that integrates into the manufacturing cell auto-mation system architecture and connects the HMI de-vices. This network provides supervision, parameter-ization and resource management. It also connects robots and other manufacturing equipment and transmits parameter and program data. In addition it offers backup functionality. The Level 2 Profi net net-work integrates into the plant process environment and includes a network infrastructure and application server for process management in each plant.

Modular operator panels for all applications

The SCUBE concept is based on a structured and mod-ular automation concept and also integrates failsafe

At the “jig” level, basic operator panels (BOP) are used, optionally with distributed (D-BOP) versions The “jig and robot” level is operated with

light operator panels (LOP), available also in a distributed (D-LOP) version (not shown here)

Main operator panels (MOP), with distributed sub-operator panels (SOP) for local operation, are used for facility-level automation tasks

6 move up | 1-2009

S7 317-F-2PNCP343-1 lean

MicroBox 420

PC 627

ScalanceX216

ET 200S

Industrial Ethernet (Level 2)

MOP SOP

Profinet(Level 0)

RJ45/M12IP 65 cable connections

24 V DC

Flat Panel 10“

24 V DC

Industrial Ethernet(Level 1)

IndustrialEthernet

Flat Panel 10“

USBport

USBport

All panels, for example, the MOP and SOP depicted here, use uniform hardware and software

S t a n d a r d i z e d a u t o m a t i o n a t R e n a u l t : t h e r e s u l t s

By implementing a standard automation solution for operation and monitoring at their plants, Renault has achieved signifi -cant improvements:

Reduced complexity of the automation 3environment: The entire automation project is covered by a limited set of functions and documentsSimplifi ed design and commissioning 3Considerable improvements in project 3qualityShorter project roll-out phase 3Signifi cant cost savings compared to 3similar projects

functions into one uniform architecture. SCUBE uses standardized software and hardware that is specifi ed in the guidelines developed by Renault and Siemens, with Simatic S7-300 PLCs, Simatic HMI devices, Simatic Industrial PCs, Microbox PCs for embedded control and Sinamics G120/G120D as standard motor converters. Additional standard components include Sirius circuit breakers for standard and specifi c han-dling applications, Simatic RFID read/write devices and data tags, and Scalance components for network-ing and communication. The controllers and distrib-uted devices are equipped with Safety Integrated fail-safe units, allowing non-safety-related and safety-re-lated functions to be performed by one device. Simatic WinCC fl exible is used for visualization tasks.

The automation and HMI units are all contained in standardized cabinets, always using identical inter-faces, installation and design. Depending on the ex-tent of the required functionality, every manufactur-ing unit or zone is equipped with suitable versions of the specifi ed operator panels that offer all required functionality.

Pre-defi ned functionality levels

Three main levels of functionality were defi ned. The jig level comprises a simple operator panel providing basic automation functions such as on/off, emergency stop and counters or simple display of manufacturing information. This basic operator panel (BOP) can also be implemented in a distributed version without an

electrical cabinet (D-BOP). The next level of function-ality is the “jig and robot” level, where a so-called light operator panels (LOP) with Simatic Touch Panel and S7-300 controllers are used. These connect to the distributed automation devices such as Simatic ET 200 I/O or frequency converters for the drives. This LOP is also available as a distributed D-LOP version. At the third level, facility-wide operation and moni-toring tasks are performed via main operator panels (MOP), providing multiple interface options. They connect to sub-operator panels (SOP) with an embed-ded Microbox 420 controller for local operation and monitoring on the line. Moreover, a set of specifi c op-erator panels was defi ned for additional tasks, such as workfl ow operator panels (WOP) for performance control and a remote version of the main operator panel (ROP).

Pre-defi ned engineering

The OEM or Renault engineering team equips the manufacturing zone or station with the required op-erator panel using the hardware specifi ed for this panel type. Programming is performed using a soft-ware function library that Siemens and Renault devel-oped especially for SCUBE. The software comprises specifi c ready-to-use Renault sub-routines that cover about 80 percent of all programming tasks and also includes the required PC software with licenses. Con-sequently, PLC programming quality is improved and PLC programming time is reduced. All software was

C o v e r F r a n c e

move up | 1-2009 7

infocontact

www.siemens.com/automotivesylvain.joly@siemens.comklaus.ruebenach@siemens.com

SIMATICET 200eco

Profinet Level 0

IP20switch

E/S IP65

Displays

SOP

Electrical cabinet

Zone Zone Zone Zone

Convertercabinet

E/S IP65

Convertercabinet

Convertercabinet

Robotcontroller

E/S IP65

E/S IP65 E/S IP65 E/S IP65

E/S IP65

Dynamic ID

SOP

SOP

SOP

SOP

IP20switch

IP20switch

Convertercabinet

Convertercabinet

IP20switch

Industrial Ethernet Level 2

Non-critical inter-PLC link

HMI / Backup –Industrial Ethernet Level 1

Critical inter-PLC link

MOP

Electrical cabinet Electrical cabinet Electrical cabinet

Robotcontroller

Robotcontroller

Robotcontroller

specifi ed by Renault and Siemens, then developed by Siemens and ultimately approved by Renault. Siemens software programming includes user guides; stan-dard functions blocks; specifi c function block per process; block libraries and documentation; move-ment and robot-controls-associated communication; and diagnosis. Additionally, OEMs received extensive training covering all aspects of the new automation approach such as safety, controller programming, HMI, network architecture and Profi net implemen-tation, RFID, control panels, converters and motor starters.

Multiple benefi ts

As a result of the SCUBE project, engineering, OEM and production teams have achieved signifi cant im-provements in facility performance. Because fewer custom specifi cations are needed in the new Siemens-

Schematic of SCUBE architecture

developed environment, engineering teams are ex-pected to reduce their commissioning times, increase quality and reduce training for PLC software from three weeks to one. OEMs benefi t by reducing their design times and expenses for customer support. Most impressive of all, however, were the immediate cost savings possible due to the standardized ap-proach. With SCUBE, Renault was able to save 11 per-cent of the costs for automation components com-pared to similar projects. p

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C o v e r F r a n c e

Faurecia Abgastechnik GmbH, Germany p

Test Rigs Fit for the Future

Automotive supplier Faurecia, in

collaboration with Siemens, has

modernized and reorganized the entire

range of measurement and testing

technology used on test rigs at its Fürth

site, without interrupting normal

operations.

F a u r e c i a A b g a s t e c h n i k G m b H

Faurecia Abgastechnik GmbH in Fürth is part of the French-owned Faurecia Group, which operates 190 production facilities in 28 countries. With sales of EUR 12.7 billion in 2007 and a company history stretching back 200 years, the Group is among the pioneers of the automotive industry and among the top eight leading automotive suppliers worldwide.

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All

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.Gey

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Complete exhaust systems and individual components are put through their paces in the test rigs

Faurecia Abgastechnik GmbH in Fürth develops and manufactures exhaust systems for the in-ternational automotive industry. Special test

rigs in which individual components or complete ex-haust systems can be tested play a key role in devel-opment and production. With Siemens as a project partner, these test rigs were gradually modernized between 2005 and 2007 together with extensive con-version and expansion projects.

Modernization with Siemens

There were both economic and technical reasons be-hind the decision to modernize. Faurecia wanted to enable 24-hour operation of the test rigs and to con-centrate all testing technology in one location. Previ-ously, units had been spread between different areas. The aim was to locate the test rigs and the evaluation units close to the central preparation area and the workshop where the test items and engines are as-sembled. In addition, the test rigs and the develop-ment and design departments were to be brought closer together in order to improve communication between the different areas. Extensive modernization was also required from a technical point of view. The existing test-rig technology had become outdated over the years and spare parts sourcing had in some cases already become diffi cult or even almost impos-sible. In addition, the old test rigs no longer met the environmental requirements with regard to noise and pollutant emissions of the relevant German emission control regulations.

Siemens was the main project partner, designing and delivering the control, measurement and auto-mation technology for the engine test rigs as well as the entire ventilation technology. Siemens was also responsible for measurement and control boxes for the engine electronics control and, in collaboration with sub-contractors, installed and commissioned all of the automation, measurement and ventilation tech-nology in the engine test rigs. During the moderniza-tion process, which was accompanied by comprehen-sive construction work, operation had to continue uninterrupted in the existing test rigs. This called for close cooperation between all parties involved and coordination on all measures.

From the outset, there were several factors which argued in favor of working with Siemens, as Franz Lüftenegger, in charge of the modernization of the test rigs at Faurecia, explains: “First of all, we wanted reliable and established technology. In this respect, Siemens sets the standard and many other suppliers use Siemens technology as well. Siemens technology is also well established on an international level thanks to its outstanding quality. So when you are looking for the right supplier, Siemens is always at the forefront. Using components from the Simatic range of automation products, Siemens provides a broad range of turnkey systems and components, so that we can fi nd the complete solution – for the test rigs, the measurement and ventilation technology and also for the supply and disposal technology – from a single source. Thanks to the open nature of the systems, there are no interface problems. The simple

10 move up | 1-2009

programming makes it quick and easy to implement specifi c adaptations.

Another factor was the CATSNT software system spe-cially developed by Siemens for test rigs. Last but not least, in addition to all of the technical and qualitative aspects, geographical proximity was a crucial factor in the choice of Siemens as project partner. We set great store by that proximity – for both on-site sup-port and follow-up maintenance.”

Comprehensive testing for top quality

The test rigs are important stages in the life cycle of Faurecia exhaust systems. The company always places great importance on the quality of its products and the perfect tuning of the exhaust system to the vehi-cle for which it is intended. Each individual compo-nent, and also the complete exhaust gas system, is therefore tested extensively throughout its various development stages on special test rigs. The behavior of the systems is tested in simulated environments, with the engines of the relevant car manufacturer and, fi nally, when built into the vehicle. Each system must pass the test program without any errors before it is delivered. The criteria for these tests include stability, vibrations, acoustics and emission levels after the ex-

haust gas has been cleaned using a catalytic converter or soot fi lter. Complex measurement technology in the test rigs constantly monitors multiple parameters during these tests. The temperature and gas develop-ment, fl ow profi les and vibrations are examined. A special loading machine is available for load tests, with which it is possible to simulate hill ascents, for example. The intensity of the load is controlled via an electronic accelerator pedal.

Short distances and state-of-the-art technology

Following the modernization project, there are now a total of ten test rigs in Fürth, all housed in a central building. The design and development department is located right next to the wing with the test rigs, a spe-cial acoustics area and the workshop for preparation of the test items. This enables processes to be per-fectly integrated within the various departments. Thanks to state-of-the-art technology and the fl exible design of the test rigs themselves, Faurecia in Fürth can work with a large number of different engine types. Engine test rigs and the acoustics area are de-signed in such a way that the exhaust systems can be tested together with engines for both longitudinal

Engine electronics actuation unit

Complete transparency: one of the new test rigs at Faurecia

B e n e f i t s a t a g l a n c e :

Reliable and internationally 3established automation technology

Broad range of ready-to-run 3components and systems from the Simatic portfolio

Simple programming for 3fl exible customization

C o v e r F r a n c e

move up | 1-2009 11

and transverse installation. In some cases, Faurecia in Fürth also tests systems for French sites, as the test rigs there are designed primarily for transverse en-gines.

All processes in the test rigs are visualized and op-erated via operator stations with Simatic Panels. Set-point specifi cation is carried out by the CATSNT auto-mation system. The test rig that actuates the engine electronics, Simovert Masterdrives converters with electric load equipment and the test rig infrastruc-ture is controlled by the CATSTC500 regulation system based on Simatic components. This also allows carry-ing out simulation runs with “uphill” or “downhill” motor load scenarios. Furthermore, the ventilation, another key component of the test rigs, was designed completely by Siemens and is also automated using Simatic technology. The ventilation system has to maintain a slight vacuum the test rigs at all times for safety reasons so that no gases can escape from the test rigs into the workshop. Moreover, the systems ventilate the engine test cells and extract all exhaust gases from the test rigs within minutes. To this end, the ventilation system provides suction of up to 30,000 cubic meters per hour. In order to ensure re liable operation at temperatures below freezing, it is possible to work in an air-recirculation mode if needed. Moreover, a CO2 extinguishing system is in-stalled in the test rigs.

All workstations are of a similar design and are now equipped with the latest technology. Operators can switch between test rigs without extra training if re-quired. The new test rigs are not rigid systems, but

can be fl exibly adapted to a variety of tasks. For exam-ple, temperature settings and measuring channels can be selected as required. “We are very satisfi ed. And we’re not the only ones. We’ve had some very pos-

itive feedback from our customers on the new central-ized concept and modern test rig equipment. Siemens is not a low-cost supplier, but they’ve got the balance between price and performance just right,” says Franz Lüftenegger. p

infocontact

www.siemens.com/automotivekramer.peter@siemens.com

The architecture of the test rig automation

Profibus

Profibus

Profibus

Load machine

Masterdrives AFE converter system

CATSMaster automation system

Control system

NT

Operator station with operator panel

Temperature monitoringAcoustics area

CATS

HC-CO fire alarm centertank system fluid

Simatic S7-300

SimaticET 200

SimaticET 200

SimaticS7-400

SimaticET 200

Simatic Rack PCIL43

TC500

Temperature monitoringPressure monitoringAmbient conditions

Vehicle power supply

Electronic acceler-ator

Ventilation system

Test piece monitoring

“ We a re very satisfi ed. Our

customers, too, have expressed

their approval of the new concept

of proximity and welcome the

modern test rig equipment.”Franz Lüftenegger, Faurecia Abgastechnik GmbH

P r o c e s s P o w e r t r a i n

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PSA Peugeot Citroën developed the MC gearbox to make driving several of their vehicles even more enjoyable. The MC can be switched to

manual mode or work as an automatic gearbox. The car needs no clutch pedal but has gearshift levers on the steering wheel. The mechanically controlled six-speed gearbox can be used for torques of up to 270 Nm, for example in typical medium class vehicles. For Citroën, this means the C4 and C4 Picasso. The MC is built in Valenciennes in northern France. Here, PSA Peugeot Citroën operates the largest gearbox manufacturing plant of any car manufacturer in the world, with a capacity of two million gearboxes a year.

PSA has designed a completely new manufacturing system for the MC gearbox. The facility is operated in two shifts and produces 850 gearboxes a day. “Our aim is to increase capacity in stages to 1,750 units a day,” says Bertrand Olivré, who is responsible for electrical automation technology at PSA. To achieve

this, a three-shift system will be introduced, the pro-ductivity of the plant will be increased and additional plant components will be installed.

A total of 142 CNC machines were needed for a wide range of machining tasks. At 215 stations, new PLCs have been implemented. Naturally, the necessary communication infrastructure also had to be set up (bus systems, networks etc.).

PSA Peugeot Citroën, France p

Effi cient IntegrationWith Solutions for Powertrain, PSA Peugeot Citroën has solved

a highly complex automation challenge in gearbox production.

The new gearbox makes driving the Citroën C4 Picasso even more enjoyable

B e n e f i t s a t a g l a n c e :

Simple system eingineering 3Short realization times 3Consistent operation and maintenance 3Low training costs and reduced spare parts 3warehousing

PSA

Peu

geo

t C

itro

ën

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infocontact

www.siemens.com/translinejerome.le_bris@siemens.com

In order to ensure PSA was getting the best ma-chines or the machines with the best price/perfor-mance ratio, the experts at the car maker decided not to use a general contractor, but to purchase the ma-chines individually and integrate them themselves. However, the heterogeneous plant components had to be automated and operated in a standardized way, in order to maintain a consistent overview and oper-ate the plant effi ciently.

Solution idéale: Solutions for Powertrain

“After analyzing the market and interviewing machine manufacturers, we opted for Siemens Industry Auto-mation,” says Jean-Marc Delavoye, head of electron-ics planning for all mechanical projects. “The decisive factor was the concept ‘Solutions for Powertrain – Transline’, which already has a proven record in the automation industry.” Based on standard compo-nents, the Solutions for Powertrain allow a system to be generated that is tailored to the respective user’s needs. The advantages include very fast implemen-tation, safe solutions, standardized operation and maintenance, a reduced spare parts inventory, simple system design, lower training costs and lower overall costs.

The Transline package includes the Sinumerik 840D CNC control, specially designed for complex plants. This includes the extensive integrated safety package

“Safety Integrated”. The Simatic S7-300 series offers scaled PLC processor performance. Realtime commu-nication via Profi net from Siemens is supported by an extensive command set and the Profi bus fi eld bus enables various options for optimum data exchange during the process.

The control system is supplemented with various operating panels with 7.45 to 15-inch screens. In com-bination with a robust industrial PC, PCU 50, fl exibil-ity and performance are safeguarded. “Transline HMI”

provides a standardized, extendable user interface for all machines. The modular solution also includes connections for intelligent peripheral devices such as sensors, diagnostic software and software for effi -cient data management.

Know what’s going on with Moby

The project team at the Valenciennes plant also or-dered the Moby RFID system for the new gearbox pro-duction facility. This RFID system includes mobile data storage units, write/read devices, mobile hand terminals, antennae, interface modules for connect-ing to the automation system and software for system integration.

“At PSA Peugeot Citroën, we use Moby to identify components and tools,” explains Bertrand Olivré. He mentions gear wheels as an example of how the sys-tem is used to identify components. The gear wheel sets in the gearboxes are different depending on in which car the gearbox is going to be used. By identi-fying the component, it is possible to ensure that the right NC program is used for the respective part.

Using Moby, it is also possible to specify informa-tion about the tool, for example information about operation times and wear. “We can only maintain the high quality we demand from our gearboxes by using tools that are in perfect working order,” stresses Olivré.

“We are equally pleased with the automation con-cept as we are with our partnership with Siemens,” says Jean-Marc Delavoye, summing up the experience thus far. “The ‘PSA – Siemens – machine manufacturer’ triangle is benefi cial for all partners.” p

OPPCU

Sinumerik840D

MPP

Profibus

PG / PC

Industrial Ethernet TCP/IP

Profibus

BTSS

1FT6ET 200 ET 200

1FT6 1PH7

IM CP

OPPCU

Sinumerik840D

MPP

Profibus

BTSS

1FT6ET 200 ET 200

1FT6 1PH7

IM CP

Loading portal head control

NC Machine 1 NC Machine 2

The building blocks: automation plan of the fl exible gearbox production lines

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Electric Overhead Conveyors p

A New Benchmark: Modular Overhead Conveyor System

An innovative modular system for electric monorail overhead conveyors

developed by Siemens is setting new standards with regard to energy

consumption, costs, planning and commissioning.

T e c h n o l o g y C o n v e y o r T e c h n o l o g y

Siem

ens

AG

move up | 1-2009 15

ment and converters with a nominal power of 3.0 kW for the monorail chassis.

The cable hoist unit developed by Siemens can be equipped with two or four cables for different appli-cations. It is driven by a powerful Motox offset shaft geared motor. A Motox helical bevel geared motor takes over the driving movement (if required, this can be expanded with an additional inverted drive to become a redundant drive concept with overload recognition as standard). Despite the very compact gear series, higher power take-off torques could be achieved than previously usual on the market. There-fore, one lifting drive is suffi cient. The fact that the motors are operated in delta circuit increases the nominal power by a factor of 1.73. The engineers could therefore choose a smaller motor size, which also has a positive effect on overall design.

Simple design, enhanced safety

The Sinamics G120D frequency converters perform all three safety functions accordance to EN 60204:

The automotive industry has always been the pacesetter for automation. With standardized automation and drive technology, as well as a

patented suspension concept (URC, Universal Rail-guided Conveyor), Siemens created a uniform modu-lar solution for electric monorail conveyors that sets new standards for overall costs, energy consumption, planning and commissioning. The modular system is based on Totally Integrated Automation (TIA) and comprises the monorail conveyor suspension system and the rail system, including points and other ele-ments such as a setting station, a maintenance jack, a stationary suspension rack opener and closer, and a 4-mast lifter.

The modular system is designed for useful loads of up to 2.5 tons, the drive components were tested with 25 percent overload. Other parameters of the mono-rail conveyor suspension system are a lifting height up to 4,000 millimeters at a system height of only 1,000 millimeters, a drive speed in the range of 1 to 40 meters per minute and a lifting speed of up to 10 meters per minute.

In addition to the system components, the modu-lar system contains a fl exible hardware and software control concept that can be adapted to different mas-ter control hierarchies via a standardized interface. The hardware uses standard Simatic components and Siemens drive technology only and the wear-free communication via IWLAN reduces the number of loops to only four busbars. After the system was launched at the 2008 Hanover Trade Fair, a total of 270 URC units, including rail components and other elements of the modular system, were supplied to the US, Canada and Russia in the same year.

Converter and motor combined

The central components of the vehicle electrics in-clude Sinamics G120D frequency converters. The converters can be operated over a wide voltage range of between 380 and 500 V at 50 or 60 Hz; all variants enable the feedback of electrical energy as standard. At the same time, this eliminates braking resistors, which has an extremely positive effect on energy bal-ance, costs, space requirements and weight. The G120D is built up modularly from different, compat-ible power modules as well as a uniform, plug-on control unit. That means greater fl exibility in the confi guration, as well as a reduction in spare parts costs. The distributed converter series covers a wide power range from 0.75 to 7.5 kW. For the electric monorail overhead conveyor, converters with a nom-inal power of 7.5 kW were chosen for the lifting move-

The Motox geared motors are optimized to enable relatively compact drive units which perform lift and linear movement thanks to their large transmission ratios

Siem

ens

AG

16 move up | 1-2009

infocontact

www.siemens.com/automotivedominik.riehle@siemens.comheinrich.niemeyer@siemens.com

R u b r i k U n t e r r u b r i k

Safe Torque Off (STO), Safety Limited Speed (SLS) and Safe Stop 1 (SS1). This eliminates the need for additional safety transmitters and contactors. The hoist unit is equipped as standard with a mechanical locking and holding brake on the cable drum. Both mechanical safety functions are also active in the powerless state and therefore increase safety in all operating states. If, despite this, the lifting drive should unexpectedly fail, an “emergency lifting tool” is available.

A Safety Integrated solution serves to control the monorail vehicles. Every vehicle is equipped with a failsafe F-CPU of the Simatic ET 200S series which takes over complete control of the subsystem. The ve-hicle’s numerous sensor signals are bundled by a dis-tributed Simatic ET 200pro I/O with IP65 protection for installation without control cabinets. Communi-cation with the vehicles takes place via an IWLAN ra-dio network with Profi net.

Part of the solution is also a stationary system con-trol based on Simatic S7-300/400 that coordinates all essential tasks of the monorail vehicles. Another task of the stationary system control is communication with the superior control hierarchy. The main bene-fi ts of this solution are the high fl exibility of the sys-tem concept, reduced load on the master control en-vironment, a reduction in the commissioning times by use of prefabricated software modules and, on the hardware side, the consistent use of Siemens control

and drive technology with worldwide availability of components and services.

Standards bring benefi ts

The newly developed modular system for electric monorail conveyors shows that only uniform, mecha-tronically-based engineering leads to an optimum system solution. The heart of the drive technology, the G120D frequency converter, offers the persuasive advantages of convenient feedback or braking possi-bilities as well as encoderless safety functions in ac-cordance with EN 60204. An extremely effi cient and compact drive package was created in combination with the Motox geared motors.

The drive and control technology is designed with a high degree of protection so that the devices can be positioned optimally within the design without additional encasement. Devices can also be changed quickly and easily. The structure of the entire electric monorail conveyor with standard components also provides excellent part availability. p

T e c h n o l o g y C o n v e y o r T e c h n o l o g y

The modular URC monorail overhead conveyor system utilizes standard components only

S7-300/400Profinet

Access Point

Wireless LAN via RCoax

Sinamics G120D

Motox geared motor

Motox geared motor

SimaticET 200SClient

B e n e f i t s a t a g l a n c e :

High fl exibility in facility development 3thanks to standardized components Notable reduction in commissioning 3times through prefabricated software modulesReduction of installation time and 3effort thanks to IP65 components and IWLANReduction of maintenance costs due 3to contact-free data communication via IWLAN

move up | 1-2009 17

T e c h n o l o g y S e n s o r T e c h n o l o g y

BMW, USA p

Perfect RecognitionSimatic code reading systems ensure reliable

recognition and traceability of components at BMW.

BMW

18 move up | 1-2009

At the BMW plant in Spartanburg, South Caro-lina, around 4,700 workers operating in shifts with fl exible working time models produce

the BMW X5 and X6 for the global market. In order to optimize the traceability of bodywork components, the quality department went in search of an identifi -cation system that would replace labeling by hand and therefore eliminate the associated potential for errors. With the previously used system, handwritten labels would frequently become smudged after mounting, rendering them illegible.

Search for a reliable identifi cation system

The central BMW planning department in Munich (FIZ) planned the new system and also supported col-leagues in the United States during the engineering and commissioning stages. The team was also helped by having access to the initial results from tests of various labeling methods and a variety of suitable components that had been gathered at the BMW plant in Regensburg as part of an masters thesis.

After testing various labeling methods, the team se-lected the process of identifying components using a pin-stamped or laser-marked data matrix code (DMC) and the part number in plain characters. To enable automatic recognition of the codes and numbers, a total of 26 Simatic VS130-2 code-reading systems were installed. BMW decided on this system because

the DMCs offer ample reserves for the application, both optically and with respect to data capacity. More-over, the camera was a perfect match for the require-ments at the plant and very simple to confi gure.

Distance from object and width of fi eld can be freely selected

Simatic VS130-2 is an intelligent camera system with integrated image analysis functions that has been specially designed for the recognition of coded in-formation in an industrial environment. The sensor head has an aluminum profi le enclosure in protection class IP65. Its CCD chip has a resolution of either 640 by 480 or 1,024 by 768 quadratic pixels. In Spartan-

BMW

B e n e f i t s a t a g l a n c e :

Minimized number of error sources by 3automated production sequencesDocumented quality thanks to a clear 3identifi cation of manufacturing partsTracking up to fi nal assembly thanks to 3consistent data management

Every single component in the

BMW body shop carries an individual

marker

T e c h n o l o g y S e n s o r T e c h n o l o g y

move up | 1-2009 19

infocontact

www.siemens.com/simatic-sensors/mvbirgit.gottsauner@siemens.com

burg, a version with a C/CS mount connection is used. In this version, the lens – and therefore the distance from the object and the width of fi eld – can be se-lected as required. The system also includes a ring light to provide optimum lighting conditions. Image evaluation is performed separately from the camera in the evaluation unit.

The link to the control panel for starting, stopping and switching modes is realized using an I/O coupling. The data from the evaluation unit is transmitted via Industrial Ethernet to the controller – usually a Simatic S7-400 – and from there to a Simatic Panel PC 877 for display. Simatic WinCC serves as the visu-alization system. The software for displaying the DMC was developed in-house at BMW in Spartanburg and runs in an integrated Web browser. The application is also connected to the host control system that allo-cates a consecutive eight-digit number for each com-ponent. This is applied as a DMC with 20 by 20 dots, as well as in plain characters, in the stamping station.

Remote error analysis

The quality of the stamp is then checked by a code-reading system and communicated to the control sys-tem. If a stamping fault is detected at a test station, the worker can report faults in the stamping by refer-encing the number. The system then sorts out all the parts that were stamped during the same test cycle and connects the appropriate numbers with the same fault. Due to the integration in the Simatic WinCC process visualization system, this check can in prin-ciple be carried out from any network workstation. The plain-character number is usually legible in the camera image, meaning that the worker can even arrange for fault analysis and acknowledgment re-motely.

In the motor compartment, the fi rst DMC inspection is carried out immediately after stamping. To check the DMC, a robot holds the stamped part in front of the code-reading system, which reads out the code in 0.5 to 0.7 seconds. In the area of the rear body, the inspection is performed in a similar way. However, the system uses both the part numbers and certain features of the DMC for type control. During the as-sembly process, the system reads the stored numbers of the order-related individual parts up to 18 times. After assembly, the numbers are “married” into one common number for all integrated parts.

DMC recognition for high process reliability

One of the reasons for checking stamp quality is that many supporting parts made from high-strength, and therefore particularly hard steels, must be marked, which pushes the labeling systems to the limits of their mechanical load capacities. The hard-ness of the surfaces means that the stamping ma-chine often has to work at pressures of up to 6 bar. This is also a very noisy process. To reduce the stamp-ing noise level, BMW is testing laser labelers. Initial

results show that the camera achieves good results, in particular with lasered square dots. Typical sources of contamination such as fi ngerprints or uneven surface refl ection have no impact.

The body shop produces engine mounts and rear-mounted rack systems made from individual compo-nents. Depending on the type of vehicle ordered, dif-ferent materials can be combined. For this reason, it is very important to be able to identify precisely which parts are currently being assembled. Automatic DMC recognition provides the necessary reliability. Since their implementation, the systems have run in Spar-tanburg without any failures. Even in the harsh envi-ronment of the body shop, where welding dust and spatter are present, the code-reading systems worked without any problems right from the start, without any special cleaning requirements. p

Light barrier (trigger)Object withcode Conveyor

Ring light

Power supply

Evaluation unit

Automation system

PC/PG for setup support

Sensor head

Profibus

IndustrialEthernet

(direct or via network)

Code reading system components

20 move up | 1-2009

Volkswagen, Germany p

Uninterrupted Supply

Worldwide, the VW Group uses around 2,000 substations to supply its production plants with power. These stations are standard-

ized and consist of circuit breakers, cable distributors, busbar trunking systems, compensation cabinet and transformer housing.

In the substations of the Volkswagen plant I, Sentron 3WL circuit breakers and

a LDA busbar trunking system form a reliable, cost-effective and fl exible power-

supply backbone for production.

Approved circuit breakers

The supply systems have a momentary reserve based on the n-1 principle, that is a single error does not lead to the failure of the power supply. Three substa-tions are often operated in parallel to improve cost

T e c h n o l o g y S w i t c h i n g T e c h n o l o g y

VW requires innovative energy supply solutions for its modern production plants

Siem

ens

AG

move up | 1-2009 21

infocontact

www.siemens.com/automotivekurt.backhaus@siemens.comj.werning@siemens.com

effectiveness. This means that every single circuit breaker must safely switch off high and low short- circuit currents with a short reaction time. In the event of accidental arcing faults, high short-circuit currents must be switched off immediately to protect individuals. In addition, although low short-circuit currents should be detected reliably, temporary cur-rent peaks should not lead to immediate tripping of the protection.

Volkswagen demands circuit breakers both for welding and production networks. This is why Sen-tron breakers from Siemens were chosen. “Since the Sentron 3WL circuit breaker has a temporary current strength of 80 kA/s and a surge current strength of 176 kA on an operating voltage of 690 V and therefore easily meets our requirements, VW has approved it for type-tested power distribution boards,” explains Hartwig Kaczor, CEO of the electrical equipper Brink Schaltanlagen GmbH & Co. KG in Hanover.

Low heat loss and fi nely adjustable selectivity

The cabinets are designed without air vents because the substations are also type-tested under accidental arcing conditions (IEC 1614) and the short-circuit current of the low-voltage circuit breaker cabinet is 110 kA per 0.3 seconds. Another property of the new circuit breaker is the fi nely adjustable selectivity. The ETU45B overcurrent trip unit enables optimum parameter ization at all times in slightly delayed and undelayed short-circuit protection. The optional N-conductor protection makes the circuit breaker a pop-ular choice for low-voltage networks, the distribution networks of which can be switched individually.

Fault-tolerant and communication-capable trip units

Today’s ETU45 trip units are much more tolerant of faults than earlier units: if, for example, a short-cir-cuit current fl ows for about 100 ms in the supply line, the tripping time of the 3WL breaker is completely suffi cient to prevent network damage. The communi-cation capability of the ETU45 trip unit enables data networking of all the stations for measured value entry and fault reporting. “We are currently examin-ing the possibility of adding communication modules to 3WL breakers/ETU45 trip units. We could then con-nect power distribution boards directly to a Profi bus network and feed data into an energy management system,” confi rms Andreas Küstermann from the Electrical Energy Supply Planning Department at Volkswagen AG in Wolfsburg.

Volkswagen is also looking at the possibility of using circuit breakers with slide-in technology to sim-plify maintenance work. It would then only take half an hour to change a circuit breaker instead of four hours. Functional and visual inspections could be car-

ried out without loss of function or the need to dis-connect the voltage networks. Type testing for the slide-in circuit breaker in substations has therefore already been carried out.

Busbar trunking system with type-tested connection

A maximum of three substations feed one section in the busbar trunking system, which is used to supply consumers in production. The standard is one 2,500 A busbar trunking system per production hall. There are additional transverse lines in very large produc-tion halls. The LDA busbar trunking system at VW has proven to be the perfect solution. The four-conductor system used has a separate 100% PEN rail. This en-sures low impedance in the event of faults thanks to an increased cross-section. The type-tested connec-tion of the rails to the appropriate fi eld in the sub-stations is established by special adapters. The con-nection to the 3WL breaker has also been type tested. In comparison to conventional wiring, a homoge-neous rail solution offers the advantages of simpli-fi ed, inexpensive assembly, lower fi re load and greater fl exibility. p

3 W L c i r c u i t b r e a k e r i n d i s t r i b u t e d s u b s t a t i o n s

Excellent reliability 3Simple operation 3Easy maintenance 3Compact design 3Can be used in welding and production 3networksLow heat losses, therefore no switch cabinet 3ventilation requiredFinely adjustable settings 3High communication capability 3Slide-in technology for easier maintenance 3and more secure power supply

L D A b u s b a r t r u n k i n g s y s t e m i n p r o d u c t i o n p l a n t s

Low fi re load compared to conventional wiring 3Greater fl exibility in assembly 3

22 move up | 1-2009

I n B r i e f

Automotive supplier Rehau turns to RFID

Enhanced Production Quality

Simatic enables cost savings at Beijing Benz-DaimlerChrysler Automotive Co. Ltd.

System Solution

Beijing Benz-DaimlerChrysler Automotive Co. Ltd. (BBDC) relies on Simatic technology to combine both standard and fail-safe tasks in one system and ensure a reliable and fl exible manufacturing pro-cess. The system has been implemented in a car factory that went into operation on September 15, 2006. The 300,000-square-meter factory is the fi rst stage of a new BBDC plant that will produce 100,000 cars per year in sophisticated production and as-sembly lines.

According to Hong Jun Gao, head of the BBDC electric material department, the Simatic solution was convincing due to its overall cost and ability to ensure high plant availability. The plantwide con-

trol system incorporates both fail-safe and stan-dard systems into the uniform Simatic platform. The integrated system and unifi ed engineering en-vironment and construction not only reduced wir-ing expenses and cabinet space requirements, but also helped reduce costs for engineering, training, operation, and maintenance and reduced the vari-ety of spare parts needed.

Industrial Ethernet is used to connect the con-trollers with the management and monitoring level, and the operation systems and drives are connected via Profi bus and Profi safe. p

www.siemens.com/automotive

Rehau AG, a leading supplier of plastic parts to the automotive industry, has opted for a Siemens RFID (Radio Frequency Identifi cation) solution to ensure seamless monitoring of bumpers. This move sees Rehau become one of the fi rst automotive suppliers to use an RFID system at part level to achieve compre-hensive quality assurance.

The vehicle bumpers produced at the Rehau plants in Brake and Feuchtwangen are manufactured indi-vidually for each vehicle using an injection molding process. They are then machined, painted the appro-priate color and supplied to automotive manufactur-ers ready to be used. In future, each bumper will be fi tted with a UHF-range (Ultra High Frequency) RFID transponder immediately after the injection molding process. This will allow identifi cation of the individual

bumpers at part level during the subsequent produc-tion stages. Rehau will then be able to track during subsequent quality testing exactly which system or machine was used to machine a particular bumper.

Siemens is set to supply the plants in Brake and Feuchtwangen, Germany with some 250 Simatic RF600 reader stations as well as the required tran-sponders. The components fall within a high protec-tion class and are robust in design, making them perfect for use in harsh industrial environments. The machines used for automatic fi tting of the transpon-ders are supplied by Bluhm Systeme GmbH in Unkel, Germany. p

www.siemens.com/rfi d

D i a l o g u e

move up | 1-2009 23

infos

If you want to know more about Siemens automation and drives technology, visit our online information platform in the Internet:

www. siemens.com/automation/newscenter

online

Under the address

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you can download the latest issue as a PDF fi le. The elec tronic archive also gives you access to all previously published issues.

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move up 1-2009Publishing HousePublicis KommunikationsAgentur GmbH, GWACorporate PublishingP. O. Box 32 40, 91050 ErlangenTelephone +49 (0) 9131 9192-501Telefax +49 (0) 9131 9192-594publishing-magazines@publicis-erlangen.de

Editor:Kerstin Purucker

Layout:Jürgen Streitenberger, Rainer Degenkolbe

Copy editor:Daisy Kraus, Désirée Bambynek

Jobnumber: 002800 17465

DTP: der Döss für Kommunikation, Nuremberg

Printed by: Wünsch, Neumarkt

Title: BMW

move up is published quarterly

Circulation: 7,500ISSN 1610-7802 (Print)

PublisherSiemens Aktiengesellschaft,Gleiwitzer Str. 555, 90475 Nuremberg,Germany

Division Drive TechnologiesCEO Klaus Helmrich

Division Industry AutomationCEO Anton S. Huber

Editorial Responsibility in Accordancewith the German Press LawArno Hoier

Responsible for Technical ContentsThomas Schott

In-house editorial staffElitza DaloukovaE-mail: elitza.daloukova@siemens.comJürgen NoldeE-mail: juergen.nolde@siemens.com

ConceptChristian Leifels

© 2009 by Siemens Aktiengesellschaft Munich and Berlin.

All rights reserved by the publisher. This edition was printed on environmentally friendly chlorine-free paper.

The following products are registeredtrademarks of Siemens AG:ET 200, MASTERDRIVES, MOBY, S7-300, S7-400, SCALANCE, SIMATIC, SIMOVERT, SINAMICS, SINUMERIK, TOTALLY INTEGRATED AUTOMATION, 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: TMOVOrder No.: E20001-M4109-B100-X-7600

infosAdditional information about our concepts, solutions and systems in the automotive industry can be found at the Automotive Internet portal, which was recently revised and updated. At

www.siemens.com/automotive

you will fi nd detailed information concerning all our offers for the automotive industry, as well as more references, webcasts and brochures. And of course you can fi nd your personal Siemens contact.

One system for the entire process chainWell-equipped with UHF – the SIMATIC RF600 RFID system for flexible system integration and reliable identification

Answers for industry.

SIMATIC SensorsThe SIMATIC RF600 RFID system with its extended range of UHF write and read devices provides you with a variety of innovative options along the complete process chain – from incoming goods to production and outgoing goods. In addition to optimum material flow control, 100 % reliable tracking and tracing and transparent asset management, you can benefit greatly from this system – thanks to seamless integration in the SIMATIC controller as well as in PROFIBUS, PROFINET and Ethernet communications networks, and a uniform system environment in accordance with ISO and EPC standards. Further information at: www.siemens.com/simatic-sensors/rfSetting standards with Totally Integrated Automation.