moveup s

Systems and Solutions for the Automotive Industry 4th Edition July 2|2005

Opel Gear Works uses

Solutions for Powertrain-Transline

Simatic WinCC
for Painting
Truck Cabs

Body Conveyor System at DaimlerChrysler:

Fast Problem Solving

Directly On Site
2 CONTENTS

Publicis CPZ
4 8 10
P. Koerber

Volkswagen presented the first Profinet The Simatic WinCC system offers a comfortable The mobile operator
applications for automobile production overview of the current painting process panel enables reliable
at the Hanover Fair local system control

3 EDITORIAL Conveyor systems

12 Fast Problem Solving Directly On Site
Body conveyor system at DaimlerChrysler
TRENDS
Profinet in practice Gear production
4 Impressive Performance 14 Power Solution for Powertrain
Volkswagen and Siemens demonstrate Opel Austria builds six-speed gear with
two Profinet applications at the Solutions for Powertrain-Transline
Hanover Fair 2005
Wheel assembly systems with WinCC
16 Consistently proactive
CASE STUDIES Ghyselinck chooses PC-based automation
solution with WinCC

move
Process visualization
8 Optimum from the prime coat
Cab painting for Volvo trucks Integrated production
20 Perfectly Integrated
Body-in-white production line for the
Production of vehicle seats Citroën C3 platform controlled and
10 Two New Lines Just-in-time visualized with Simatic
Johnson Controls in Geel (Belgium)
Vehicle testing systems
22 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 3

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.
20

PSA Group
W. Geyer

VW spotlighted the quality of production and

gave a few key suppliers – including Siemens –
The body-in-white production for the Citroën C3 the opportunity to present the capability of their
is equipped with Totally Integrated Automation 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
18 TELEGRAM throughout the branch that Profinet has the best
chance of becoming the future fieldbus standard
Loch GmbH, Ergolding
for the automotive industry.
Volvo Truck, Brisbane, Australia
Our goal is to introduce Profinet uniformly as the
Kührer Papst Industrieautomation (KPI)
central fieldbus system in all units as the PNO, a
GmbH, Benningen
manufacturer neutral body, propagates. We hope
Rausch GmbH & Co. KG, Haan
that the branch has learned its lesson from the
Nimak Automatisierte Schweißtechnik “fieldbus war” of the 1990s which considerably
GmbH, Wissen
hindered technological development.
Opel Azambuja, Portugal
Because system manufacturers and users are
dependent on a common “backbone” in which the
23 DIALOGUE best system wins in technological competition.

eup
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.

Ralf-Michael Franke
Head of the Industrial
Automation Systems Division

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4 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

to use Profinet with integrated personal

safety in future where the overall econom-
ical and technical conditions allow.
Of interest to the automotive industry as
well as to other branches are the new pos-
sibilities for effective data archiving which
are becoming increasingly important for
quality assurance and process documenta-
tion in addition to the greatly increased
transmission performance in comparison
with conventional bus systems. Other ad-
vantages are the real-time capability and
clock synchronicity which enables ex-
tremely demanding motion control appli-
cations on a common Profinet bus by
means of IRT (Isochronous Real Time) tech-
nology.
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 produc-
tion. During the fair the professional visi-

A
utomation in the automotive indus- automobile manufacturers Audi, BMW, tors were able to see two production instal-
try – and not only there – is due to DaimlerChrysler and Volkswagen who have lations of the automotive industry automated
change paradigms. At a joint press joined forces in the AIDA interest group with Profinet in action: one plant for auto-
conference during the SPS/IPC/Drives in (Automation Initiative of the German Au- matic complete production of radiators and
Nuremberg 2004 the four German leading tomotive Industry) declared that they want a mobile fastening system for assembly. ■

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 5

Automatic radiator production

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

Simatic CPU 416F-2 Drive Cliq

Sinamics CU 320
Simotion D435
Sinamics Active Line Module
16 Sinamics Motor Modules
Switch cabinet
ET 200S ET 200S

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

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

Console Coil locked SG5

Fin SN3 Fin back locked
Fin front locked

Core builder
Panel PC ET 200S ET 200S ET 200S ET 200S

IE/PB Link
Light curtain

Emergency stop
Emergency stop

Emergency
Servo motors

stop
Light curtain

Absolute value encoder

Configuration of the Fin radiator machine with Profinet IO

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6 TRENDS
Profinet in practice

Mobile fastening system

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

Corebuilder of the Fin machine In the tightening process itself the Points or Client Modules and leak wave
torque with the respective setpoints conductor is used. The drive controls
from the joint database is compared by
the electromechanical nutrunner
from Atlas Copco which are connected via
with the distributed periphery. The indi- among other things Industrial Ethernet are also integrated
vidual safety-oriented Simatic ET 200S for smoothly in the automation network.
the corebuilder, fin machine and switch The new assembly station runs in an
cabinet communicate with the central plant Tightening used to be done at VW in aluminum profile rail and is driven by a
PLC Simatic S7-416F2 via Profinet IO. The assembly by different fastening system – gear motor. The station moves in exact
Simatic Panel PC 670 for HMI is also equipped from handheld EC nutrunners to com- synchronization with the workpiece car-
with the Simatic PLC via Profinet. pressed air tools suspended from over- rier mounted on a moving skid conveyor.
This plant proves that distributed plant head rails and having to be pulled into At the end of the respective assembly step
configurations with integrated safety can the respective position by the workers. the fastening system automatically re-
be implemented based on Profinet IO and a An assembly technique which demanded turns to its home position and is then po-
high product quality and process reliability constant physical exertion and where the sitioned exactly parallel with the next
achieved. In the near future, also motion fastening procedures could only be doc- workpiece. The exact position of the nu-
control functionality based on Profinet with umented worker-independently with a fastening system is defined by a perfo-
IRT will be available. considerable effort. rated rail code running parallel to the car-

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 7

Configuration of the
Rail suspended assembly
Cross-section of the mobile
of the rail
fastening system

Scalance
Scalance
L1
L1 L2
L2 N
N PE W
PE W 788-1
788-1

Suspended
Fastening control AC assembly
Scalance
W 744-1

The powertrain for the

new generation of the
Switch VW Passat are assembled
Sinamics G110 at the mobile fastening
Switch system already installed
Simatic Panel PC
Sinamics G110 Simatic ET 200S at VW in Emden

Simatic ET 200S

Simatic Panel PC

Scalance
W 744-1
Fastening control AC

rier profile which supply an absolute path- been done correctly the fasten-
actual value. ing system automatically re-
The energy supply is single-phase via turns to its home position and is
Vahle busbars. The Sinamics G110 con- ready for the next assembly step.
verter takes care of conversion into a three- The data of every single joint
phase power supply for the three-phase is transferred to the central
current gear motor. The feeding is there- screw data server and buffered
fore implemented with little effort and low- additionally in the PC of the fas-
maintenance three-phase current motors tening station. This data trans-
can be used. fer also takes place wirelessly via
The ET-200 of the fastening system com- the radio bridge of Scalance
municates with the plant PLC via a radio WLAN Access Point and leak
line consisting of a leak wave conductor wave conductor via the Profinet protocol. concept with leak wave conductor has
and Scalance W WLAN network compo- The Touch Panel PC of the assembly sta- proven its practical use in this demon-
nents. The actual position of the moving tion receives the code number of the re- stration installation. The Volkswagen AG
platform is synchronized with that of the spective workpiece from the plant PLC via is so impressed by the system that it has
fastening system and the drive is con- Profinet – Wireless LAN for every new work already ordered 80 units which are to be
trolled accordingly. step and the appropriate assembly instruc- used in the Emden factory.
In the fastening process itself several tions are displayed.
parameters are recorded by the electro- The mobile fastening system sets new
mechanical nutrunner (for example the standards in terms of ergonomics for work-
torque) and compared with the respective ers and thus ensures better productivity, More information:
nominal data from the joint database. process safety and high flexibility in as- www.profibus.com
When all joints at an assembly station have sembly line balancing. The new W-LAN www.siemens.com/profinet

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8 CASE STUDY
Process visualization

Cab painting for Volvo trucks

Optimum from the

Volvo
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.

T
he Volvo Truck Corporation is one of The driver cabs are offered in numerous
the world leaders for heavy trucks. variants – from the comfortable sleeper
The company has production and de- with a miniature office for long distance
velopment sites in Sweden, Belgium, the haulage to the simple day cab. A modular
Publicis CPZ

USA and Brazil. The trucks for the Euro- system with standardized components is
pean market are built in Gothenburg (Swe- therefore used for the cabins which can be
den) and Gent (Belgium) whereby the en- applied for many models. At present Volvo Robots developed by Dürr take over the
application of the prime paintwork with a
gines, gears and driver cabs are supplied Umeå makes three cab series with a total of 100 % repetitive accuracy
by different factories in Sweden. 11 different models.
The cabs are fully prepared for installa-
Cabin production for the whole
tion in Umeå and then transported to the extension. The most important investment
of Europe
assembly works by rail. The production in- here was a new painting plant for the prime
The Volvo factory in Umeå is Volvo’s only cludes the complete metalworking, cab paintwork of the driver cabs. Dürr Paint
production site for truck cabs in Europe. In body construction, surface treatment, Systems in Stuttgart received the general
this factory in Northern Sweden, 250 miles painting and final assembly. The whole contract for this.
away from the Polar Circle, the cabins for production in Umeå is automated to a great The new painting plant from Dürr con-
all Volvo models are built and then trans- extent with robots. sists of a cleaning system, a hand painting
ported to the assembly works in Gothen- system EcoMacc, two airbrush systems for
Higher capacity due to new
burg and Gent. The Umeå factory also sup- the interior painting with automatic door
painting line …
plies CKD (completely knocked down) as- openers, two ESTA systems for the outside
sembly kits for the cabs to factories in Asia, The annual production was to be increased painting and two dryers. The plant is con-
Africa, Australia and America. from 50,000 to 60,000 cabs with a capacity sidered one of the most modern in the

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 9
Schematic plant config-
Control room level WinCC uration of the new
archiving server painting plant at Volvo,
WinCC Clients Umeå

Router

WinCC Server

OSM OSM

Redundant TCP/IP-Ring (Fiber optic/twisted pair)

OLM

S7-400F
Profibus with Profisafe

Robot Robot
control control
WinCC WinCC
Clients Clients

Publicis CPZ
Profisafe Profisafe
ET 200S-F The Simatic WinCC system offers a
Robot Robot
comfortable overview of the current
Control level Application level painting process

world and meets the strictest environmen- into the painting control system. Accord- process as well as the process and conveyor
tal regulations regarding solvent emis- ing to the respectively identified cab the technology. The control level is equipped
sions. master Enterprise Resource Planning (ERP) with ten Simatic-400Fs with which the whole
system requests the appropriate painting painting plant is controlled. The communi-
… with distributed control technology
data and outputs them to the correspon- cation is distributed on two TCP/IP net-
Dürr suggested the Siemens AG to the Vol- ding painting controller. Volvo uses three works: one network for linking the process
vo Truck Corporation as the supplier for different paints for the prime paintwork data, another for visualization with inte-
the automation and control technology. which depend on the shade of the final coat gration in the factory network.
The Swedish auto manufacturer decided, of paint. At the control level Profibus with Profi-
after detailed evaluation, to accept Dürr’s The painting control system receives safe technology is used in which safety-ori-
suggestion and had its new painting line the current quality data such as type, color, ented functions such as light barrier, emer-
equipped with Simatic WinCC as a control process data and alarms from the control gency stop switch, door position switches
system and failsafe Simatic S7-400F con- level as a reply and passes them on to the together with the standard control func-
trollers and a distributed periphery. The ERP system so that a continuous record is tions are linked decentrally. The communi-
system concept with WinCC as a process vi- available for tracing the individual body cation with the superior ERP system takes
sualization system was designed and im- right into the ERP level. The data are also place based on TCP/IP and Web Services.
plemented in cooperation with the available locally through the archive serv- Volvo is very pleased with the user friend-
Siemens Paint Center and WinCC Compe- er for long-term analyses. liness of the new control system. The ca-
tence Center in Stuttgart. The WinCC server is designed redun- pacity, availability and productivity have
The system concept of the WinCC-SCA- dantly with two servers. This server system increased considerably in comparison with
DA system with client-server structure and is supplemented by an archive server for the old painting plant according to factory
the distributed automation architecture archiving the message data and value information. A second painting plant is be-
with homogeneous programming and da- archives as well as an engineering station ing planned for the final painting at Volvo
ta storage ultimately proved superior to with which both WinCC and all controllers Umeå. ■
the PC-based single station systems previ- and the Micromaster drives are parameter-
ously used in the paint shop sector. ized, loaded and saved. The backup and
version management is user-friendly with
Painting control technology of the
Simatic A&D Data Management ADDM.
highest standard
As operating stations 11 WinCC Clients More information:
The cabs entering the paint shop are regis- are integrated at the moment for the visu- www.siemens.com/wincc
tered via a mobile data system and logged alization and operation of the painting E-mail: micael.amandusson@siemens.com

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10 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?

Johnson Controls
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 The production data acquisition by
time and bring its control up to the latest state-of-the-art. RFID systems such as Moby E is now
also a must for suppliers

J
ohnson Controls is above all a special-
Just-in-time to VW and Opel: Production of vehicle seats at Johnson Control, Geel
ist for vehicle seats. One of the more
than 500 just-in-time production sites
of the company is Johnson Controls Auto-
motive in Geel in Belgium. Here the com-
pany 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 produc-
tion 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 Au-
tomation took over the project manage-
ment whilst Siemens Automation and Dri-
ves 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
Johnson Controls

Year. Production for the old Astra ended on

December 23 and the line was completely
dismantled. The new Opel line had to be

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 11

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

Ethernet
Simatic Simatic Simatic Simatic
S7-416 2DP S7-412 2DP Simatic S7-416 2DP S7-416 2DP
S7-313 2DP

Screwdriver
control

Frequency
converter

Screwdriver
control

OP17 OP17 ET 200eco Moby E OP17 OP17 Profibus

Frequency
Datatags converter Datatags
Moby E ET 200S ET 200eco Moby E ET 200eco ET 200eco ET 200S Moby E

Schematic plant configuration at Johnson Controls, Geel

turning out 800 units a day by January 2 al- A Simatic S7-416 2DP was installed for positioned at different points along the
ready – and that’s exactly what it did!” controlling both the Opel and the VW line, production line. They are linked by
supplemented by an S7-412 2DP for Profibus as are the frequency converters
Complete data in focus
graphic visualization of the Andon signal and the servo controllers. Electronic tags
The changeover from several independent system of the VW production line and an are used in many places.
applications to an integrated complete sys- S7-414 2DP in the test area of the Opel line. There is a growing trend in the automo-
tem was the major aim of both projects. The latter controls the automatic test tive branch to rely on the tags and process
Koen Vanharen of Johnson Controls ex- process and stores the recorded data in a lo- their information locally instead of com-
plains: “Our customers get more demand- cal SQL database the contents of which are municating the whole data flow through
ing by the day and complete tracking is be- transferred to the central process database the increasingly overloaded network.
coming more and more important. The of Johnson Controls at regular intervals. Koen Verharen stresses the flexibility of
problem was to pick up the different data One example of the importance of an ex- the whole system: “The system can be trans-
such as those on the barcodes.” Ivan Vos tensive data acquisition is the complete en- ferred easily to new customers. Every auto-
adds: “Everything starts at the database try of the data which result from packing of motive customer demands a just-in-time or
level. Here the orders of both customers the airbags which are recorded as safety- just-in-sequence delivery but since every
are registered and the information for relevant information. These can be con- seat has the same components, extensions
every single seat such as the upholstery sulted for example when an airbag fails to are not a real problem.” For Siemens the
type is saved. That is the first decisive step.” work properly because these data are kept double project at Johnson Controls in Geel
A special feature was that the automa- for up to ten years after the model is dis- was further proof that a highly flexible con-
tion system also had to include the six sup- continued. trol system which combined existing tech-
pliers working under the roof of Johnson nologies with Totally Integrated Automa-
Flexible solution with a future
Controls. Siemens suggested installing tion can be implemented with Simatic. ■
Simatic ET200 Eco modules at the suppliers Siemens implemented the communication
thus providing the basis for Totally Inte- with the different HMI Systems in the More information:
grated Automation which covers all the proven way with Ethernet. Readers for www.siemens.com/tia
processes in Geel. scanning the Moby tags on the seat are E-mail: ann.arys@siemens.com

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12 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 ex-
tended.

Computer calls service technicians

If a conveyor system comes to a halt there is
All pictures: W. Geyer

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 tech-

I
t is a room in which everything is con- Integration by specific upgrading nician directly by radio signal. This gives
stantly on the move. Body-in-whites file the technician concrete data about the fault
past end to end. They roll in on a glass- The eleven Simatic S7-400s comply with that has occurred and he arrives on site
paneled steel bridge. Over 100 feet above the inhouse standard of DaimlerChrysler well informed about the event and may al-
the production line and an impressive which also prescribes WinCC frontends ready have the necessary spare part with
140 yards long it connects the body pro- with ProAgent process diagnostics, ProTool, him. Signal lamps mounted at head height
duction with the paintshop. Up to 1,300 S7-Graph and S7-PDiag. show where the fault has occurred already
raw bodies roll in and empty body plat- The conveyor system is linked smoothly from a distance.
forms out every day here on three lines. with the following buffer store with nine
Mobile operation for greater safety
The bodies are specifically ordered and Simatic S7-400 controllers. Step 7, V5.2 was
ultimately land optimally sorted in a changed over to in the course of plant up- One of the real innovations of the new con-
two-tier buffer store. grading. All existing WinCC clients were veyor system is the apparently modest
But the new conveyor system is not replaced by Simatic Panel-PC 670 with Win- hand-held operator panel. This is simply
only a fascinating construction, it is also dows XP. connected to one of the terminals distrib-
equipped with a new control system with From the order to commissioning of the uted throughout the plant and allows op-
Simatic 400. conveyor system about 18 months were erating statuses to be displayed as well as

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 13

Existing clients FLP, New clients Redundant

upgraded bridge server
Foreman’s
office

Simatic Simatic
Panel PC 670 Panel PC 670 Factory network
Industrial Ethernet
Simatic S7-400 Simatic S7-400 DAKS Server

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 di-

rectly on site.
Bojan Skufca, the man in charge at
DaimlerChrysler in Sindelfingen for main-
tenance and repair of this conveyor sys-
tems, 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 sec-
ond person who he calls to activate the nec-
The mobile operator panel allows safe Clear and comfortable plant overview
essary functions. With the mobile operator local plant control with WinCC on a PC 670 Panel
panel, the function can be controlled ex-
actly where the situation can be assessed.”
An additional advantage is that the The starter also takes care of monitoring for every single drive element can be called
whole system does not have to shut down the motor and automatically releases a and critical operating statuses are visually
in the event of a fault but only a limited warning to the controller when a settable highlighted.
segment is blocked. This guarantees the limit value is exceeded. This allows pre- All in all the latest conveyor system at
safety of the service technicians and the ventive plant maintenance and proactive DaimlerChrysler in Sindelfingen is an ex-
plant operation is disturbed as little as plant management. ample of how greater operational reliability
possible. and maximum availability can be achieved
Everything in good view
by the use of state-of-the-art control tech-
Easier, more intelligent, better all round
The whole plant is distinguished by a ho- nology. ■
Another advantage of the new conveyor mogeneous control and visualization con-
system are the motor starters. Neither a cept. Both at the control stand and in main-
circuit needs to be switched off nor any ca- tenance and directly on site, the current
bles disconnected for servicing assign- operating status of every single conveyor
ments. Instead the starter is simply re- line can be viewed. Is it empty or is there a More information:
moved from its holder and exchanged with vehicle body on it? Is there an unexpected www.siemens.com/simatic
a few actions. standstill? Also, the current operating data E-mail: peter.gunsser@siemens.com

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14 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 Aus- machines are equipped with Sinumerik their developments primarily with Siemens
tria Powertrain GmbH in Vienna- and Simatic control technology. A Manu- components and software. Siemens was the
Aspern is specialized in drive com- facturing Execution System (MES) links the first address for us in this respect too,”
ponents for small and medium-sized production and office environments and Seidl says.
automobiles of the GM company such as therefore guarantees among
the Opel Astra. A new production line for other things that remote main-
six-speed gears went into operation in 2004 tenance and control are sup- The gear production in the Vienna-Aspern works
which is planned for an output of 300,000 ported via the Internet.
units in 2005. The production is to be “The decision for the project
boosted to 800,000 gears per year in three- was made three years ago. We
shift operation in 2006. Altogether, six- examined the distribution of
speed gears with 200 and 320 Newton- the machines of the respective
meters in about 50 variations with 15 manufacturers for the different
different transmissions are produced and controller providers, their mas-
mounted on 340 machines and systems. tery of the individual processes
Production technologies are used which and of course the price/ per-
satisfy the highest standards regarding en- formance ratio,” Dipl. Ing. (FH)
vironmental compatibility, quality, costs Erwin Seidl, Head of Electrical
and flexibility. These include for example Planning Gears at Opel Austria
dry turning and milling, laser welding or Powertrain explains.
low pressure carburizating system with The decision in favor of
high pressure gas quenching. Siemens fell after assessing the
The machine park chain of the new pro- availability, response time to
duction line is made up of 89 lathes, 37 problems and local support. In
grinders, 34 washing machines, 24 slotting addition the companies were
and 24 test machines, 18 scrapers, 14 drills, evaluated on the question of
12 measuring machines, 10 roll mills, 6 whether they were at all able to
broaching machines, 13 labeling machines provide such a large number of
and other special machines. controllers or axes in the allot-
ted time.
A top address as system supplier:
“Apart from that, the pro-
Siemens
cesses running in metalwork-
Opel Austria Powertrain planned the new ing machines are extremely
six-speed gear production with Siemens as complex. They reflect the know-
a fully integrated production plant based how of the different machine
on “Solutions for Powertrain-Transline”. All manufacturers who have made
 15

Another aspect in favor of Siemens was

the extensive wealth of experience of the Solutions for Powertrain-Transline
Siemens developers which represented an
As a single source system provider, Siemens offers the automotive industry and its suppli-
indispensable safety factor for Opel espe-
cially in the run-up phase. ers a comprehensive, homogeneous automation concept for the mechanical production
and assembly for large series. Areas of application for Transline are for example transfer
Partner for plant owners and machine
lines for the construction of engines and assembly lines for gear production. Basis for this
manufacturers
are the product series Simatic, Sinumerik, Simodrive and Profibus and Profinet as bus sys-
Opel Austria Powertrain specified a works
standard with a uniform user interface, ho- tems. The solutions include standardized hardware concepts, homogeneous user inter-
mogeneity in the automation concept, stan- faces and well-developed programming guidelines. On the basis of the Siemens standard,
dardized hardware, slim logistics and low changes can be made at any time, the user can respond easily to model and design
staff training effort. changes. Works management and Siemens experts work hand in hand during the whole
Within this scope Solutions for Power-
integration process of the modules in a working system – support accompanies all devel-
train offered machine manufacturers
enough freedom to apply their technologi- opment phases right into the operating phase, training and service included. And all this
cal know-how to the automation platforms worldwide in line with the size of the Siemens A&D Division.
Sinumerik 840D and Simatic.
The machine manufacturers were there-
fore able to concentrate on their specific der and MES systems which enable inte- sive know-how and great solution compe-
technological domains and select the sub- gration in the existing company control tence. We have only had good experience
sequent topics such as visualization and landscape. Opel’s experience with local with Siemens to date.” ■
communication from the range of system Siemens support was positive. Two
modules. This consisted of the Simodrive Siemens technicians are always present at More information:
family, the HMI systems, the open inter- the factory. Dipl.-Ing. Seidl confirms that www.siemens.com/transline
faces and the networking with superior or- “these specialists operate with very exten- E-mail: andreas.goestl@siemens.com

Test bench in assembly

All pictures: Opel AG

move up 2/2005
16 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 struc-
tures. The new machine generation is
now equipped with an automation
solution based on the PC-based
Simatic WinAC controller and is there-
fore perfectly prepared for the vertical
integration in Supply Chain Manage-
ment systems.

O
ver 35 years ago Willy Ghyselinck
developed a machine with which
tires could be mounted on differ-
ent 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 sup-
pliers among its customers. One of the suc-
cess factors – in addition to technically path-
breaking and innovative machine solutions
– is certainly the unusual sales concept
which Ghyselinck pursues consistently: the
machines are installed at the customer’s In addition to the competitive price view of the problem immediately and in-
within the scope of a leasing contract. This and the cost guarantee for the whole life tervene directly at the manufacturer site.
solution reduces investment expenses for cycle of the machine it is precisely this Any faults can therefore be eliminated
the customer and gives Ghyselinck a deci- guaranteed quality which is a decisive immediately and quickly without travel
sive competitive edge – and at the same time factor for the customer and is also en- times and expenses – advantages which
protects the company’s many patents. sured by extensive support of the ma- the company’s customers can appreciate.
Ghyselinck applies the highest stan- chines at the customer’s. Telediagnosis
Standardized and modular
dards to its solutions and makes no com- and telemaintenance have been part of
promises in quality and reliability. The the standard scope of delivery since the The automatic assembly machines are
machines achieve an availability of 100 per- year 2000. By telemaintenance the Ghy- compact and modular in design with a
cent after being run in for 3 days. selinck service engineers can get a clear high degree of standardization. Every

move up 2/2005
 17

Industrial Ethernet

Station 1 Station 2
IPC 670 IPC 670 From distributed to PC-based
WIN CC V6
Options:
- Proagent Another step was the decision in favor of
- User Archives
- Win BDE a PC-based machine control a good 12
WIN AC SLOT 416
months ago. Especially in branches with a
high logistic effort such as the automotive
PROCESS FIELD BUS PROCESS FIELD BUS

industry there is a clear tendency towards

Profibus DP Profibus DP
integrated Supply Chain Management. For
this it must be possible to exchange ma-
chine data easily and reliably with the cor-
responding 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.
Camera system Ghyselinck again relied on a solution
ET 200S ET 200S
with Siemens products because the two
companies had been cooperating success-
Automation schematic of the Ghyselinck machines with Simatic WinCC
fully 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
The new generation of wheel assembly systems from Ghyselinck is equipped with
a PC-based automation solution based on Simatic WinAC Siemens guarantees us with its products.
Therefore we can also guarantee our cus-
tomers 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 in-
terfaces as standard. Simatic WinCC V6.0 is
used as a visualization system. This solu-
tion is extremely robust, immune to faults
Ghyselinck N.V.

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
Pictures: Ghyselinck N.V.

stresses. “Our customers work with just-

in-time (JIT) systems and expect our ma-
chines 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
module – for mounting the tires, check- ery in the year 2000 was an important the whole process – and our machine con-
ing the valves and uniformity and bal- step for Ghyselinck with which the au- cept meets exactly these requirements. We
ancing and testing the wheels – fits in a tomation was also adapted to the modu- are therefore a proactive components in
standard container and can work totally lar concept. Since the introduction of our customers’ communication chain.” ■
independently in the assembly works and Profibus DP and the distributed periph-
can be loaded with any tires and rims by eral systems Simatic ET 200S there have
an operator for example. The modules not only been savings in time, space,
can also be combined easily in complete wiring and complexity – the system also
automatic assembly lines depending on guarantees a higher availability of the More information:
the customer’s requirements. The change- whole assembly line through simplicity www.siemens.com/wincc
over to distributed systems in the periph- and stability. E-mail: geert.de_coninck@siemens.com

move up 2/2005
18 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.

Fa. Loch GmbH

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 Safety-

Integrated 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 CE-

based Simatic Multi Panels as a close-to-the-machine

HMI system for a leading German automobile

manufacturer.
Kührer

move up 2/2005
 19

With the new, mobile HMI device Simatic MP 170, a well-

known manufacturer of deburring machines, Rausch

GmbH & Co. KG (Haan, Germany), uses just one single,

hand-held device instead of many distributed operating

stations.

W. Geyer
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.

Opel AG

move up 2/2005
20 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 Central diagnosis decisive In addition the graphic editor offers nu-
the Citroën C3, Citroën C3 Pluriel merous possibilities for visual design of the
and Citroën Xsara models at their The most important feature in the automa- production processes. Up to 20,000 tags
Villaverde factory in Madrid. For the pro- tion concept of the new body shop for the can be processed.
duction of the new small automobile series Citroën C3, however, is the use of the S7- Finally all the alarms and the appropri-
C3 and the multifunctional Citroën C3 Pdiag diagnostic software for the diagnos- ate data can easily be updated automati-
Pluriel a new body-in-white production line tic management of all production stations cally thanks to the integrated software in
was installed for which Siemens supplied in the central control under WinCC. In ad- WinCC ProAgent. The operator can have the
the automation and control technology. For dition, ProAgent is used on the OP27 Oper- respective program segment of the PLC
the automation, PSA Peugeot Citroën chose ator panels for local fault diagnosis on the that triggered the alarm displayed or the
Totally Integrated Automation with Simatic individual cells. appropriate S7 graph step sequence visu-
S7-400 controllers, Simatic OP27 Operator Simatic WinCC in connection with Pro- alized in WinCC.
Panels, Profibus DP as a field bus system Agent was chosen as an ideal HMI system The Head of Maintenance on the new
and the distributed peripheral equipment for management and collection of all production line Francisco Javier Tejedor ex-
Simatic ET 200. Simatic WinCC was in- alarms from the production cells because it plains: “We decided to use the WinCC soft-
stalled as a master plant monitoring and could be easily integrated in the plant’s ware because the diagnostic functions of
control system. automation structure. the plants were to be centrally grouped and

move up 2/2005
 21

the system had already been successfully system (WinCC and ProAgent). This consid- tion with the production software, the sta-
tested in other factories of the PSA Peugeot erably simplifies the handling and pro- tus of robots or welding sequences can be
Citroën Group. The ProAgent solution is gramming becomes almost totally obsolete. checked.
used because it is the best link between the The operator of the WinCC process visu- All 40 Simatic S7-400 controllers in the
PLC diagnostics controlled by PDiag and alization system has the whole area moni- plant are connected to the HMI systems via
the WinCC control system.” tored on one screen and can concentrate of Industrial Ethernet. Because of the harsh
the diagnosis when a fault occurs. With a conditions to which this network is ex-
Total communication
few mouseclicks he can switch from the posed, Simatic Industrial Ethernet compo-
The biggest advantage of the integrated au- view of the complete line to a single cell nents have been used. To ensure the de-
tomation concept in the new body-in-white and even check the state of a sensor. manded high availability and reliability of
production is the communication between In addition to the process views, the the equipment in the rugged production
the programming software of the PLC (Step WinCC systems also has masks for the data environment, Simatic Panels PC 670 have
7 and PDiag) and the process visualization management on which the communica- been installed on the machines themselves
in all areas to be monitored. A server col-
lects all the data from the different areas.
Status diagrams can be called up in These PCs contain the programming soft-
various degrees of detail on every ware of the Simatic PLCs and the HMI de-
operator panel vices. Changes to the devices can be en-
tered directly online.

Exact error localization

Thanks to the alarm management by Pro-
Agent and the display functions of WinCC
which can be extended by “Graphic De-
signer” the system pinpoints the exact lo-
cation of the error in the event of a fault
regardless of whether it is process or hard-
Schematic plant ware related and offers help texts for local-
configuration of the new ization and elimination.
body shop (section)
Using the integrated WinCC alarm sys-
Citroen

tem in connection with ProAgent, the sys-

tem informs the operator about the differ-
PSA Group

ent process errors and creates an alarm

archive which can be printed or exported to
Server Simatic a file. Then the response time of the oper-
+ IL 40 PC 670 ating personnel in the event of fault will be
shortened and downtimes on the produc-
tion line minimized as a result. The large
Industrial Ethernet (optical) capacity of the message acquisition of the
OSM 6/2 TP OSM 6/2 TP OSM 6/2 TP WinCC is extremely important for this task.
This function also makes preventive
maintenance work on the production line
easier. Diagnostic data can be exported
Simatic S7-300 simply and therefore enable easy monitor-
Simatic S7-400 ing of the downtimes and error times.
The Spanish version of WinCC 5.1 was
installed under the Windows 2000 operat-
ing system. In this way both the visualiza-
tion system and the programming software
are embedded in the Spanish language en-
vironment. This makes possible extensions
Simatic S7-400
easier for the owner to handle and mini-
mizes training expenses. ■

More information:
www.siemens.com/wincc
E-mail: diego.garcia@siemens.com

move up 2/2005
22 CASE STUDY
Vehicle testing systems

Siemens develops chassis adjustment benches for BMW

Assembly of the
BMW Roadster Z4 in
RAMA For Even More Spartanburg, USA

“Pleasure of Driving”
Highly modern chassis measurements are essential to BMW for assuring their
familiar sporty driving properties. Siemens supplies these systems for the

BMW
adjustment which BMW uses in series production and new development in
almost all its factories.

T
alk of “RAMA” at BMW rarely has any- ment system which measures the contour ored stripe projection and enables a much
thing to do with that common Ger- of the tire and computes the position of the greater measuring accuracy. In addition, a
man margarine brand of the same wheel in space. measuring disc fixed directly to the wheel
name but usually with a chassis adjust- The automobile specialists at Siemens and printed with a special black and white
ment system, the “Reference Axis Geome- A&D PT 3 developed a system in which a code can determine the exact wheel posi-
try Measuring System”. This system takes Simatic S7-414-3 is responsible for con- tion so that even a minimum drift can be
over the chassis tuning and adjustment trolling the servo drives, sensors, actuators detected and the measuring result cor-
and contributes considerably to optimum and operator buttons among other things. rected accordingly.
driving properties. Still the adjustment A Windows XP measuring computer han- The test benches with the standard func-
process for a vehicle rolling off the assem- dles the test process logic, processing and tional scope for production in the Munich,
bly line has to be completed in about three displaying of measured values. This also Leipzig and South African plants have
minutes. In this time the vehicle is com- provides the interface to the IT systems of already been delivered as have the test
pletely adjusted and the individual wheels BMW and handles the transfer of result benches with extended functions for the
are measured and adjusted accurately to a data in XML format for example. Munich, Leipzig, Regensburg, Dingolfing
few angle minutes. and South African plants as well as for the
Company-wide application
BMW Development Center. The new chassis
High end test systems from Siemens
In addition to their use in series produc- adjustment benches are also planned for
Siemens received an order from BMW to tion, BMW will be installing an additional the production of the Z4 and X5 in Spar-
replace the existing chassis test benches in chassis adjustment bench for the Analysis tanburg, USA, and for the production of the
their factories in Munich and South Africa department in all its plants as well as in Mini in Oxford. ■
with state-of-the-art technology and to vehicle development on which more
equip the Leipzig factory with new chassis extensive measurements can be made on
adjustment benches. the chassis. A&D PT 3 has developed a new More information:
The heart of these chassis adjustment kind of measurement system for this www.siemens.com/testsystems-automotive
benches is a non-contact laser measure- which is based on a two-dimensional col- E-mail: andreas.luczak@siemens.com

move up 2/2005
DIALOGUE 23

move up
infos 2/2005
Publisher
Siemens Aktiengesellschaft,
Further information about our concepts, solutions and systems in Bereich Automation and Drives (A&D),
Gleiwitzer Str. 555, 90475 Nuremberg, Germany
the automotive industry can be found at our Automotive internet
www.siemens.com/automation
portal. There you will also find your personal Siemens contact
Group Executive Management
www.siemens.com/automotive Helmut Gierse, Anton S. Huber, Alfred Ötsch

Editorial Responsibility in Accordance

If you want to know more about Siemens automation and drives with the German Press Law
Peter Miodek
technology, log on to our online information hub in the internet:
Responsible for Technical Contents

www.siemens.com/automation/newscenter Thomas Schott

In-house editorial staff:
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kathrin.braemer@siemens.com
Jürgen Nolde
juergen.nolde@siemens.com

Concept
Christian Leifels

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ISSN 1610-7802 (Print)

© 2005 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 registered
trademarks of Siemens AG:

support
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
Folder: Wireless LAN With Leak Wave they are not protected.
The information provided in this magazine
Conductor RCoax-Cable 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
With Scalance W from Simatic Net access points and clients are development of the products. An obligation to
available which, with a large number of features, enable radio net- provide the respective characteristics shall only
exist if expressly agreed in the terms of
works to be set up under harsh basic industrial conditions. Innova- contract.
tive processes such as rapid roaming and the leak wave conductor IWI: TMOV
Order No.: E20001-M4205-B100-X-7600
RCoax-Cable offer new potential to increase the reliability and effi-
ciency 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 E20001-
A2909-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 in-
formation everywhere for true operational excellence. You’ll get there with
PROFINET. Based on Industrial Ethernet, PROFINET is open and the most com-
prehensive networking solution for all applications. PROFINET is the most ad-
vanced 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