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AGG line Sebes
The AGG (Differential Gear System) line, which commenced production in 2022, was designed not only to manufacture spare parts for previous versions but also to meet the high demand for the product. Despite utilizing a compact Siemens 1500 PLC, the system’s complexity was notably high. It incorporated various third-party devices, including SCL-laser cleaning, Kistler-presses, Trumpf-welding system, Komeg-measuring system, Vogt-ultrasonic measurement, and Trumpf-marking system.
Ensuring flawless coordination between two robots and three PLCs within a secure work cell demanded meticulous attention to detail. The Kuka robots played a vital role in facilitating the transfer system by accurately picking up and placing the parts for processing.
To achieve comprehensive data traceability, we implemented a system where process data was transmitted after each step, enabling us to track the progress. Additionally, virtual identifiers were utilized to associate with the traveling parts, further enhancing the traceability process.
PB400 Jawor
Undertaking our first high voltage battery construction project posed significant challenges. As a prerequisite for working with high voltage, we obtained the HV-K2 qualification. The construction of the production line revolved around utilizing the S7-1500 PLC by Siemens, incorporating approximately 50 processing stations.
High quality of the product was achieved using leakage tests with helium and air pressure, also camera systems ware integrated as NeuroCheck and Baumer.
Due to safety concerns, meticulous data traceability was imperative, which we achieved through the implementation of the Daimler Zellsystem and storing quality data in PLA.
PB340 Brühl
Although we had prior experience with battery lines, we needed to reobtain the HV-K2 qualification and additionally the EFK-HV certification. The brains behind the production line ware Siemens’ S7-1500 PLC, integrating approximately 70 processing stations. To meet the required cycle time, some of these stations were duplicated.
We ensured the high quality of our products through helium and air pressure leakage tests, alongside the integration of camera systems such as NeuroCheck and Baumer.
Leveraging our previous experience with the Daimler Zellsystem made the process less challenging. However, certain modifications and adjustments were necessary to ensure accurate message transmission and quality data.
8-FDCT Sebes
In 2019, production began on the 8-FDCT project, an innovative eight-speed dual-clutch automatic gearbox. Advanced production lines were constructed, incorporating over 200 controllers, including Siemens 315/317 and ET200SP.
Precise operations were ensured through the use of Kistler sensors and Bosch-Rexroth Nutrunners in the pressing units. Kuka robots and Sinamics Axis motion control systems were integrated for efficient manufacturing. IFM and MV400 camera systems played a crucial role in quality control.
To meet the deadlines, more than 20 programmers were onsite, and coordinating such a large team presented challenges. However, effective teamwork and organization ultimately helped us meet the deadlines.
EHS NAG 3 Sebes
Star Assembly SRL is a subsidiary of Daimler AG company, responsible for managing the EHS line in Romania, which is a simplified version of the line in Germany with more manual workstations. Our team of five colleagues, under my coordination, was tasked with managing workload, accomplishing different tasks from the OPL, and teaching Bosch software to the team members.
In June, we continued working on the EHS line in Sebes, and with the upgrade to the latest software version, Indraworks 13V14, the German software team left at the end of July. Our team was left with two colleagues, and we had to take care of software modifications, improvements, and corrections on 70 stations. Additionally, I represented IWM Automation locally in the Star Assembly factory during the project.
EHS-NAG 3
The EHS, ElectroHydraulic Actuator, is an integral part of NAG 3, the New Automatic Gearbox 3, which our company worked on using Indraworks 13V08. Our team acquired the necessary knowledge to establish communication between a PLC and various devices using ProfiBus and Ethernet. We were required to modify parts of the PLC program and create the entire chain sequence with actions and transitions for some stations from scratch. Additionally, we updated the HMI after the PLC changes.
During the project, our team made changes and improvements on the FDCT Hedelfingen during weekends. After relocating in April, we worked together with all the programmers to update the Daimler template and the software to 13V10, making necessary modifications to prepare the line for production tests.
Our team faced the challenge of teaching, delegating workload, and coordinating with two new colleagues who had no experience in Indraworks. Despite the challenge, our team successfully completed the project with precision and efficiency.
7-FDCT
Star Transmission Sebes is Daimler AG company. The project started at IWM Automation GmbH in Porta Westfalica Germany.
We worked with Indraworks 11V08 and made changes to the PLC program: changed the sequence of the process, movements, operation modes, communications with other devices. Also we did HMI modifications: new buttons, messages, images, added new language.
After the pre-acceptance the line was relocated to Sebes. After the line was installed we did some minor HMI and PLC modifications to prepare the stations for ramp-up.
After the start of production also the prime minister at the time visited the factory.