Date: 2023 to 2024
Contracting entity: DS AUTOMOTION GmbH – Linz /Austria
End customer/site of installation: BMW Spartanburg

Project description:

• Planning (hardware construction, software project planning)
• Control cabinet construction
• Supply of new subdistribution boards and human interfaces
• Assembly and installation
• Software and commissioning
• Disassembly of the existing system

In the course of an expansion of the final assembly, the existing plant must be moved and expanded. The AGVS will be moved in several steps and expanded according to construction progress. In addition, the general contractor also delivers other vehicles that we provide. Due to the increased power requirements, new cabinets need to be built and installed. New panels are used for the visualization. The software has to be changed and put into operation depending on the step and track. Our scope includes the complete disassembly and reassembly of electrical components.

Technologies (excerpt):

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

Date: 2022 to 2023
Contracting entity: MBN
End customer/site of installation: BMW Spartanburg

Project description:

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

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

Technologies (excerpt):

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

Date: 2020 to 2023
Contracting entity: DS AUTOMOTION GmbH – Linz /Austria
End customer/site of installation: BMW Dingolfing (W2.20)

Project description:

• Entire electric planning (hardware construction, software project planning)
• Control cabinet construction
• Provision of control technology
• Assembly and installation
• System commissioning

Technologies (excerpt):

• 1 piece S7-1500 with CPU 1518F – PN/ DP
• 2 pieces OC visualization with WinCC TIA V14 on Staudinger 0C-9-22-677D-V04/ EKS
• 2 pieces OP visualization with WinCC TIA on Staudinger OP-9-22-477E-V04/ EKS
• 8 pieces access points for Wi-Fi coverage (communication with vehicles)
• 5 pieces Loop 1 vehicles for the transport and assembly of the high-voltage storage systems (HVS)
• 19 pieces Loop 2 vehicles (exclusively manual workstations) with lifting and swiveling unit for the transport and assembly of the high-voltage storage units

Process description:

The central control system developed by Kocher for the automated guided vehicle system (AGVS) carries out not only the data management with the hall master control system of the end customer (from order data preview to error messages), but also all process-relevant orders of the vehicles through the robot cells and manual processing stations.

The master controller with its own Wi-Fi communication is the heart of the entire plant workflow.

It controls and monitors the process from the transmission of order data (marriage) throughout the production line at all station controls.

The production line is designed for the output of 30 HVS per hour and is divided into two areas.

Loop 1 with 65 vehicles and a mix of manual and automatic stations.

Loop 2 with 19 vehicles and manual stations only. These vehicles are equipped with a lifting and swiveling unit, which, after preselection for each station, enables targeted alignment and an ergonomic working position.

In a transfer station, the workpiece carriers with the partial body of the HVS are transferred alternately/step by step between Loop 1/2. The order data is transferred from the source vehicle to the new target vehicle in each case, so that communication between the vehicles and the stations is ensured for a reliable process. 

A visualization interface allows, for example, input for the adjustment of parameters, HVS ident numbers, process dial-in/dial-out. All processes, positions of the vehicles and the on-board swivel devices, interface overviews to station and vehicle controls, and error messages are displayed.

In addition to the standard process sequences, emergency strategy concepts are implemented according to customer requirements.

Date: 2023 to 2024
Contracting entity: DS AUTOMOTION GmbH – Linz /Austria
End customer/site of installation: BMW Dingolfing (W2.20)

Project description:

• Entire electric planning (hardware construction, software project planning)
• Control cabinet construction
• Provision of control technology
• Assembly and installation
• Virtual commissioning, physical system start-up

Technologies (excerpt):

• 1 piece S7-1500 with CPU 1518F – PN/ DP
• 1 piece OC visualization with WinCC Unified on Beckhoff CP3224-2003-0020
• 2 pieces OP visualization with WinCC Unified on Beckhoff CP3224-2001-0020
• 3 pieces access points for Wi-Fi coverage (communication with vehicles)
• 45 pieces vehicles with swiveling unit and workpiece carrier for the transport and assembly of the high-voltage storage systems (HVS)

Process description:

The central control system developed by Kocher for the automated guided vehicle system (AVGS) carries out not only the data management with the hall control system of the end customer (order data preview to error messages), but also all process-relevant orders of the vehicles through the robot cells and manual processing stations.

The master controller with its own Wi-Fi communication is the heart of the entire plant workflow. It controls and monitors the process from the transmission of order data (marriage) throughout the production line at all station controls.

A visualization interface allows, for example, input for the adjustment of parameters, HVS ident numbers, process selection/deselection. All processes, positions of the vehicles and the on-board swivel devices, interface overviews to station and vehicle controls, and error messages are displayed.

In addition to the standard process sequences, emergency strategy concepts are implemented according to customer requirements.