Siemens Automation Concepts for Paint Shop

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Siemens Automation Concepts

for Paint Shop

Siemens Industry

Competence Center Automotive

V1.2

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 3 18.02.2010

Siemens offers a integrated solution portfolio for paint shops

Press Shop Body Shop Paint Shop Powertrain Assembly

Key challenges:

Non-stop production (6x24h)

Slow and time-intensive

processing

Harsh production environment

(heat, fouling etc.)

High energy consumption

Highest requirements on availability and energy efficiency

Logistics Logistics Logistics Logistics

Automotive

process

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 4 18.02.2010

Process steps and core challenges

Core challenges

in paint shop

Pretreatment E-coating PrimerBase &

Clear Coat

Multi-stage

degreasing and

rinsing

Zinc phosphating,

multiple rinsing with

VE water

Repassivation

process

E-coating

Heating & Cooling

Quality check

Quality check

Sanding

Cleaning (by washing

machine, robot, EMU

system)

Coat Provision

Primer

Heating & Cooling

Sanding

Cleaning

Base coat

Clear coat

Heating & Cooling

Quality check

Underbody Protectionand Sealing

Underbody protection

Seam sealing

Material supply (PVC)

Quality check

Special transportation process of the car body:

Rotations by painting and underbody protection application

Special requirements on Machine Safety:

Fast movements of robots in operation

Clear identification of the car body: Process control depends from car body /skid type

Energy efficient components:High Energy consumption at drying and cooling processes

Innovative visualization concept:

Need for higher flexibility and cost reductions in HMI installation

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 5 18.02.2010


Technological

answers


Clear Coat

Multi-stage

degreasing and

rinsing

Zinc phosphating,


VE water

Repassivation

process

E-coating

Heating & Cooling

Quality check

Quality check

Sanding


machine, robot, EMU

system)

Coat Provision

Primer

Heating & Cooling

Sanding

Cleaning

Base coat

Clear coat

Heating & Cooling

Quality check



Seam sealing


Quality check



I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 6 18.02.2010

Optimized communication at E-Coating with wireless technology

Leaky feeder signal transmission

Access

Point

Control box

PLC

Dip basin

E-coating

Rotating car body carrier in dirty environment

Abrasion of the sliding contact surface soils the coat

Chemical vapors cause chemical reactions at the sliding surfaces

Use of contact-free and environment independent wireless

technology for data und energy (up to 1,5kW)

Technological

answers

Client

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 7 18.02.2010

Wired vs. wireless communication solution in paint shop (E-coating, 200m, 20 skids)

WiredInitial Investment Wireless

Client (23 pieces) and communication infrastructure

(Access points, power supply, switches etc.) 24.600 €

Lifecycle cost

Total 39.800 €33.800 €

Total -16.500 €/year

Power rail booster (24 pieces) 17.800 €

Installation costs 40.000 €40.000 €Slip ring (200m) and communication infrastructure 4.000 €

RCOAX infrastructure

(RCOAX cable, connectors, antenna cable, …)3.200 €

-

-

-

-

Installation costs 40.000 €40.000 €Material (power rail booster, …) 1.500 €/year

Maintenance (2 FTEs for 1 day/month) 15.000 €/year

-

-

Installation and commissioning 12.000 € 12.000 €

Technological

answers

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 8 18.02.2010

ROI of wireless solution after 1,5 years

Euro

Break evenCumulated cost savings of wireless

vs. wired solution

ROI calculation of wired vs. wireless communication solution

Discount rate: 20%

Life

cycle

ROI of wireless solution after 1,5 years

Technological

answers

-6.000

7.750

19.208

28.757

36.71443.345

48.87153.476

57.313

60.511

-20.000

0

20.000

40.000

60.000

80.000

100.000

1 2 3 4 5 6 7 8 9 10

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 9 18.02.2010

Optimized communication at underbody protection with wireless technology

Floor conveying technology incl. rotation of the car body simplifies the drop-free

application of underbody protection

Floor conveying technology easier to implement than overhead monorail conveyor

Wireless technology creates user-friendly work environments

Control Unit

PLC PLC

Underbody Protection

and Sealing

PLC

HMI

Access

Point

Technological

answers

HMI HMI

Access

Point

Access

Point

Client Client Client

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 10 18.02.2010

Wireless network configuration with Siemens SCALANCE W

PLC

PROFIBUS

Wireless communication between all kinds of automation

components in different applications

Distributed I/O

IWLAN

Link

…Up to 8 devices

Dual

Access

Point

I/O

Client

RCoax RCoax

Wireless

Mobile Panel

PLC PLC

PC/PG

Client

Access

Point

Rapid Roaming

HMI

Technological

answersPROFINET

Triple

Access

Point

Access

Point

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 11 18.02.2010

Increased flexibility with Siemens wireless technology

Reliable and stable wireless communication Deterministic data exchange in real-time

Redundant wireless networks

Rapid roaming for fast handover of mobile devices

Robust Hardware

Metal enclosure with high degree of protection IP65

Protection against vibration and shock

Extended temperature range (-40°C to +70°C)

Secure access and data transfer

Access control (authentication)

Data encryption

Fast commissioning and reduced maintenance cost

Radio field Planning, Simulation, Engineering, Commissioning, Maintenance & Service

Integrated PROFINET IO diagnostics

Support of PROFIsafe applications

Substitution of dragging leaders and dragging cables

Maintenance free data communication

Client Modules

Antennas

Configuration/Simulation

Access Points

Technological

answers

Reliable

Wireless

Technology

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 12 18.02.2010


Technological

answers


Clear Coat

Multi-stage

degreasing and

rinsing

Zinc phosphating,


VE water

Repassivation

process

E-coating

Heating & Cooling

Quality check

Quality check

Sanding


machine, robot, EMU

system)

Coat Provision

Primer

Heating & Cooling

Sanding

Cleaning

Base coat

Clear coat

Heating & Cooling

Quality check



Seam sealing


Quality check





I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 13 18.02.2010

Safety technology in paint shops

Base &

Clear Coat

One system for standard and safety results into cost savings

Technological

answers

Personnel protection in area of moving robots during painting

Safety Technology integrated into the automation technology

Securing access to robots for maintenance and cleaning

Safety Technology for definition of secure areas in paint cells

Robot

1

Robot

2

Robot

3

End position

End position

Muting

sensors

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 14 18.02.2010

Siemens offers a comprehensive SAFETY portfolio

Use of Safety PLC and Safety Network

Emergency stop

Safety bus

Standard PLC

StandardI/O

PROFIBUS

Fail-safePLC

Safety relays in separate cabinet

Approx. 20 control relays

Approx. 15 safety relays

Approx. 50 multi-conductor cables,

connectors and plugs

Inter panel wiring

Big cabinets

No safety relays and complex circuits

Less hard wired devices

No inter-panel wiring

Smaller cabinets

Reduction of:

Wired logics

Cabinet size

Time & costs for wiring

Emergency stop

Emergency stop

Fail-safeI/O

Fail-safeI/O

Fail-safeI/O

Emergency stop

Emergency stop

StandardI/O

Standard PLC

Emerg. stop

Safetyrelays

Fail-safeI/O

additional network

additional PLC+Software+Engineering

additional Periphery

Use of Safety PLC and Safety NetworkSafety relays in separate cabinet

Technological

answers

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 15 18.02.2010

Initial Investment Reduction up to 20% by implementing Distributed Safety from Siemens

Use of Safety PLC and Safety Network

Standard & Fail-safe I/O

Fail-safeSIMATIC

PROFINET with PROFIsafe

Standard and SAFETY in one System

Reduction of:

Hardware

Space

Engineering

effort

Components

variety

Programming

Tools

Approx. 20 control relays

Approx. 15 safety relays

Approx. 50 multi-conductor cables,

connectors and plugs

Inter panel wiring

Big cabinets

Elimination of one cabinet incl.

modules

Standard & safety data on one cable

Standard & safety data in one station

Standard & safety program in one PLC

Engineering with one software tool

Less investment average 20%

Emergency stop

Emergency stop

Emergency stop

Emergency stop

Emergency stop

StandardI/O

Standard PLC

Emerg. stop

Safetyrelays

Fail-safeI/O

Technological

answers

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 16 18.02.2010

Investment savings by using PROFIsafe in a typical paint shop robot cell (3 robots) : ~ 20%

Investment w/o

PROFIsafe

Investment w/

PROFIsafe

Reduction of cabinets through elimination of

hardware (cabinet space + control & safety relays)14.000 € 10.000 €

Additional safety modules in distributed operator

panel1.800 € 3.500 €

Reduction of wiring material

(cables, connectors, plugs)3.700 € 2.700 €

Reduction of installation and commissioning costs 12.000 €

(15 days)

9.600 €

(12 days)

Total 31.500 € 25.800 €

Maintenance cost to be neglected

Technological

answers

Investment savings with PROFIsafe: ~ 20 %

Initial Investment

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 17 18.02.2010

Levers for Reduction of Life cycle costsby implementing Distributed Safety from Siemens

Shorter planning and implementation phase

Standardized cabinet design by applying software instead of hard-wired relays

Use of one common engineering and programming tool for standard & safety program

Cost saving by material and warehousing

Less component variety leads to lessspare parts inventory

Increased flexibility in production line

Thanks to program alterations and system add-ons (hard- and software)

Reduced service and maintenance

Fully integrated and system diagnosis

Continuous and consistent operation

Technological

answers

Emergency stop

Fail-safeSIMATIC PLC

Emergency stop

Emergency stop

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 18 18.02.2010

Conventional Safety vs. Safety IntegratedImplementation steps

Conventional Safety Safety Integrated

Modification of the safety logic

within the electrical layoutInstallation of safety I/O modules

Installation of standard input modules

for feedback signals

Modification of the standard

and safety PLC program

Wiring of the safety relays

and feedback signalsCommissioning

Modification of the

standard PLC program

Commissioning

1

Time saving through less

implementation steps

2

3

4

5

1

2

3

Standard & Fail-safeI/O

Fail-safeSIMATIC

PROFINET with PROFIsafe

Emergency stop

Emergency stop

Emergency stop

Faster from design to operation with integrated safety technology

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 19 18.02.2010

Conventional Safety Relays vs. Safety Integrated with PROFIsafe

Before: with safety relays

After: with Safety Integrated

Technological

answers

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 20 18.02.2010


Technological

answers


Clear Coat

Multi-stage

degreasing and

rinsing

Zinc phosphating,


VE water

Repassivation

process

E-coating

Heating & Cooling

Quality check

Quality check

Sanding


machine, robot, EMU

system)

Coat Provision

Primer

Heating & Cooling

Sanding

Cleaning

Base coat

Clear coat

Heating & Cooling

Quality check



Seam sealing


Quality check







I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 21 18.02.2010

Cost reduction and more flexibility through wireless mobile HMI panel in interim storages

Primer Base Coat

50mPC 477

Thin Client Thin Client

Thin Client

Visualization with conventional mounted HMI panels

Visualization with wireless mobile HMI panels

Primer Base Coat

Technological

answers

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 22 18.02.2010

Mobile Panel 277 wireless with integrated Safety

Features: IP65 housing, max. drop height of 1,2m

7,5” TFT Touch screen, 640 x 480, 64K colours

18 membrane keys with LED

Emergency stop

Key-operated switch

2 x illuminated push buttons

Handweel

Externally accessible USB connection

Configuration with WINCC Flexible 2007

Failsafe Operating and monitoring TÜV / BGIA certified according to SIL 3

HMI authorization for individual operators or places / spots

Identification and distance measurement by transponder technology

Safety function (acknowledge button, emergency-stop) via PROFISAFE

Safety-related operating elements (acknowledge button, emergency-stop)

Increased availability Flexible changing of batteries for continuous operation without interruption

Support of Sm@rt Access und Sm@rt service for flexible plant concepts

SD-/Multi Media Card Combi Slot for fast data transmission

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 23 18.02.2010

Investment savings by using wireless mobile HMI panel: ~ 54%

Technological

answers

Initial Investment

1x PC 477 incl. housing 3.000 €

Total 9.715 €4.475 €

1x Switch X108 (8 port) 340 €

-

-

Mounted HMI panelsWireless mobile

HMI panel

1x wireless mobile HMI 277 IWLAN

1 x access points W788/1Pro

3.300 €

950 €

Cabling for access point (50 m)

1 Switch X005 (5 port)

-

-

3 x Thin Client incl. housing 6.000 €-

Cabling (250 m) 375 €-

75 €

150 €

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 24 18.02.2010


Technological

answers


Clear Coat

Multi-stage

degreasing and

rinsing

Zinc phosphating,


VE water

Repassivation

process

E-coating

Heating & Cooling

Quality check

Quality check

Sanding


machine, robot, EMU

system)

Coat Provision

Primer

Heating & Cooling

Sanding

Cleaning

Base coat

Clear coat

Heating & Cooling

Quality check



Seam sealing


Quality check




Fast movements by robots in operation

Clear identification of the car body:

Process control depends from car body /skid type



I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 25 18.02.2010

Optimized communication at E-Coating

Identification of body type, color etc. for optimized planning and dispatching of orders

Rough environmental conditions (high temperatures, acid, fouling etc.) requires special

product features

Pretreatment

RFID

Interface Interface

PLC

Data storage on mobile data carriers

Heat resistant and dirt resistant data carrier, mounted on car body or on skid

Technological

answers

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 26 18.02.2010

Siemens offers a comprehensive RFID portfolio for paint shops

Comprehensive portfolio for individual

applications and environments:

Heat resistance up to 220°C

Data storage up to 32 Kbyte

Extended write/read distance - up to 0,2m for skid identification

- up to 3m for body identification

For hazardous location use (ATEX)

Protection up to IP68

Highest reliability Fast and high reliable identification (100%)

Reduction of engineering and maintenance costs Fully integrated in SIMATIC portfolio

Standard programming interface

Highest flexibility and scalability Combination of RFID with I/O modules

in distributed periphery systems e.g. ET200pro with up to 6 RFID modules

Easy connectable to PROFBUS and PROFINET

Reader/Communication Interfaces

Moby MDS D139 Moby MDS U589

RF 380T

Moby MDS SLG D 12 S

Technological

answers

High temperature Transponder

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Core challenges

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Technological

answers

Automation

concept

References

Page 27 18.02.2010


Technological

answers


Clear Coat

Multi-stage

degreasing and

rinsing

Zinc phosphating,


VE water

Repassivation

process

E-coating

Heating & Cooling

Quality check

Quality check

Sanding

Cleaning (by

washing machine,

robot, EMU system)

Coat Provision

Primer

Heating & Cooling



Sanding

Cleaning

Base coat

Clear coat

Heating & Cooling

Quality check



Underbody

Protection

& Sealing


Seam sealing


Quality check

Clear identification of the car body:

Process control depends from car body /skid type

Energy efficient components:

High Energy consumption at drying and cooling processes



I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 28 18.02.2010

Paint shop with highest energy consumption in automotive production process

Press Shop Body Shop Paint Shop Powertrain Assembly

Metal forming:

2-9%

20-80 kWh/car

Welding:

9-11%

80-95 kWh/car

Paint systems:

27-50%

230-320 kWh/car

HVAC:

11-20%

95-170 kWh/car

Lighting:

15-16%

130-140 kWh/car

Compressed air:

9-14%

80-120 kWh/car

Materials handling:

7-8%

60-70 kWh/car

Miscellaneous:

4-5%

35-45 kWh/car

Electricity

ConsumptionTotal:

730-1040 kWh/car

* Source: Ernest Orlando Lawrence Berkeley National Laboratory (2003): “Energy Efficiency Improvement and Cost Saving

Opportunities for the Vehicle Assembly Industry”

Production

processTechnological

answers

Due to highest energy consumption in the paint shop

energy efficient components are needed

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 29 18.02.2010

Example paint shop:Drives for ventilation/exhaust cause high energy consumption

High energy consumption due to:

High need of ventilation and exhaust air in primer

and top coat sub-processes

Slow and time intensive processing require

constant production and energy supply

E-coat oven

Energy efficient

drives

technologies

Technological

answers

http://images.google.de/imgres?imgurl=http://www.gangolf.de/produkte/bilder/grossraum/ventilator2.jpg&imgrefurl=http://www.gangolf.de/landtechnik/angebote.php&h=200&w=200&sz=12&hl=de&start=20&tbnid=SBSpQLoyEvhInM:&tbnh=104&tbnw=104&prev=/images%3Fq%3Dventilator%26gbv%3D2%26hl%3Dde


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Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 30 18.02.2010

Example paint shop:

Reduced energy consumption through innovative drives

Energy efficient

drives

technologies

Energy-efficient motors from Siemens

with high efficiency (EFF1 class) due to compact

design with up to 40% less power loss compared

to standard motors

SINAMICS frequency converters

Frequency converters capable of energy recovery

with innovative infeed technology where the

braking energy is fed back into the line supply

50

0

Life

cyc

le c

ost

s [%

]

100

0.9

96.8

2.3

0.2

98.7

1.1

0.1

99.0

0.9

12 2015

Purchase price

Installation andmaintenance costs

Energy costs

Motor lifetime in years

1.50 11015 Rated power [kW]

85

70

95

90

75

80

1 10010 PN /kW

highly efficienct motor (EFF1)s

Improved efficency motors (EFF2)

Division into 3 efficiencyclasses acc. to agreementbetween EU and CEMEP

%

N

hstandard motors

Technological

answers

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Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

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References

Page 31 18.02.2010

Example paint shop:Reduced energy consumption through innovative drives

Plant capacity: max 300.000 cars/year

Plant uptime: 6 x 24 h / 310 days per year

Plant life cycle: 10 years

Motor utilization: 100 %

Energy costs: 0,09 €/kwh

Assumptions

Motors

used for

ventilation

and exhaust air

Motor type (in KW) Amount15 20

18,5 4

22 2

30 (4-pole) 2

30 (6-pole) 7

37 3

45 (4-pole) 3

45 (6-pole) 1

55 22

75 1

90 4

110 8

132 (4-pole) 4

132 (6-pole) 15

160 7

Energy efficient

drives

technologies

Technological

answers

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Core challenges

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Technological

answers

Automation

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References

Page 32 18.02.2010

Example paint shop:Application of energy efficient motors reduces energy costs

ROI of solution with energy efficient drives after 1,5 years

Total cumulated energy cost savings after 10 years: 0’4 €

Energy efficient drives

(EFF1*) Initial Investment

Standard drives

(EFF2*)

Approx. 100 motors (15 kW - 160 kW)

for ventilation and exhaust air supply320.000 €340.000 €

Energy cost

Price per kWh: 0,09€ 40.000 €40.000 €5.000 Mio €/year

*Energy efficiency class 1, energy efficiency class 2

5.110 Mio €/year

ROI calculation EFF 1 motors vs. EFF 2 motors

Break even

Euro

Life cycle

Discount rate: 20%

-20.000

71.667

148.056

211.713

264.761

308.967

345.806376.505

402.088

423.406

-50.000

50.000

150.000

250.000

350.000

450.000

1 2 3 4 5 6 7 8 9 10

Calculation for a typical paint shop (300.000 cars /year)

Energy efficient

drives

technologies

Technological

answers

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Automation

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References

Page 33 18.02.2010

E-coating with rectifiers in paint shops

Rectifier 1

800-1600 A

Rectifier 2

800-1600 A

Rectifier 4

for backup

800-1600 A

DC bus system

Car bodies to be ionized for proper coating of corrosion protection

Coating quality depends on consistency and availability of the ionization process

High direct current (DC) for ionization process generated by large rectifiers

Due to the high energy consumption of the rectifiers

alternative solutions for the ionization process are needed

Anodes 1,…,n

Rectifier 3

800-1600 A

Zone 3

Anodes 1,…,n

E-coating

++++ + + +

-- ------

Technological

answers

Zone 1

+++++++++ +++++++++ +++++++++

--

-

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Core challenges

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Automation

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References

Page 34 18.02.2010

New rectifier concept with modular anode control for optimized paint processing

Traditional concept with static anode control New concept with modular anode control

Rectifier 1

800-1600 A

Rectifier 2

800-1600 A

Rectifier 3

for backup

800-1600 A

Static electrical field results into

inhomogeneous coating thickness

Limited availability due to central architecture

( Back-up solution necessary)

Body specific dynamic field control

guarantees homogenous coating thickness

Highest availability due to modular architecture

via fieldbus and PLC control

Zone 1 Zone 2Anodes 1,…,n

Technological

answers

+++++ + + + +Anodes 1,…,n Anodes 1,…,n

DC bus system

Network (PROFIBUS)

Loop controlled rectifiers

linked via field bus and PLC

PLC

+++++++++ +++++++++ +++++++

--

+++++++ + +

--

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answers

Automation

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References

Page 35 18.02.2010

Rectifier solution with SIMOREG DC master improves coating quality and generates energy cost savings

Improved coating quality

Improvement in the coating quality through < 1% ripple

More uniform coating thickness through partial coating of selected areas

Cost savings in coating material and energy

Lower material usage through targeted coating

Energy cost saving: ~ 20 % because of reduction of reactive power

Shorter coating times: ~ 10% because of the homogenous coating process

Efficient network topology

High performance loop control for voltage and current

No back up solution necessary

Technological

answers

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Core challenges

in paint shop

Technological

answers

Automation

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References

Page 36 18.02.2010

Feedback from GM regarding the Siemens rectifier solution

Technological

answers


Automation Concepts for Paint shop

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Automotive

process

Core challenges

in paint shop

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answers

Automation

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References

Page 38 18.02.2010

Paint ShopTypical Automation Concept for a paint cell

Wired Communication

with Profinet & Profibus

Distributed I/O

with ET200 in IP20 & IP65

Integrated Safety

with PROFIsafe

Plant Visualization

with HMI panels and

WinCC Flexible

Plant control

with SIMATIC PLCs

PC 677 WinCC flexible

ET 200S failsafe

Main control panel

CPU

319F-3PN/DP

Distributed panel

SIMATIC HMI - Push

Button Panel PP17-II

Panels with robot controller

SIMATIC FS400 light curtain

Paint robots

Scalance X208

ET 200S

with

failsafe

motor

starters

and

emergency

stop

ET 200S

with

failsafe

motor

starters

and

emergency

stop

ET 200S

with

failsafe

motor

starters

and

emergency

stop

ET 200S with failsafe

motor starters and

emergency stop

PROFINET

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 39 18.02.2010

Paint ShopTypical Automation Concept for a conveyor system in paint shops

PC 677 WinCC flexible

ET 200S

ET 200S failsafe

Main control panel

CPU

319F-3PN/DP

Distributed panel

Wireless

Mobile Panel

ET200pro with motor starter

and geared motor

Rail or chain conveyor

IWAN AP 786-2RR

Scalance X208

Monorail overhead conveyor and Lift application

RCoax Antenna Access Point

ClientDrives

Wireless LAN

PROFINET

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 40 18.02.2010

Paint ShopTypical Automation Concept for process engineering in paint shops

Ventilator Motor

Sinamics G130

Anodes 1,…,n

+ + + + + + ++

SIMATIC HMI -

Operator Panel

ET 200S wih Siwarex

weighing modul

…

E-Coating

PC 677

WinCC flexible

PC 677

WinCC flexible

PC 677

WinCC flexible


motor starters and

emergency stop

CPU

317F-3PN/DP

Painting mix roomBooth and oven

ET 200S

Scalance

X208

Scalance

X208

Scalance

X208

SIMOREG DC-Master

PROFIBUS

CPU

317F-3PN/DP

CPU

317F-3PN/DP


motor starters and

emergency stop


motor starters and

emergency stop

PROFINET

Control panel Control panel Control panel


http://www.automation.siemens.com/bilddb/picdetails.asp?objID=56767&aktPrim=0&tab=prop&lang=en&nodeID=&useStructure=1&att17t=display&att14s=35&att7s=-&att9t=&att21t=&att15s=-&att20t=&att99t=&x=0&y=0

I IA / HQ / CC A


Automotive

process

Core challenges

in paint shop

Technological

answers

Automation

concept

References

Page 41 18.02.2010

Technological

answers

Increase your Productivity with Siemens

RFID Technology

Safety Integrated

Mobile HMI panels

Industrial Wireless

Energy efficient components

Productivity


References

Bereich / Region / Abteilung

Schutzvermerk / Copyright-Vermerk

Seite 43 18.02.2010 Autor

Initial Situation

Consistent rating in the top 10 by JD

Power and Associates in spite of

outdated technology

Plant retrofit including a safety

solution and a new plant for the Lexus

RX 330 luxury SUV

Requirements

Increase safety and production

through better diagnostic

Integration of the new safety solution

with the existing controls platform

Reduced downtime

Customer: Toyota, Canada, CambridgeSolution: Future-oriented safety technology and a plant retrofit

Technical Solution

Modernization of the factory through a

retrofit

Installation of top-notch, Control

Reliable safety solution

Space for

milieu photo/

photo of application




Implementation:

Siemens safety solutions that meet EnN954-1

and IEC 61508 standards

Upgrade of "antichip" and "black out" booths

with new Control Reliable safety systems

Using Siemens AS-Interface at Work and the

Simatic S7-300F

Benefits

Higher availability and increased productivity

Implementation with marginal downtime

Reduces hardwiring to nearly zero

Ease of installation

Reduction of commissioning cost and site

time required for retrofit

Ensures enhanced operator safety

Up-to-date safety technology with AS-Interface and Simatic S7-300F





Initial Situation

Production of around 250,000 VW

Polos p.a.

The plant in Navarra exists since 1984

Renovation and development of the

paint shop

Requirements

Highest levels of environmental

compatibility to be assured

Reliable communication between

central control unit and individual

rotary carriers

Maximum availability to be ensured

Customer: Volkswagen, Navarra, SpainSolution: Optimized communication with Profinet

Technical Solution

Rotational movements that implicate

communication via Wireless LAN

Identification of the bodyshell type by

a tracing system




Implementation:

Simatic S7-416F

Simatic S7-315F onboard carrier control

Sicalis central control system

Communication via Industrial Ethernet

Wireless LAN using leak wave conductors

Scalance Access Points and a switch

Scalance client and an IE/DP link

tracking system Moby I

Benefits

Attrition is avoided as there are no

mechanical links

No conflicts with other IWLAN networks,

mobile telephony and Bluetooth

=> Higher availability

Reduced radiation





Initial Situation

Originally installed drives reached

their life cycle and synchronization

limits

Stretched and stressed transport

chains led to fractures and many

downtimes

Requirements

Precise synchronization and load

sharing of the conveyor systems

Detection of the stress points

Long life-cycle

Reduction of downtimes

Technical Solution

Innovative drives solution controlling

the speed of every individual drive

→ highest level of synchronization

Space for

milieu photo/

photo of application

Customer: Chrysler, St. Louis, USA Solution: Conveyor technology for a paint shop with Simotion




Implementation

Simotion C motion control system

Operation in sync with the Simotion C230-2 in

combination with Simovert Masterdrives

converters, external encoders and control

software

Two communication networks over Profibus

DP

Touch screen panels Simatic TP270

Benefits

High level of productivity

Extended operation

Control of the speed of every individual drive

powering ach of the conveyor systems

Detection of slightest fluctuations in speed

and chain torque

Control of the positioning and speed of the

individual drives

Communication: Continuous data flow

Real-time images of the entire paint prep

conveyor system

Simotion increases productivity in the paint shop


Siemens Automation Concepts for Paint Shop

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