Automotive Days 2012

EMS technology is a mayor demand of the automotive

companies
Gerhard Wurzrainer, 09.02.2012
Content
• Why and where are Electrified monorail systems used in the automotive
manufacturing process ?
• How do we approach this segment?
• Product and technology overview
• Solution examples
• Time schedule

2 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

Advantages Electrified Monorail Systems
• Requires no floor space since it is mounted on the ceiling
• Very flexible –different parts can be transported with the same
system
• High transportation speeds
• Heavy loads can be transported
• High positioning accuracy
• Low noise level

3 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

EMS in the car manufacturing process

4 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

EMS in the Body Shop

• Characteristics
• low weight
• only a few speed levels (fast, slow)
• high volume of carriers per line
• several lines for different parts (side parts, doors,
under body..)
• single axis systems

5 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

EMS in the Body Shop

6 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

EMS in the Paint Shop

• Characteristics
• not very common
• medium weight
• several speed levels according to process
• low volume of carriers per line
• single axis systems

7 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

EMS in the Paint Shop

8 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

EMS in the Final Assembly
• Characteristics
• heavy weight
• total speed control according to process
• absolute positioning
• medium volume of carriers per line
• multi axis systems
• safety requirements

• Preassembly of doors, cockpit, frontend, seats,.. is also a part of the

final assembly
• Characteristics
• low/medium weight
• speed control according to process
• medium / high volume of carriers per line
• single/multi axis systems

9 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

EMS in the Final Assembly

10 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

EMS in the Final Assembly
• Skillet platforms and AGVs are also part of the
final assembly
• Skillet platforms
• floor based
• lifter only
• heavy loads
• safety requirements

• AGVs
• used for axis and motor/gearbox transport
• medium loads
• safety requirements
• inductive power supply

11 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

EMS in the Final Assembly

12 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

How do we approach this segment?
Requirements Lenze response

Global support Build Expert Team EMS

Lenze EMS directions

Energy efficient operation Standardized applications

Reduce complexity costs Predefined EMS packages

EMS communication systems New EMS controller platform

Half wave, Power wave, DECA-Bus, Wireless

Know how transfer of

Multi axis support (1,2,4)
Lenze solutions

Safety: STO, SLSpeed, SLPosition Predefined safety concepts

13 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

Lenze‘s solution
We offer predefined solutions for the application types
The packages consist of ..... Geared motor

EMS Controller

Software &
Function Blocks
Cables &
Accessories

System integration

14 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

The 4 Application Levels
Customers requirements
Final Powertrain
Assembly (AGVs)

Skillet lines Sub Assembly

Body shop

High
Low Mid Customized
System Functionality

15 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

The 4 Application Levels

Low Mid High Customized

transport 1 axis transport transport transport
halfwave communication + + +
optional axis multiple axis multiple axis
speed control absolute positioning absolute positioning

HWC and DECA bus DECA bus

Powerwave communication WLAN
communication communication

power range >4kW

8400protec EMS 8400protec EMS 8400protec EMS 8400protec EMS

CCU210B CCU210B 8400protec HL 8400protec HL
8400motec 8400motec
8400 IP20
DrivePLC / 3200C

16 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

8400protec EMS

M12 Connectors
0,75-4kW power output

8*+4 Digital Inputs
Integrated 24VDC supply

2 Digital Outputs
Integrated brake chopper

RS485 Interface*
V/f open loop

SSI Interface
Sensorless Vector Control

CAN Interface
V/f closed loop

Integrated PLC*

EMS specific communication*

Memory Module
400/500VAC 50/60Hz

LED Display
560VDC

IR Remote Control*
180V/210VDC Break

IRDA Interface
24VDC Break*

L-force Interface * differences to 8400protec HL

17 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

Energy supply
Multipole conductor rails

L1
L2
L3
PE
Data
Data

inductive power and data transmission

18 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

Communication @ EMS

• Point-to-Point communication; in small blocs

• Half Wave (3 commands)
• Half Wave coded (200 commands)
• Power Wave (1024 commands)

• Bus communication with addresses; in large segments

• DECA – Bus
• PROFInet WLAN

19 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

Communication Half Wave
stationary PLC
4 Commands 4 Feedbacks
SS – Command Rail MS – Feedback Rail
digital I/Os
0 0 Command 1 i.e. Stop 0 0 Feedback 1 i.e. OK

0 1 Command 2 i.e Speed 1 HM-RX 0 1 Feedback 2 i.e. present

HM-TX
1 0 Command 3 i.e. Speed 2 1 0 Feedback 3 i.e. in Position

1 1 Command 4 i.e. Speed 3 1 1 Feedback 4 i.e. Error

L1
L2
L3
PE
SS
MS

20 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

Communication Half Wave coded
stationary PLC
200 commands 4 Feedbacks
SS – Command Rail MS – Feedback Rail
Field Bus
0000000000 Command 1 i.e. Stop 0 0 Feedback 1 i.e. OK

0000000001 Command 2 i.e Speed 1 0 1 Feedback 2 i.e. present

0000000011 Command 3 i.e. Speed 2 1 0 Feedback 3 i.e. in Position

1111111111 Command 200 i.e. Speed x 1 1 Feedback 4 i.e. Error

L1
L2
L3
PE
SS
MS

21 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

Communication Powerwave stationary PLC
1024 Commands 1024 Feedbacks
SS – Communication Rail SS – Communication Rail
Field Bus

no Feedback rail needed !

L1
L2
L3
PE
SS

22 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

Communication DECA Bus
stationary PLC

Field Bus

LDC + LM-DC

L1
L2
L3
PE
Data
Data

7 13 4

23 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

WLAN – 8400 protec HL Profinet
stationary PLC

Access Point

L1
L2
L3
PE

Profinet Profinet Profinet

24 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

Solution examples ......

25 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

Solution for Body and Paint Shop
L1
L2
L3
PE
DATA
DATA

Postitioning system (if needed)

8400protec EMS

Sensors

Geared motor GKK

Parameter download

Software download

Diagnostics

26 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

Solution for Preassembly
L1
L2
L3
PE
DATA
DATA

Postitioning system

8400protecEMS

Sensors

8400protec SL/HL

System bus CAN

Sensors

8400motec

Parameter download

Software download

Diagnostics

„Drive Package“ Geared motor Geared motor GKK

27 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer
Solution for Final Assembly
L1
L2
L3
PE
DATA
DATA

Postitioning system

8400protecEMS

Sensors

System bus CAN

Geared motors
Parameter download

Software download
Safety
Diagnostics
8400
Device

Geared motor GKK

28 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer
Solution for AGV‘s
Power
Pickup

Data, Guidance and transponder system

8400protecEMS

Sensors

8400protecEMS

System bus CAN

Sensors

Parameter download

Software download

Diagnostics

Geared motor left Geared motor right

29 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

Time schedule
Low Mid High / Customized

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2011 2012

? ?
M6 M6 M6 M6
8400protecEMS 8400protecEMS 8400protecEMS 8400protecEMS
Half Wave HWC Powerwave DECA Bus

30 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

Why Lenze?
• Lenze provides the total package
• Global presence and support
• Defined applications makes start up easy
• Free programmable PLC
• High productive user interface
• L-force 8400 series fits all applications
• High level of quality due to mass production

31 EMS technology Automotive_Days_2012 09.02.2012 Gerhard Wurzrainer

Thanks for your attention !

Gerhard Wurzrainer, 09.02.2012