Automation solutions for the automotive industry.

Transcription

1 Lenze Automotive Automation solutions for the automotive industry. As easy as that.

2 More than 30 years experience in the automotive industry.

3 As one of the leading automation specialists with extensive know-how in the automotive industry and a worldwide network of experts, we work closely with you to find the best solution for your needs. We love being able to set your ideas in motion, regardless of whether you want to upgrade an existing machine or develop a completely new one. Member2018 In accordance with your ideas and requirements, we provide all the support you need from the planning of individual production plant sections or complete systems to commissioning and start-up of the installed equipment. We develop innovations for the car production as easily as that: Experienced experts understand your requirements and goals A comprehensive automation platform consisting of modular software and scalable hardware Reliable drive systems for typical manufacturing applications. Use of open standards Global production with uniform Lenze quality standards Worldwide logistics concept Global service network and range of training courses offered 3

4 A comprehensive and open automation platform for car production. Shorter and shorter innovation cycles, aggressive competitors and high pricing pressure are challenges that mechanical engineering companies are having to face up to. Good reasons for us to make your everyday work easy. With our engineering tool chain, we offer tailor-made tools for all aspects of your engineering and in all the different phases of a machine's overall life cycle. These tools are designed for the performance of mechatronic engineering tasks and have been precisely tailored to both user and task. For the performance of very different automation tasks, we offer you a consistent portfolio from the control to the field level to the electromechanics. Our energy-efficient mechatronic portfolio means you profit from reliable technologies, durable quality and easy handling with all our products. Not only can you reduce the variety of drives but also minimise your engineering process. At the end of the day it benefits everyone. Efficient software solutions Consistent engineering tool chain over the entire life cycle Intelligent motion control with standardised technology functions Reduced amount of engineering work A comprehensive automation platform The right system and the right products for every machine Reduced investment in drives and automation 4

5 Functionality Engineering Mechatronics Engineering Toolchain Technology modules Modular machine Application template Modular software structure Motion Positioning Camming Control level Field level Actuator/sensor level electromechanics Process level Visu Motion Logic Non- Lenze HW Integration 5

6 Exactly what you need for the car manufacturing. From the press shop to assembly With our intelligent automation system, we work closely with you to find the best solution for any machine task. You can rely on: Scalable hardware in a comprehensive and open automation platform Modular software for efficient software engineering Open networking thanks to the use of market standards Solutions that meet the requirements of digitalisation A thorough understanding of your machine from experienced experts in your sector 6

7 Software engineering made easy With Lenze FAST, our application template, you can combine intelligent standardised software modules for very different machine functions in a single template and thus create your machine software the easy way. This reduces your motion software engineering work by up to 80 %, which, in turn leads to a considerable reduction in the time you need to develop the basic functions of your machine. FAST Technologiemodule FAST Motion Camming Positioning FAST Application Template Open standards Lenze automation systems are open systems! Due to the use of market standards, we can network with the manufacturers of other control and drive systems at any time, an ability that enables easy integration into higher-level line structures. This openness makes mechanical engineers and end users confident of being able to adapt to changes in the future. 7

8 Industry 4.0. Cooperative competence becomes a new core competence. Mechanical engineering has always been characterised by a high degree of orientation to the customer, converting the needs of its customers into real technical solutions. With Industry 4.0, possibilities and new facets offering new opportunities arise from outside the known-world of mechanical engineering. Anyone who cooperates with partners faster and more effectively and integrates these partners into their ongoing processes will always win in competition with others. Cooperative competence generates a level of expertise that has answers to end users' trends and the requirements that will be placed on the next generation of machines. It creates technical solutions and innovations that bring decisive benefits: What benefits are most important for you? What technical measures have already been taken? Where do your greatest challenges lie? We look forward to talking to you about possible joint projects and opportunities for the future. 8

9 C O N N I N T E E C T I V L L I T Y I G E N C E Flexibility C O N N I N T E L L I G E N C E E C T I V I T Y Design by efficiency Resource efficiency Individualisation Interactivity Easy operability I G E N C E E C T I V I T Y L L Transparency I N T E Availability L I G E N C E E C T I V I T Y I N T E L C O N N C O N N Industry 4.0 in all its many facets can only succeed if everyone concerned the end users, machine builders, technology providers and the scientific world all pull together. 9

10 Extremely demanding production requirements: networking, high throughput rate and safe and reliable processes. Production in the automotive industry is influenced by two crucial factors: just-in-time and just-in-sequence. Both of these have to be guaranteed at all times as, whenever a part of the factory is shut down, enormous costs are incurred as a result. Our Intelligent automation concepts combined with flexible and efficient drive solutions enable compliance with these essential two requirements. Irrespective of the process within the production plant, whether it be the press shop, body shop, paint shop or assembly section, our experts know your processes and can help you to work faster and more reliably, whilst ensuring efficiency and reducing energy consumption. 10

11 Press shop 2 Body shop 3 Paint Shop 4 Assembly 11

12 Automobile production: Conveyors and turntables Conveyors and turntables: efficiency in motion. Simple and efficient decentralised drive solution for variable and fast conveying speeds of horizontal material handling systems High degree of reliability due to more than 30 years experience in the area of material handling technology Reduced energy consumption during idling and partialload operation utilising the VFC eco energy saving function Soft starting and braking with adjustable ramps mean less strain and stress on material and goods being transported, while simultaneously reducing the amount and cost of maintenance work needed Minimal installation and wiring complexity due to decentralised drive concept Compact drive solution for constant speeds, even in heavy load conditions 12

13 Solution example automobile production: Turntable 3rd Party PLC Control level Feldbus (safe) STO Field level 3rd Party Safe I/O Sensor Sensor Sensor Safety Sensor Actuator/sensor level electromechanics 13

14 Automobile production: Lifter and assembly facilities Lifter and assembly facilities: for the strictest requirements. High degree of reliability where great heights have to be overcome thanks to low-wear brake management As the load is held in position at standstill, the brake is not applied therefore less stress is applied to the system Fast and easy replacement during maintenance thanks to pluggable technology Reduced energy consumption due to power recovery in the case of very large heights 14

15 Solution example automobile production: Lifter 3rd Party PLC Control level Feldbus (safe) Field level Sensor Sensor Sensor Actuator/sensor level electromechanics 15

16 Automobile production: Storage and retrieval unit Storage and retrieval unit: highly automated warehouse worker. Complete solution package for advanced storage and retrieval units of the next generation Easy commissioning due to ready-made technology functions More available storage capacity due to reduction of buffer zones High degree of availability due to decades-long experience with storage and retrieval units Reduced energy consumption due to DC bus connection of travelling drive and lifting drive Regenerative modules for optimum energy balances 16

17 Solution example automobile production: Storage and retrieval unit Actuator/sensor level electromechanics Field level Control level 17

18 Automobile production: Clinching & riveting Clinching & riveting: Always the best connection. The high precision of the servo axes enables the innovative and proven clinching method The exact torque of our motor ensures that permanent connections can be made solely on the basis of local cold forming without the need for supplementary or auxiliary joining components The integration of external sensors into our automation system enables the autonomous performance of joining tasks in the pre-series and small-series area The intelligence in our inverters makes it possible for process measurements that have to be documented to be organised in the inverter and made available as a data file 18

19 Solution example automobile production: Clinching 3rd Party PLC Control level Feldbus (safe) 3rd Party I/O System Field level Sensor Sensor Actuator/sensor level electromechanics 19

20 Much more than just remote maintenance: Remote Services & Analytics offer added value for OEMs and end users. Industry 4.0 is based on the digital networking of machines, products and components and people as well, of course. We provide a secure platform for remote maintenance in that we link the service technician to the machine via a connection that can be monitored. The machine operator therefore has the assurance that only authorised persons can gain access to the machine and can do so only at the selected time. Moreover, data collected from machines can be saved in a private cloud. The data is then analysed and converted into meaningful figures that enables a deeper insight into how the machines are functioning. We offer you a complete cloud-based quality management system. You can obtain all cloud services from us in the form of a flexible subscription service, which makes the online transfer of machine data scalable. This has several advantages over an in-company system. IT investment, costly software licences and maintenance of any kind are unnecessary. What is also decisive is the fact that complex, individual programming is rendered necessary. Undoubtedly, the most secure solution: The maximum security level Financial Grade Security Encrypted data from the network to the cloud NCP standard Transparent data exchange in the company network Ready for the future OPC-UA/MQTT access to Lenze controller Permanent data transfer to the cloud All data is available for immediate or future analysis Plant management Monitoring of machine utilisation and availability Remote maintenance Worldwide data access Remote diagnostics and servicing Reduces field service assignments by up to 80% Predictive maintenance/ Digital services Predictive detection of potential faults on the basis of the "cloud data Big data as the basis for advisory services for production optimisation by the OEM 20

21 LEVEL 1 LEVEL 2 Remote service Data Monitoring Downtime Tracking Predictive Maintenance Application Programming Interface LEVEL 3 LEVEL 4 LEVEL 5 LEVEL 6 LEVEL 7 Wide Area Network (Encrypted) Cloud interface Shop Floor Network (Non-encrypted) Machine interface Data consolidation Control Control Data generation Drives/sensors Drives/sensors Drives/sensors Machine 1 Machine 2 Machine 3 21

22 Lenze Digital Services offer added value with perspective for OEMs and end users. Lenze has the right solution for everything that digitalisation requires from ready-to-use cloudbased applications for the digital networking of humans and machines to tailor-made digital products: for setting up a range of IIoT solutions on the way to digital transformation We support you as you start working in the Industrial Internet of Things (IIot) and as you set up new digital business models. TODAY The moment you connect your machine, you have complete transparency about its current status and you know exactly what is happening. TOMORROW Only a short time after recording the data, you can analyse it and work out why something is happening. THE DAY AFTER TOMORROW You can use data that has been recorded over a longer period of time to work out predictive data models and gain an insight into what is going to happen. Benefits for OEMs Benefits for end users TODAY What is happening? All the machines are connected There is a permanent data connection to a private cloud infrastructure Relevant data are recorded -- Setpoints -- Feedback -- Status -- Faults Secure and transparent access to remote maintenance Reduction in commissioning costs Reduction in support costs through efficient remote maintenance Retrospective fault analysis Secure and transparent access to remote maintenance Higher machine availability through faster fault elimination by the OEM 22

23 DAY AFTER TOMORROW What is going to happen? TOMORROW Why is it happening? Analysis and use of recorded data to work out appropriate actions Analysis of machine availability and calculation of KPIs (OEE, MTBF ) A record of the contractually guaranteed machine availability Optimisation of the machines based on recorded data Reduction in unplanned downtimes because the reasons for the downtime are known Realtime and historical OEE data are displayed More efficient utilisation of the entire machine outfit Performance analysis within a multipoint line configuration Optimisation of machine performance Predictive maintenance Optimisation of the repair intervals Development of new business models -- Pay per use -- Performance-based --Contracting Improved reputation in the market 23

24 Efficient in all respects. Energy-efficient with Lenze BlueGreen Solutions On the basis of a holistic consideration of the tasks involved, we show you how the energy efficiency of your drive applications can be increased with intelligent drive and automation technology. We also assist you regarding adherence to important standards and laws. Three approaches are pursued in order to increase the energy efficiency of drives: 1. Using electrical energy intelligently: as little as possible Needs-based dimensioning Controlled operation (frequency inverter) Energy-efficient motion control 2. Converting energy with a high degree of efficiency Components with a high degree of efficiency (motors, gearboxes) 3. Using regenerative braking energy Energy exchange between several drives Temporary storage of braking energy Regeneration of braking energy and potential energy % Proportion of potential savings 15% 10% 24

25 Efficient drive sizing with Drive Solution Designer (DSD) Intelligent drive design is the basis for a drive system that has the right components, is exactly dimensioned and is therefore as small as possible. Thanks to DSD, the energy saving potential is apparent at a glance and is documented in the Energy Performance Certificate. It is also easy to comprehensibly compare different solutions. The reason is that DSD incorporates a great deal of useful systems-design knowledge with solidly based driveapplications know-how in areas such as drive physics, variants and energy efficiency. Drive design is based on calculations with individual process data and on speed profiles, and takes into account the complete drive structure for the requirements of the machine in question. In our DSD training course, we will be happy to tell you more about how easy it is to use this engineering tool. 3 AC Comparison of DC supply 2DC Comparison of drive axes Energy exchange via DC bus connection 25

26 A powerful performance in any situation. If you can react individually and quickly to continually shortened delivery times, burgeoning costs and increased capacity requirements, you have a considerable advantage. We, as a company, have adjusted to these challenges and, with our many years of know-how in drive design and our adapted product portfolio, we can support you in this regard in accordance with your specific needs! Ready for anything: Well thought-out systems enable device replacement during ongoing operation The scalability of the products considerably reduces the variety of devices needed Need-based drive sizing with optimised energy balance Functional safety technology lntelligent systems for bridging short power-supply interruptions as well as for generator-controlled shutdown of the line in the event of a power failure 26

27 Central/distributed drive technology Distributed drive solution Integrated safety technology Flexible interfaces for fieldbus connection Needs-based drive design with Drive Solution Designer (DSD) In-depth knowledge about drive applications such as drive physics, variants and energy efficiency Calculations with individually applicable process data and speed profiles Complete drive structure for all of the machine s requirements Energy Performance Certificate makes savings potential visible at a glance Fast and easy replacement during maintenance Aluminium gearbox instead of heavy grey cast iron gearbox Pluggable connection system Parameterisation by means of NFC Connection dimensions usual in industry Safety technology Simplification of the structure of the system Less wiring/cabling Greater clarity Avoidance of the need for external safety components Increase in system performance Shorter switch-off and switch-on times Easy engineering tools Software solutions for easy engineering Support for service technicians during commissioning and maintenance Graphic user interface with only a few buttons Easy online diagnosis, parameterisation and commissioning No danger of accidental changes in the application Ready-to-use applications can be loaded into the device 27

28 Worldwide service for the requirements of the automotive industry. Productivity, reliability and new peak levels of performance every day these are our decisive success factors for your system. We offer individually and thoroughly thought-out service concepts for permanently safe and reliable operation. The focus here is on our service modules combined with competent support based on the excellent application know-how of our experienced specialists. Wherever, whenever and however you need our support, we are always there to help you. 28

29 Lenze inspection What is the current status? You know your machine exactly. Working with you closely, we create the basis for suitable measures. For example, we uncover weak points or risks and find value performance reserves. One thing is certain: With us, you machine is in the very best hands. Lenze prevention Prepared for the unexpected. Our comprehensive preventive service is the ideal way to minimise potential risks to your machine. We support you in increasing machine availability and minimising reaction times and downtimes in the event of faults. This saves you time and money and soothes your nerves. Lenze optimisation Making good things even better. We ensure that your systems work perfectly and show you intelligent optimisation possibilities: this includes reducing your energy costs, shortening your set-up times for production changeovers, or improving efficiency. We take care of it. Lenze emergency service Perfectly equipped to handle any challenge. You can also rely on us in the event of an emergency. We make extensive preparations for potential problems. Should something unforeseen ever occur, we will make sure that your systems are back up and running quickly and also perform an in-depth error analysis. With us, your projects are in safe hands. 29

30 Lenze makes many things easy for you: in every phase of the engineering process. We always work with you closely to find the very best solution. We set your ideas in motion with great enthusiasm and an eye for what works. Irrespective of whether you want to improve existing equipment or develop a completely new machine or application for overall automobile production. We always strive to make things easy and seek perfection therein. This is anchored in our thinking, in our services and in every detail of our products. Developing ideas 1 Ensuring productivity5 2 Drafting concepts Manufacturing machines 43 Implementing solutions 30

31 31

32 Dieses Dokument ist das geistige Eigentum von Lenze SE, Hameln (Deutschland). Sämtliche in diesem Prospekt enthaltenen Angaben entsprechen den zum Zeitpunkt der Drucklegung vorliegenden Informationen und dienen nur der Vorabinformation. Mögliche Farbabweichungen vom Orginalprodukt sind drucktechnisch bedingt. Lenze ist der alleinige und exklusive Besitzer des Copyrights und des Leistungsschutzrechtes. Jegliche Nutzung, insbesondere Verbreitung, Nachdruck, Verwertung und Adaption dieses Dokuments ist nur mit der ausdrücklichen, schriftlichen Zustimmung durch Lenze gestattet