Siemens Automation Concepts. for Powertrain. Siemens Industry Competence Center Automotive V1.1. All rights reserved / Siemens AG

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1 Siemens Concepts for Powertrain Siemens Industry Competence Center V1.1

2 Siemens offers a integrated solution portfolio for powertrain Press Shop Body Shop Paint Shop Powertrain Assembly Logistics Logistics Logistics Logistics Increase of productivity: Reduction of production hours per powertrain component Key challenges: High plant availability due to serial production Need for innovative logistics due to JIT/JIS* production High need for line flexibility due to high model variety and shorter product life cycles Page 3 2/18/2010

3 Main es and core challenges in powertrain Production Production of parts for engine, transmissions, axles engine: cylinder head, motor block, crankshaft, camshaft, transmission: gears, ring gears, shafts, cases, Milling, turning, drilling, hobbing, welding, finishing Heat treatment Washing machines Test Assembly Assembly of cylinder head, short engine, complete engine Assembly of transmission (e.g. manual, automatic, double clutch, differential) Assembly of axles Setup Screwing station Press station Test station Automatic and manual stations Project support worldwide: High model variety and shorter product life cycles require mix production on the same assembly line Life cycle costs: Downtime of one sub- step causes downtime of complete line due to serial production ing Increased productivity: JIT/JIS production for cost efficient production and logistic es Storage of product quality data for liability reasons Lower engineering costs: Cost efficient production ing with high number of manual production tasks Page 4 2/18/2010

4 Process steps and core challenges in powertrain Production Production of parts for engine, transmissions, axles engine: cylinder head, motor block, crankshaft, camshaft, transmission: gears, ring gears, shafts, cases, Milling, turning, drilling, hobbing, welding, finishing Heat treatment Washing machines Test Assembly Assembly of cylinder head, short engine, complete engine Assembly of transmission (e.g. manual, automatic, double clutch, differential) Assembly of axles Setup Screwing station Press station Test station Automatic and manual stations Project support worldwide: High model variety and shorter product life cycles require mix production on the same assembly line Page 5 2/18/2010

5 Siemens technologies support highest plant flexibility Customer requirements Project support worldwide Customer Support Project coordination Page 6 2/18/2010

6 Customer support Corporate Account Manager End customers Account Manager Country concepts and promoters Mach. constr. OEMs Local sales I DT MC MT Page 7 2/18/2010 Global, comprehensive support of the automotive industry by a competent team

7 Project coordination Powertrain projects automotive industry & suppliers Siemens, local Machinery construction OEM A Siemens, local Machinery construction OEM B Siemens, local Machinery construction OEM C Spare parts Service Support Training Project Manual Component list Project DVD Project information Siemens project team Page 8 2/18/2010 Support from a single source over the complete lifecycle through standardized es

8 Solutions for Powertrain Teams Stockholm Nuremberg Budapest Vienna Istanbul Moscow Mexico City Toronto Detroit Manchester Paris Porto Madrid Turin Mumbai Bangalore Tokyo Changwon Beijing Shanghai Sao Paulo Melbourne Competent support through local teams around the world Page 9 2/18/2010

9 Main es and core challenges in powertrain Production Production of parts for engine, transmissions, axles engine: cylinder head, motor block, crankshaft, camshaft, transmission: gears, ring gears, shafts, cases, Milling, turning, drilling, hobbing, welding, finishing Heat treatment Washing machines Test Assembly Assembly of cylinder head, short engine, complete engine Assembly of transmission (e.g. manual, automatic, double clutch, differential) Assembly of axles Setup Screwing station Press station Test station Automatic and manual stations Project support worldwide: High model variety and shorter product life cycles require mix production on the same assembly line Life cycle costs: Downtime of one sub- step causes downtime of complete line due to serial production ing Page 10 2/18/2010

10 Siemens technologies support highest plant flexibility Customer requirements Reduction of Life cycle costs Seamless Project Manual and automation concepts Project DVD Increasing the energy efficiency Page 11 2/18/2010

11 SINUMERIK 840D sl New levers to reduce life cycle costs Scalable panels Integrated HMI Lower engineering costs Long-term spares availability Cross NC PLC operator concept Rotatable connector outlet for 1FT7 motors Increased energy efficiency Product-related investment costs Costs that are incurred during the life cycle of the plant/system as a result of service, spare parts, training, etc. Rugged products Page 12 2/18/2010

12 Seamless and integrated automation concepts - from production through to assembly Transfer lines Flexible production lines NC series machines, special machines Assembly lines Rotary cycle machines Cascading/interlinking Page 13 2/18/2010 Integrated and seamless machine concepts reduce costs for training and spare parts

13 Standardized manuals Transline standardized manuals Overview Component list Application examples General software guide Software guide HiGraph Software guide S7-Graph HMI Pro HMI Lite CE Safety Integrated Motion Control Information System eps Network for Powertrain IT Configuration Project-specific description of differences Contact persons Notes Application examples etc. Page 14 2/18/2010

14 Standard project manual - Component List - Basis for reduction of component-variety Current components (update annually) All supplementary components listed in the catalog are included in the standard Basis for sample applications The component list includes all control- and drive components defined for the project Not listed components can normally only be used with a special release Basis for project specific variations Project specific differences to the standard can be displayed with Excel-macros A separate component list for CD- Components is available Page 15 2/18/2010

15 Extending the spare parts availability of MC products to 20 years after SOP / 2nd commissioning Market requirement Product strategies strategy Component list, automotive 6FC5356-0BB15-0AA0 6FC5357-0BB15-0AA0 6FC5357-0BB25-0AA0 1PH7103-2NG02-0CJ0 1PH7105-2NF03-0CJ0 1FK7080-5AF71-1EG2 1FK7080-5AF71-1EH2 1FK7063-5AF71-1EG2 6SN1146-1BB01-0BA1 6SN1111-0AA00-0BA1 6SL3000-0CE35-1AA0 6SL3120-1TE32-0AA0 6SL3320-1TE32-6AA0 6SL3162-2BD00-0AA0 6FC5203-0AF22-0AA2 6FC5203-0AF22-1AA2 6FC5303-1AF00-1AA1 Reduced to selected components Component list with Long Term Spares 6FC5356-0BB15-0AA0 6FC5357-0BB25-0AA0 1PH7105-2NF03-0CJ0 1FK7063-5AF71-1EG2 6SN1146-1BB01-0BA1 6SN1111-0AA00-0BA1 6SL3000-0CE35-1AA0 6SL3320-1TE32-6AA0 The list is revised every year A project-specific agreement is required Machine documentation (location at end customer) using EUNA forms the basis Life cycle costs are reduced through long-term spare parts supply Page 16 2/18/2010

16 Project DVD standard software for all machines types Pre-tested customized software package Image types: Integrated HMI NCU image PC based HMI Ghost image Identical basic software package for all suppliers Inexperienced users are immediately provided with a basic system ready to run Reproducible system to support the user Solutions for Powertrain Basic V4.0 NC-Version for PCU 50.3 TRANSLINE Reduces update costs and speeds up support Page 17 2/18/2010

17 Environment High efficiency drives Increasing the energy efficiency SINAMICS S120: Using energy recovery up to the magnitude of the infeed power Using adjustable reactive power compensation By reducing the line-side current harmonics Through energy management in the DC link 1FT7 servo drive: Up to 26% lower energy consumption when compared to 1FT6 (the average is 9%) Lower operating costs Page 18 2/18/2010

18 Main es and core challenges in powertrain Production Production of parts for engine, transmissions, axles engine: cylinder head, motor block, crankshaft, camshaft, transmission: gears, ring gears, shafts, cases, Milling, turning, drilling, hobbing, welding, finishing Heat treatment Washing machines Test Assembly Assembly of cylinder head, short engine, complete engine Assembly of transmission (e.g. manual, automatic, double clutch, differential) Assembly of axles Setup Screwing station Press station Test station Automatic and manual stations Project support worldwide: High model variety and shorter product life cycles require mix production on the same assembly line Life cycle costs: Downtime of one sub- step causes downtime of complete line due to serial production ing Increased productivity: JIT/JIS production for cost efficient production and logistic es Storage of product quality data for liability reasons Page 19 2/18/2010

19 Siemens technologies support highest plant flexibility Customer requirements Increased productivity SINUMERIK Thin Client 840D sl architecture Manufacturing Excellence 3 Support 1 Develop SINUMERIK Manufacturing Excellence 2 Operate Page 20 2/18/2010

20 SINUMERIK NCU 720.2PN / 730.2PN The selected controls for Powertrain NCU 720.2PN and 730.2PN cover the requirements from the Powertrain production area. Increased performance: Integrated HMI PLC that can be quickly integrated Extended PLC memory PROFINET interface onboard Shorter boot time Faster 3D graphics Higher productivity through high performance hardware Page 21 2/18/2010

21 System configuration with thin-client architecture OP TCU MPP Factory network Standard platform for CNC and PLC-based machines Maintenance-free operator components No hard disk No fan No battery S7-300 PCU 321 Fieldbus ET D sl Higher degree of availability through maintenance-free HMI platform for CNC and PLC-based machines Page 22 2/18/2010

22 Example Powertrain: solution for linked plants Plant visualization with mobile HMI and Thin Client CNC Machine (e.g. milling) PROFINET HMI Client SCALANCE X208 HMI Client PLC Machine (e.g. inspection) SCALANCE X208 HMI Client HMI Client HMI Client PLC HMI Client HMI Server SINUMERIK SINAMICS HMI Server ET200 ET200 Requirement: Flexible control concept in Powertrain manufacturing Page 23 2/18/2010

23 Example Powertrain: Comprehensive portfolio of flexible control components Plant visualization with mobile HMI and Thin Client Scalable range of control panels based on thin client - Fixed control panels for different equipment sizes - Usable both on PLC- and CNC-controlled machines - Integrated HMI on controller Flexible use of mobile control units - Use of mobile control units with integrated safety - Without additional configuration on thin client basis CNC Machine (e.g. milling) HMI Client SCALANCE X208 HMI Client HMI Client HMI Client HMI Server ET200 Page 24 2/18/2010

24 Example Powertrain: Creating customer value with thin client components Plant visualization with mobile HMI and Thin Client Significant cost savings through Maintenance-free components and elimination of wear parts (hard disk, blower and battery) Use of control components with minimum configuration requirements Flexibility of control concept through Client/server architecture approach centralized application update via server Easy expansion of the number of thin clients (up to 4 devices per machine unit) This results in total savings of investment and life cycle costs Page 25 2/18/2010

25 Example Powertrain: PC-based solution vs. thin client solution in a typical Powertrain Shop with 120 NCUs Plant visualization with mobile HMI and Thin Client Initial Investment Machine equipment HW ( PC-based HMIs) Machine equipment HW (Thin-Client based) Installation & commissioning PC-based Solution 900,000-30,000 - Thin-Client Solution - 520,000 30,000 Total 930, ,000 Life Cycle Cost Installation Wear parts costs and spare parts (battery, blower, hard disk etc.) Maintenance 35, / year ,000 / year 2,500 / year 1,000 / year Total 37,500 / year 14,000 / year Page 26 2/18/2010

26 Manufacturing IT Functions for manufacturing planning and implementation Performance measurement / OEE Tool management NC program management and transfer Order management Preventive maintenance Part tracking and documentation IT and data security CAD/CAM chain Networking Machine optimization and transparency Page 27 2/18/2010

27 The eps Network Service - Platform Internet-based condition monitoring with eps network services Test procedures (e.g. circularity test, synchronous operation test) and load monitors Limit value monitoring and workflow service Reporting Machine Health Check Geometry measurement, vibration measurement, thermography Reporting Advantages at a glance Prevention of machine failures Reduction of the maintenance costs Page 28 2/18/2010

28 Costs Loss of Production Unplanned Maint. Cost savings with Condition Monitoring Reactive Maintenance Start Time Page 29 2/18/2010

29 Costs Loss of Production Unplanned Maint. Planned Maint. Costs Loss of Production Unplanned Maint. Cost savings with Condition Monitoring Reactive Maintenance Preventive Maintenance Time Stop Start Time Page 30 2/18/2010

30 Costs Loss of Production Unplanned Maint. Planned Maint. Condition Monitoring Costs Loss of Production Unplanned Maint. Planned Maint. Costs Loss of Production Unplanned Maint. Cost savings with Condition Monitoring Reactive Maintenance Preventive Maintenance Time Time Condition Based Maintenance Stop! Start Page 31 2/18/2010 Time

31 IT security Products and services to achieve the protective goals IT security products Application security Rugged products Products that are explicitly used to increase the level of IT security in production or include IT functions to increase the level of IT security e.g. SCALANCE S -> Increased IT security for production Products and functions that already take into account IT security requirements in production. These products/functions have been specifically designed and adapted to the particular application and task. (user concepts, protective levels) -> Easy to use, IT security without requiring extensive know-how e.g. comply with the relevant legislation Increased ruggedness of automation products for IT security - e.g. testing virus scanner software, MS security updates, firewall integrated in SINUMERIK (NCU, PCU) -> to secure the highest level of availability and stability for production systems in the case of faults or hacker attacks. IT security services Page 35 2/18/2010 Provide support during the planning, implementation and commissioning IT assessment and security check of the plant/system network infrastructure Development of an IT security concept Customer service to maintain the productivity of the plant or system -> Professional support with know-how relating to industrial network technology and automation technology.

32 Main es and core challenges in powertrain Production Production of parts for engine, transmissions, axles engine: cylinder head, motor block, crankshaft, camshaft, transmission: gears, ring gears, shafts, cases, Milling, turning, drilling, hobbing, welding, finishing Heat treatment Washing machines Test Assembly Assembly of cylinder head, short engine, complete engine Assembly of transmission (e.g. manual, automatic, double clutch, differential) Assembly of axles Setup Screwing station Press station Test station Automatic and manual stations Project support worldwide: High model variety and shorter product life cycles require mix production on the same assembly line Life cycle costs: Downtime of one sub- step causes downtime of complete line due to serial production ing Increased productivity: JIT/JIS production for cost efficient production and logistic es Storage of product quality data for liability reasons Lower engineering costs: Cost efficient production ing with high number of manual production tasks Page 36 2/18/2010

33 Siemens technologies support highest plant flexibility Customer requirements Lower engineering costs SINAMICS S120 PROFINET Page 37 2/18/2010

34 SINAMICS S120 booksize Shorter engineering and commissioning times A transformer can be eliminated by directly connecting to the line supply: Line supply types TN, TT, IT line supplies Voltage levels 3-ph. 400 V AC 3-ph. 415 V AC 3-ph. 480 V AC Page 38 2/18/2010 Faster commissioning through: Motor, encoder and power unit are automatically identified (self-identification routine) Technical and logistical data are saved in the power unit module Equivalent circuit diagram and encoder data are saved in the motor 1FK7, 1FT7, 1PH motors using SME 1FN, 1FE1, 1FW6 SINAMICS S120 international, energy-efficient, rugged, compact and quick to commission

35 PROFINET High degree of flexibility and performance Flexibility by using Ethernet and well-proven IT standards Investment protection for PROFIBUS devices and applications Engineering and commissioning costs are reduced as a result of modularization Flexible, modular plant and system concepts Page 39 2/18/2010

36 CBA - Component Based Graphically configuring the plant communications SW component Int. module A FB FB FB FB SW component Int. module C FB FB FB FB SW component Int. module B FB FB FB FB Communications between the modules are configured Graphic lines are used in the technological view Detailed knowledge about the communication functions is not required Configuring communications instead of programming Page 40 2/18/2010

37 Powertrain Proposed Concept Flexible Line SCALANCE X208 SCALANCE X208 SCALANCE S612 Machine control with SINUMERIK 840D sl Wired Communication with Profinet & Profibus Wireless Communication with SCALANCE W Distributed I/O with ET200 in IP20 & IP65 Integrated Safety with PROFIsafe Drives technologies with Sinamics Identification and with Sensors and RFID Visualization with Thin Client or PC based Operator panels Page 41 2/18/2010

38 Powertrain Proposed Concept Assembly Line SCALANCE X208 SCALANCE S612 Machine control with SIMATIC S7-300 Decentralized PLC for manual workplaces in IP65 Wired Communication with Profinet & Profibus Distributed I/O with ET200 in IP20 & IP65 Integrated Safety with PROFIsafe Drives technologies with Sinamics Identification and with Sensors and RFID Visualization with Thin Client, PC based Operator panels or SIMATIC OPs Page 42 2/18/2010

39 s Increase your Productivity with Siemens Productivity Intelligent maintenance MES Industrial WLAN RFID technology Safety Integrated Mobile HMI Drives Technology

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41 s Customer: Solution: Daimler, Kassel, Germany Harmonization of production and assembly Initial Situation Because of the limited production capacity available, temporary storage for parts is required to harmonize production and assembly Technical Solution Intelligent decoupling module (DCM) System safety Requirements 2800 storage spaces to be created and that in an existing assembly hall Assure availability at all times Automated transportation of parts Individual part storage

42 s Customer: Solution: Daimler, Kassel, Germany Harmonization of production and assembly Implementation: Sinumerik 840D CNC control system Simodrive 611D control unit Data security of the DCM allocation is achieved by means of redundant storage of the data in both Sinumerik 840D controllers Communication between controllers via Profibus and Ethernet (TCP/IP) Safety Integrated with Profisafe Distributed I/Os Simatic ET 200 is also connected via Profibus Benefits Standard and safety-oriented communication on the same bus line All future component variants can also be handled without additional setting-up or adjustments having to be performed Connection to the inventory control system established Equipped for the future with innovative control, drive and safety technology from Siemens

43 s Customer: Solution: Daimler, Kassel, Germany Harmonization of production and assembly

44 s Customer: Solution: Volkswagen, Salzgitter, Germany Siemens Motion Control Information System in crankshafts production Initial Situation Manufacturing of 25 percent of all engines for VW, Audi, Seat and Skoda Set up of a new crankshaft production line Need to increase product diversity and to reduce production runs in order to stay competitive Technical Solution Manufacturing technology with a high degree of automation and the utmost flexibility Precise motion control system Implementation of an integrated safety package Requirements Short changeover times Facilitate the economic production of prototypes All es are kept transparent Possibility to track each work piece

45 s Customer: Solution: Volkswagen, Salzgitter, Germany Siemens Motion Control Information System in crankshafts production Implementation: Siemens solution for Powertrain package - Transline The Transline package includes Sinumerik 840D CNC control Extensive integrated safety package: Safety Integrated Motion Control Information System (MCIS) Benefits Completely uniform user guidance with intuitive and simple operation Extremely flexible production structure Rapid implementation Reliable solutions Uniform operation and maintenance Reduced spare parts stocks Simple system configuration Reduced training costs and higher OEE (Overall Equipment Efficiency) Siemens Motion Control Information System ensures cost-efficient production

46 s Customer: Solution: Chrysler, Kokomo (IN), USA Common control system for different machines in the transmission plant Initial Situation New Transmission Plant II in Indiana (ITP2) Rear-wheel drive transmission used in various vehicle models are produced in this plant Technical Solution Homogeneous architecture for the es of power train manufacture such as milling, drilling, grinding, assembly and testing Requirements A common control system for different machines Simple operator support Standardization Binary communication protocol Simplified centric assembly to minimize the distances covered by personnel Space for milieu photo/ photo of application

47 s Customer: Solution: Chrysler, Kokomo (IN), USA Common control system for different machines in the transmission plant Implementation Transline system solution Uniform hardware and software components and homogeneous HMI in all machine tools Homogeneous architecture for the es of power train manufacture CNC control Sinumerik 840D Direct integration of PLC, CNC and the Profibus field bus system Benefits Incorporation of Chrysler Group requirements for control, technology, provider, uniformity of operator interfaces, quality testing system and networkability Simple and efficient plant concept Simple operator support Standardization Binary communication protocol Simplified centric assembly to minimize the distances covered by personnel Reduction of training times Perfect coordination and simplification using Transline as a common control system in the transmission plant

48 s Customer: Solution: Chrysler, Kokomo (IN), USA Common control system for different machines in the transmission plant