Ingolstadt, Audi's production base in Germany, uses a highly flexible and highly automated production line to manufacture a variety of models such as the A3, A4, A5, A6, and Q5. In the body shop and final assembly shop, overhead conveyors are used to ensure that materials such as large chassis parts can be transported efficiently. To meet this requirement, Audi relies on drive and automation solutions that are tailored to Lenze.
At the Audi Ingolstadt plant, the lower level of the body shop is the robot's work area, which is isolated by protective light grids and footbridges, where the robot arm assembles and welds the components transported by the overhead conveyor. More than 800 suspended tracks are loaded from the press shop with different interior and exterior parts of the car body and transported to the body shop for welding, with a total length of more than 7 km. Conveyors transport the parts to temporary storage points and then to welding stations on both production lines. The transport of components requires sufficiently precise positioning of the overhead conveyor.
Lenze's Monorail Overhead Conveyors Systems (EMS) are widely used in the automotive production industry, where the high degree of automation and reliability of the system makes it possible to improve the efficiency of the material conveying process.
In the Monorail Overhead Conveyors System (EMS), the Decentralised Motor Control Unit is matched with the GKK series of spiral bevel gear motors with clutches to provide a diverse and flexible solution for material handling in automotive production.
The control and drive technology of the monorail overhead conveyor system has the following characteristics:
Decentralised Motor Control Unit
DETO series
CONTROLLER POWER RANGE 0.5 – 10 KW, 180S OVERLOAD TIME
Power supply transmission and control signal transmission by contact electric circuit (OCU) or non-contact inductive system (ICU)
Distributed control in the entire motion control system, including speed control, motor monitoring, independent monitoring, data transmission and diagnostic monitoring
User parameters can be written
8400 Protec EMS Series
The controller power range is 0.75 – 4 KW
Built-in PLC
Half-wave; Power-wave; DECA; WLAN and other modes of communication
8+4 digital inputs; 2 Digital outputs
RS485 / SSI / CAN interface
Integrated 24V DC power supply; Integrated braking resistor
GKK series spiral bevel gear reducer motor with clutch
Matched dedicated GKK geared motor with a maximum radial force of 36,000 N
At the Audi Ingolstadt plant, individual components sometimes weigh more than 70 kg due to the large size and weight of the components transported. Precise positioning becomes even more difficult. Combined with the weight of the carrier and the EMS monorail overhead conveyor system itself, the total weight can reach more than 250 kg, and the entire system needs to be precisely positioned during the start-run-stop process.
In the past, the overhead conveyor used by Audi was only controlled by a positioning switch, but now in the process of designing the overhead conveyor system for the new plant, Audi has introduced inverter technology, and at the same time, the distance sensor replaces the positioning indicator, and the distance between the two suspended small workshops is continuously monitored in real time, which solves this major technical bottleneck. The new design greatly reduces the volume required for the equipment, and at the same time, the application of frequency conversion technology also ensures that the components with large dimensions and loads can be transported smoothly. And, if two speeds are required, only an additional inverter is required, so that the increased costs are quickly absorbed.
At the Ingolstadt plant, Audi selected Lenze products for the construction of the overhead conveyor system for the new plant. For lightweight conveying applications, Lenze company uses GKK04 / GKK05 geared motors in EMS (Monorail Overhead Conveyors Systems), which can provide an output torque of 70Nm / 160 Nm and a radial force of 5,600N/8,000N. For heavy-duty conveying applications, the GKK05 / GKK06 / GKK07 geared motors are a more suitable choice, providing an output torque of 200Nm – 900Nm while a permissible radial force of 10,000N – 36,000N.
The GKK series geared motors used in Lenze's EMS Monorail Overhead Conveyors Systems meet the VDI3643 (C1 standard) standard, and the GKK geared motors can switch the torque transmission between the motor and the gearbox in real time through a mechanical clutch, which makes it possible for the flexibility of the monorail overhead conveyor system in special situations.
While providing excellent technical data, the compact size makes the GKK series geared motor more suitable for integration with monorail overhead conveying systems, and its gear meshing is selected for a more efficient hyperboloid spiral bevel gear match, and its mechanical efficiency can reach more than 96%, so that the transmission efficiency and speed/torque match is more perfect, reducing energy consumption, that is, reducing operating costs.
When there is a need for maintenance, GKK geared motors can be easily separated from the equipment components, which will greatly reduce downtime and improve production efficiency for automobile manufacturers.
Thanks to the arrangement of the clutch switch handle and the tail of the geared motor, the horizontal conveying equipment placed on the ground will also be suitable.
The Decentralised Motor Control Unit represents the combination of EMS Monorail Overhead Conveyors Systems and more advanced automatic control technology, and the whole system will be very suitable for both simple and complex conveying applications:
For the doors in the final assembly workshop, the EMS monorail overhead conveyor system with a single-shaft drive of 0.75 – 1.5 KW is suitable.
The features of these stations are:
The conveying load weight is relatively low
Linear speed is usually 60 – 80 m/min,
Fewer control settings (variable speed, start and stop)
Simple sensors
Low-end communications
The number of devices is large
Also in the assembly workshop, for the assembly assembly and other vehicle stations, it is more suitable to choose a high-power, multi-axis EMS monorail suspension conveyor system, a typical "grab-lift-tilt (rotation)-translation" conveying drive distributed motor control system (Decentralised Motor Control Unit) can control four drive motors in real time to complete the corresponding actions
The features of these stations are:
Heavy load, the maximum required power is 10KW
Precise speed control (low speed control) and position control (position measurement)
Advanced sensors
Two-way communication
The number of devices is smaller
As an international company that has been continuously driving innovation since 1947, Lenze has always focused on the promotion of control and drive products that are adapted to the energy efficiency requirements of future drives.
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