Quality in automation prevails…in the paint-shop and the vehicle identification

In the factory, the body-in-whites come from the body shop and enter the paint shop via the Body Distribution Center (BDC) to apply pre-treatment, ELPO (Electro Deposition) coating, primer, sealing, and painting. After these processes, the car body is sent via the BDC to the general assembly shop for further assembly.

The entire paint shop systems are controlled with SIMATIC S7-416 and S/-317 PLCs. SIMATIC TP 270 touch panels are used as Human Machine Interface (HMI) to operate and monitor the systems, ET 200S as distributed I/O’ s and the RFID system MOBY-I for identification. All devices are tied to the PLC’s via PROFIBUS.

The AVI (Automatic Vehicle Identification) system for SGM’s South Plant controls the areas Body Shop (BS), Body Distribution Center (BDC) and Paint Shop (PS) until the vehicles exit the BDC to the General Assembly (GA). Each AVI is connected via Ethernet to the FLEX/SFE system. AVI request production data from FLEX/SFE or send vehicle information data to FLEX/SFE.

The AVI system is controlled by a Siemens PLC with CPU 416-3DP and CP 443-1 IT communication modules for Ethernet access.

The AVI stations on site consist of: Desk with SIMATIC TP270 touch panel and Symbol hand held barcode scanner, MOBY I read/write unit ASM452/SLG43, ET200S modules for signals and hand held scanner connection, signal lamps for process status, sensors for transporter and body recognition. At some stations there is a barcode scanner to read the barcode label at the vehicle in automatic mode.

Between AVI main cabinet and local stations are two separate PROFIBUS segments. The first one is responsible for the data-exchange between the S7-CPU and the ASM452 modules of the connected stations. The second PROFIBUS segment is responsible for the signal-exchange between the S7-CPU and the ET200S units, barcode scanner units and TP270.

SGM South Plant utilizes Siemens MOBY I tags MDS506 and MDS439E. The tags are mounted at transport medium (skids, hangers).

The AVI system has different types of stations. Some stations request production data from FLEX/SFE at the beginning of a transport cycle. The received data are than written to the data tags at the skid or hanger. Other stations read vehicle information from skid or hanger tag or from the barcode label at the vehicle and send this information to FLEX/SFE. Some stations delete tag information on tag at end of a transport cycle.