Volkswagen AG, Germany
Easy to use I/O solutions for car body shop and final assembly

Application

For many years now, Volkswagen AG has been using an Interbus-based communication solution for economical and quick transmission of the data generated during production. The existing production system was replaced for manufacturing the new panel van model T5.

In the new system, the conveying technology in the car body shop and during the final assembly was to be controlled using IP20 and IP67 components in the new system. Furthermore, the Siemens S7 control systems had to be connected to a higher-level Ethernet network via Interbus.

Solution

VW AG was impressed by the high modularity and easy assembly of the inline installation system. More than 1500 inline stations were therefore installed in standard terminal boxes in the car body shop. Since every terminal box has a transparent cover, the maintenance engineer can immediately identify the status of the bus and the I/O levels from the LED.

The simple local diagnostics greatly facilitates troubleshooting in the case of an error. During the final assembly, use of terminal boxes was impossible due to space limitations. As a result, Phoenix Contact fulfilled all requirements for direct application in the field with the rugged product range Rugged Line and the reliable I/O system with IP67 degree of protection.

IP400 motor starters control the drives in the extensive conveying systems around the panel assembly. Fiber optics bus cables which stand out on account of their high EMC resistance, simple installation and preventive Interbus diagnostics, are used for communication between all I/O modules and control systems as well as robots.

The CMD automation software and the DIAG+ diagnostics tool are responsible for planning, designing, startup, monitoring and diagnostics.

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