"Emerson CT Drives Drive Innovation in Mercedes-Benz’s New ‘Sprinter’ Production Line"
At the cutting edge of manufacturing technology, Emerson CT is proud to be a key player in the latest innovations in production line efficiency and quality. Take, for instance, the new "Sprinter" production line at Mercedes-Benz’s Ludwigsfelde factory, where Emerson CT drives are playing a vital role in bringing the future of manufacturing to life.
A Backbone of Efficiency and Precision
The Ludwigsfelde factory, located near Berlin, is a hub of activity, with over 800 AC discs from Emerson CT on site. The reason for this is simple: flexibility and openness. According to Technical Engineer, Mr. Wagner, "Flexible programming and openness are the main reasons we chose the Unidrive SP series. We have a wealth of experience in the Vaneo project on Unidrive SP discs and have found the global characteristics of Unidrive SP to be ideal in many applications."
Streamlining Production with Unidrive SP
The Unidrive SP series from Emerson CT is designed to provide seamless integration with existing systems, allowing for precise control and monitoring. In the case of the "Sprinter" production line, this means that over 600 Emerson CT discs are used in the Vaneo production line, with a further 600 discs installed in other areas, such as body workshop, painting workshop, and mounting chain.
Body Workshop: Where Flexibility is Key
In the body workshop, wrinkles are welded with metallic plates preformed using welding robots and a fully automatic material delivery system. Over 200 SP Unidrive drivers are used in this area, with some operating in open-loop mode, while others operate in closed-loop mode. The automatic welding unit is a prime example of precision control, with two Unidrive SPS connected to a servomotor operating in master-slave mode.
Painting Workshop: Where Ventilation and Exhaust are Key
In the painting workshop, ventilation and exhaust work is carried out by more than 200 driving units assessed at a power up to 110 kW. These units use an open-loop control mode and are connected to the automaton corresponding to an Interbus communication line. 15 – Synchronous engines used in the impregnation electrolysis workstation and its decompression feedback signal is sent to the Unidrive SP control system. In this section, all discs use Profibus communication lines, including the lifting discs controlled in open-loop.
Mounting Chain: The Heart of the Production Line
In the mounting chain, around 400 Unidrive SPS are used, both in open-loop and closed-loop mode. All open-loop transport devices of the high-position conveyor system provide CC power supply to driving/electronics on board via a dedicated bus line that allows Canbus communication. Unidrive SP discs use integrated installation technology to make the control box very compact.
Automated Vehicle Transport Systems: The Power of Induction
Automated vehicle transport systems use the inductance generated by ground drivers to transport components such as the entire Sprinter powertrain (engine, transmission, drive shaft, and axle). Six SP Unidrive inverters (1.1-1.5 kW) are powered by 500 V CC. Two induction engines are used to control movement and steering, two UMD Unimotor type 142 UMD synchronous servomotors are used for lifting and work platforms, and two UMD type 115 Unimotor motors are used for fine adjustment. The control signal is obtained from the access point located on the ground so that the vehicle can move if necessary and move in a given mode. The Canbus/Interbus bridge is located inside the vehicle and communicates with these six inverters via Interbus.
Storage Systems: Precision and Flexibility
Two high-density storage systems use Unidrive SP AC readers for automated access operations. The shell storage device is 198 storage locations distributed on two tracks, and four high-position racks are used as a transfer station between paint and assembly operations. The three axial movements require precise control, adopting a closed-loop control mode with a background signal from the coder. Longitudinal and lifting trees have additional feedback signals, which are supplied by a long-distance laser that measures the entire length of the track and an absolute coder mounted on the lifting shaft rotor, allowing for monitoring and error correction if necessary.
Conclusion
In conclusion, the new "Sprinter" production line at Mercedes-Benz’s Ludwigsfelde factory represents a quantum leap in manufacturing technology, with Emerson CT drives playing a vital role in this revolutionary plant. With their flexibility, openness, and precision, these drives are set to transform the future of manufacturing, and we are proud to be at the forefront of this technology.
