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The Magazine for Automation in the Automotive Industry

Volume 7, Number 2, 2008

Door production with Profinet and Profisafe

Just-In-Time
Doors

Highlight of the
Hanover Trade Fair Making of … VW Tiguan
Content move up | 2-2008

Volkswagen AG

W. Geyer

W. Geyer
Siemens will be building the Volkswagen in Wolfsburg has The intermediate buffers in door
VW Tiguan live at the Hanover Trade upgraded a press for bulky body assembly at BMW in Dingolfing,
Fair to demonstrate its value as a parts with automation technology Germany, are given a state-of-the-art
partner for the entire process chain from Siemens automation system based on
Profisafe with Profinet

Page 4 Page 7 Page 12

p Editorial p Assembly Shop

12 Just-In-Time Doors
p Cover BMW, Dingolfing

Hanover Trade Fair

4 The Making of ...
VW Tiguan 18 In Brief
Hanover Trade Fair, Germany
Automotive Lines 19 Dialogue
7 Equipped for Greater Variety
Volkswagen AG, Germany

p Technology
MES
10 Intermediary between
Environments
Simatic IT
Profinet CBA
16 Faster Commissioning
ThyssenKrupp Krause, USA

2 move up | 2-2008
Editorial

Automotive Highlight in Hanover

The Hanover Trade Fair/Interkama 2008 is the undisputed high-

light of the year for the manufacturing industry and the most
important platform for technical innovations. Due to be held
from April 21 to 25, it will be an opportunity for trade visitors to
find out more about all aspects of networked automation solu-
tions, electrical drive technology and innovations in the fields
of mechanical engineering and robotics.

In expert circles, all eyes are currently trained very intently on

Thomas Schott the automotive industry – considered to be one of the trend-
Head of Factory Automation setters for automation systems. So the focus this year at the
Siemens AG Siemens stand in hall 9 will be on car manufacturing.
A visit to our stand offers the chance to experience the entire
manufacturing process of the Volkswagen Tiguan, from start to
finish, through interactive presentations and talks and at actual
reconstructed workstations from the body shop, powertrain and
final assembly. Siemens technology will be ever-present through-
out the entire process chain, with many highlights and innova-
tions to see.
This exhibit offers striking proof that Siemens is a unique partner
for the automotive industry. Through our technology, we help to
maintain the highest of quality standards at every stage of a
product’s lifecycle, thereby ensuring a leading position for our
partners in global competition.
Come to Hanover and see for yourself – I look forward to meeting
you at our stand!

move up | 2-2008 3
Cover H a n o v e r Tr a d e Fa i r

p Hanover Trade Fair, Germany

The Making of … VW Tiguan

With its “Automotive Line” at the Hanover Trade

Fair/Interkama 2008, Siemens will be providing a
live exhibition of the complete process chain in
the production of the VW Tiguan.

T he automotive industry: for all other sectors it

is a pioneer and pacesetter in automation tech-
nology. With its high degree of automation in
the manufacture of vehicles, the automotive industry
is ideally suited to presenting Siemens comprehen-
sive range of products, systems and solutions for
industry.
Siemens along the whole line
In cooperation with VW, Siemens will be exhibiting
production technology at this year’s Hanover Trade
Fair using the manufacture of the new VW Tiguan as
an example. At the heart of the Siemens exhibition
area in hall 9 – dubbed “The Tube” – is a presentation
of the complete lifecycle of VW’s new all-terrain
vehicle. Using virtual and live presentations and real
production demonstrations, Siemens technology
will be used to demonstrate the process steps in the
production line – from ore winning and coil produc-
tion through to the press shop, body shop, paint
shop, powertrain and final assembly.
In live production, the roof for the Tiguan will be
put in place in one station, while the doors will be
welded in another. A notable innovation is color-
coded triangulation (CCT), used to measure clear-
ance and alignment. This patented technology from
Siemens, which has already proven itself in chassis
adjustment, is now capable of measuring complete
bodies-in-white – thereby increasing productivity

4 move up | 2-2008


Bildnachweis ???
Welcome to “The Tube”: the theme of this year‘s stand in hall 9 is automobile production
and improving quality, while providing greater flexi-
bility at the measuring stations.
More innovative assembly
An electric overhead conveyor with the latest-genera-
tion lifting gear will be presented live on the assem-
bly-line stand. As is almost standard now at Siemens,
communication between the conveyor and the sys-
tem controller is wireless using Profinet.
The mechanics of the conveyor system are also
constructed and implemented in their entirety by
Siemens. In the automated assembly of the rear
screen, which will also be shown live, Siemens engi-
neers use the CCT procedure for adjustment, en-
Not just for automotive:
Solutions for
manufacturing industry
Using state-of-the-art vehicle manufacturing
as an example, equipped at every stage
with Siemens technology for automation and
drive technology as well as energy supply,
Siemens demonstrates how it is the ideal
partner when it comes to the industry‘s most
complex requirements.
Away from the automotive field, the Siemens
stand will also be presenting solutions that
provide answers to automation system design
problems in other manufacturing sectors. Key
areas of interest to show visitors include:
3 PLM/Automation Designer
3 Plant Intelligence, MES/Identification
3 Identification/Human Machine Interface,
Thin Client Concepts
3 Power, Power Management/Industrial
Communication
3 Maintenance, Condition Monitoring/Safety
3 Safety/Conveyor Technology
3 Conveyor Technology
3 Manufacturing Equipment
3 Automotive Competence Center/
50 years of Simatic
Volkswagen AG
abling a robot to glue the screens in place with even
greater precision.
There will also be a live demonstration of the fully-
automated union of the powertrain with the bodyshell
using an innovative pallet – once again courtesy of
Siemens. This innovative workpiece holder offers
flexibility and cost benefits over conventional solu-
tions.
One spectacular highlight for visitors to the fair
will be an autonomous navigation system, developed
by Siemens, which will be demonstrated using the
example of a forklift truck. The system uses the hall
ceiling for accurate positioning.
The control system can be fitted in conveyor vehi-
cles. The advantages are that costly induction loops
move up | 2-2008 5
Cover H a n o v e r Tr a d e Fa i r

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Volkswagen AG

The automation system diagram of the body shop
production station at the Hanover trade fair

in the floor are no longer required and path adjust-
ments caused by changes to processes can be easily
taught.
Secure Profinet: Communication backbone
All of the automation components in the individual
production sections are connected wherever possible
via Profisafe on Profinet, thereby complying with
the specification for field bus systems developed by
AIDA – the consortium of leading German vehicle
manufacturers.
In the realm of materials handling, the new Sinamics
G120D-F-PN drive converters, which offer a high de-
gree of protection, and new Flender geared motors
are presented as new high-performance drive sys-
tems and can be examined by the expert public. p
i n fo www.siemens.com/automotive
c o n t ac t tino.hildebrand@siemens.com

6 move up | 2-2008
Cover Automotive Lines

p Volkswagen AG, Germany

Equipped for
Greater Variety
Retrofitting a body panel press at the VW plant in Wolfsburg.

H all 1A, line 60 – this is the address of the

38,000 kilonewton press from Weingarten,
which has been in use since 1988. The ma-
chine is used to produce interior and exterior parts
of the hood and trunk lid for the Golf, Golf Plus,
keep up with increasingly short setup times. At the
same time, controllers and drives are struggling to
achieve the response times required today. There
have also been new requirements in terms of tool
technology and mechanization.
Tiguan, Touran and Caddy models, along with vari-
ous structure parts. Long-term strategy requires retrofitting
Like all machines that are getting on in years, over
time it has become increasingly tough to maintain “The system is part of the press shop’s long-term
the electrical components, obtain spare parts and strategy and is due to be operated until beyond

The Weingarten press produces large

body parts for the VW Golf, Golf Plus,
Tiguan, Touran and Caddy

move up | 2-2008 7
Cover Automotive Lines
Quick and convenient
setup with the new
Mobile Panel 177 PN
2018,” explains Rainer Schierding from the electrical
planning department. “Modifications were no longer
possible as the memory was fully utilized and the cy-
cle times were too high, which meant that a complete
retrofit of the system was an absolute necessity.”
Retrofitting began as long ago as 1997 and initial
concepts were developed to install a Simatic S7 PLC
to replace the Simatic S5 that was previously used.
However, it took ten years for the measures to actu-
ally be implemented.
The retrofitting initiative was led by the internal
electrical planning department, who drew up a con-
cept together with operators and maintenance per-
sonnel that reflected the needs of the staff at the
Wolfsburg press shop in terms of operation and flex-
ibility. In parallel, Siemens developed a technologi-
cal concept for removing and refitting the entire sys-
tem electrics within a maximum timeframe of eight
weeks.
The main control
“The press was originally fitted with electrical com-
panel for the press is
more user-friendly
ponents from various manufacturers,” says Rainer
and easier to Schierding. “However, when it came to the retrofit, we
understand with decided to rely exclusively on Siemens technology.
the new Simatic First, we had excellent past experience with the com-
Panel PC 677
Photos: W. Geyer
8 move up | 2-2008
pany and second, it would give us an integrated and
homogeneous system. This was a big advantage for us,
primarily because we could then be sure that we would
not have any interface problems.”
This certainty was crucial for everyone involved. To
give just one example, in the original machine, the
linear encoders were connected by interfaces but
could never be diagnosed. The aim was to avoid situ-
ations like this. All subscribers on an intelligent bus
network should be able to communicate with one an-
other.
Narrow time frame
The project team at VW was made up of ten people,
as was the Siemens team. However, to ensure the
smooth implementation of the designs, a team of up
to 70 people worked around the clock for the first two
weeks. “We had a very narrow time frame,” recalls
Jens Lorke from the electrical planning department,
who was also involved in the project. “The outage of
a press brings certain problems. We had to pre-pro-
duce parts in advance and store them in a warehouse.
Other production lots that were needed during the
retrofit project had to be assigned to other plants.
Overall, we had a major logistical challenge to over-
come.”
Eight engineers and technicians needed a further
two weeks to implement the modifications carried
out so far for operation. The Siemens technicians
working on site all had extensive experience of
presses and safety technology, which enabled them
to keep to the narrow timeframe.
“Our own project management enabled us to carry
out repairs to the gears and mechanics while the en-
tire electrical system was being replaced,” says Jens
Lorke. “The close cooperation between all parties in-
volved allowed us to complete the entire retrofit in
just eight weeks and we were able to start producing
parts again after six weeks. The investment required
also turned out to be significantly less than origi-
nally anticipated.”
Profisafe on Profinet
The machine now has an integrated automation con-
cept. Where Simatic S5s were previously used, two
Simatic S7-416-Fs with safety technology now mon-
itor the entire system. They are responsible for
all conventional processes in the system and, at the
same time, perform all of the safety functions on
the machine, which represents a major benefit for
the operator as safety processes can be programmed
without additional hardware.
Use of the Profibus and Profinet field bus systems
involves a total of 104 stations. The PLCs enable data
to be exchanged with the distributed I/O via the bus
system. 3610 inputs and 1280 outputs have to be re-
plement the comprehensive solution. All relevant
processes for both production and for the operating
personnel can be configured easily on the user-
friendly platform.
“We are completely satisfied with the planning,
implementation and timings,” confirms Rainer
Schierding. “Now that the system has been success-
fully retrofitted and equipped with state-of-the-art
safety and control technology, it can be used beyond
2018 and our long-term strategy is completely se-
cured. The sister machine in line 90 will also be ret-
rofitted starting in March. The concept drawn up by
the electrical planning department and Siemens has
proven extremely effective. Thanks to the excellent
cooperation between the various partners, it has Automation diagram
of the press retrofit

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corded and processed in the system. This illustrates been very successful and can be adapted for other
the huge scope of the work carried out. similar presses in Wolfsburg and throughout the
The main control panel is now more user-friendly Group.” p
and easier to understand. Three Panel PC 677s with
WinCC flexible 2007 are installed to perform all oper- i n fo www.siemens.com/automotive
ation and monitoring functions. Mobile MP 177 PN c o n t ac t michael.reupke@siemens.com
control panels at different points on the press sup-

move up | 2-2008 9
Te c h n o l o g y MES

PSA Peugeot Citroën

The Simatic IT
Manufacturing
Execution System
p Simatic IT (MES) enables central
user and license

Intermediary
management, as well
as automatic data
browsing, enhancing
Totally Integrated
Automation

Between
Environments
The Manufacturing Execution System Simatic IT
supports vehicle manufacturing with a broad range
of powerful tools.

C omplex data management requirements have

increased the pressure to harmonize compa-
nies’ internal IT landscapes. This is particu-
larly true in the automotive industry. Production
processes must be integrated both horizontally be-
yond individual processes in the production chain,
and vertically between the ERP and control levels.
Planners’ specifications also require production se-
quences to be simplified, made more flexible and
synchronized across plants.
In this respect, Manufacturing Execution Systems
(MES) represent a key element in maximizing opti-
mization potential. The systems allow the entire
supply chain to be kept lean, and enable production

10 move up | 2-2008
processes to be controlled and optimized through
reliable information available in real time at each
site.
In Simatic IT, Siemens offers an MES system that
conforms to the ISA-95 international standard. All
of the functionalities described, such as production
scheduling, dispatching, execution, tracking and
analysis – as well as resource, product definition and
historic data management – are based on the Simatic
IT framework and components.
Synchronized, transparent production
sequences
To synchronize production sequences, Simatic IT
uses production modeler contained in the framework
with which production sequences can be mapped.
Processes are modeled graphically according to pre-
defined rules and the sequences of the entire pro-
duction chain stored. They are then processed using
data managed in the components, such as materials,
employees and systems. Monitoring of the modeled
process sequences enables a high degree of trans-
parency of the entire production sequence and or-
ders currently being processed.
What is special about Simatic IT is that it makes it
possible to display individual, customized produc-
tion sequences while incorporating existing appli-
cations, for example an ERP system, through the use
of a standardized interface. Production and process
changes can be included at any time using graphic
customization of business logic, ensuring invest-
ment security.
Clever libraries
The Simatic IT Industry Libraries allow a high degree
of adaptability. They consist of proven, preconfig-
ured production stages for a host of different engi-
neering tasks. The Simatic IT Libraries include:
• Equipment Management
• Tracking and Tracing
• ERP Integration.
Simatic IT Libraries therefore ensure rapid, secure
and flexible engineering before, during and after
commissioning.
Detailed order management
Production, assembly and test sequences are mapped
in detail in Simatic IT and can be traced at any time.
For status tracking in “real time”, current informa-
tion is recorded directly from the machines/devices,
or is entered manually by workers at manual opera-
tion stations.
For components that are quality-sensitive or which
require documentation, current process parameters
such as torques or dimensions can be recorded and
assigned directly to the respective vehicle. Simatic IT
Reporting enables all orders to be filtered and ana-
lyzed in accordance with these parameters.
Uniform electronic information flow
Simatic IT manages all order-related material move-
ments in production, as well as material provision to
workstations and intermediate products and buffers.
Using Radio Frequency Identification (RFID), mate-
rial movements and additions at goods entry or in
the relevant assembly area are detected automati-
cally or via a hand-held reader. Depending on the
rules in Simatic IT, quality tasks and automatic noti-
fications can be activated, for example.
Simatic IT manages materials along with their
properties, as well as their complete tracing, for ex-
ample when which material was installed in which
component.
Once an order has been approved, it is possible to
use the parts list to find out whether the required
parts and consumables are present at each station. If
not, an appropriate material request can be placed
automatically and an order activated via the ERP
system.
Transparent production processes
An extremely high level of transparency is indispens-
able for process analysis and optimization – and
ultimately also for high levels of availability and
productivity.
This includes the recording of all relevant process
parameters, as well as machine and quality data.
Simatic IT records these with relation to both pro-
cesses and products and enables any role-specific
evaluation (from the shift manager to the plant man-
ager). The data is permanently available for quality
and process optimization, as well as for analysis and
validation.
Compatible with the TIA environment
As part of the Totally Integrated Automation environ-
ment, Simatic IT is based on consistent standardiza-
tion of interfaces. This offers compatibility with all
Siemens components and solutions for automation
systems used in vehicle production, such as Simatic
controllers and Sinumerik-NC control systems, as
well as SCADA and engineering systems.
Use of the same engineering platform and stan-
dard license management is advantageous – as is
central user management. The application of OPC
standards means that Simatic IT is also able to
guarantee full integration of products from other
providers. p
i n fo www.siemens.com/mes-simaticit
c o n t ac t raffaello.lepratti@siemens.com
move up | 2-2008 11
Assembly Shop

From painted body to fully

assembled car – thanks to
innovative control technology,
the flexible store at the Dingolfing
BMW plant can handle all doors
from the assembly line for mid-
range and luxury automobiles
and requires minimal floor space

12 move up | 2-2008
 p BMW, Dingolfing
Just-In-Time Doors
Profinet with Profisafe and distributed control technology minimize
space requirements and increase the flexibility of an assembly line.
A t its Dingolfing plant in Germany, BMW pro-
duces cars for its 5, 6 and 7 Series. As is stan-
dard procedure in assembly, the doors are
removed from the vehicle so that workers can fit the
necessary components inside more easily. The doors
then need to be re-fitted to the vehicle in parallel to
the assembly process. Providing the right doors for
each vehicle on the assembly line at the correct time
poses a logistical challenge.
Minimizing space requirements
First of all, the doors need to be marked, stored, fit-
ted with all supplementary components, stored again
and then returned to the assembly line. The previous
logistical solution with sequential storage before and
after door assembly required an excessive amount of
floor space.
As a result, BMW decided to work with control
specialists from Staudinger GmbH in Loiching and
mechatronics experts from Rofa Rosenheimer
Förderanlagen GmbH to develop a totally new con-
cept. A comprehensive range of components from
the Siemens control system provide the necessary
Photos: W. Geyer
flexibility and safety in the new processes.
Electric overhead conveyor for flexible store
After removal, doors are carried up to the storage
level of the flexible store via elevators. From here,
they are conveyed to door assembly on special as-
sembly racks and back to the vehicle assembly line
on a vertical elevator. In the flexible store, a pair of
doors is loaded onto suspension racks on an over-
head conveyor, which stores the doors in an exten-
sive network of classification areas and transport
routes on the upper floor of the assembly shop. A key
feature is that unassembled and fully assembled
doors can both be held randomly in the same store.
As a result, the flexible store only requires a minimal
amount of floor space.
Random temporary storage –
reliable control
The crucial factor behind the success of this innova-
tive storage concept is the sophisticated control tech-
nology, which features a number of components
from Siemens. Each load carrier on the electric over-
head conveyor has an RFID chip. Moby type read/
write stations assign each of these storage locations
move up | 2-2008 13
Assembly Shop

Photos: W. Geyer
a comprehensive individual data record to uniquely The robot station for transferring the doors from
identify the doors. The advantage of Moby type RFID the flexible store racks to the assembly racks is also
technology is that the data can be read and updated fully integrated. Special Simatic ET 200R interface
at any point when the doors pass a read/write station. modules protected against strong electromagnetic
In addition, once the storage locations have been fields are used here. A flexible sorting store is also
fitted on the suspension racks they can be reset and part of the automation system networked using
rewritten any number of times. This provides the re- Profinet and Profibus. The doors pass through this
quired flexibility to load the racks on the conveyor after assembly to allow a response to any changes in
with doors in any order. Mechanically, the racks can the vehicle assembly sequence.
be adjusted quickly and easily for different door
models. In conjunction with a total of 122 read/write Flexible design without switch cabinets
stations, the racks are directed through the flexible
store in different directions and on changing routes Because of their IP65 protection class, the Siemens
using points in the electric conveyor rails. The read/ automation components for distributed control of
write units and the points are controlled and moni- the system have a key advantage: They provide the
tored decentrally by distributors. All 76 of the sta- required degree of flexibility for cost-effective ex-
tions have terminals, some of them Simatic PC 677, pansion of the automation network. The components
for reading and editing system parameters and sta-
tuses. Simatic ET 200pro interface modules integrate
the read/write units for the RFID store and the motor
controllers for the point drives into the data net-
work.
The Safety Integrated concept is particularly im-
portant for communication via Profinet. In conjunc-
tion with Simatic S7 programmable logic controllers,
it ensures maximum operating safety in the system.
Sensors, drives and controllers are diagnosed and
evaluated for any malfunction. The data is transmit-
ted from the distributors to the subordinate Simatic
S7 PLCs via Profinet. Siemens has implemented an
open system, which allows Safety Integrated to be
combined with any other standard components as re-
quired. The two loading and unloading stations and
the conveyors at the vertical elevators are integrated Simatic ET 200pro with power modules allows
into this concept for controlling and monitoring the decentralized and flexible automation solutions
flexible store. to be set up

14 move up | 2-2008
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The automation network for the flexible store uses Profinet and Profisafe in conjunction with a Simatic S7
programmable logic controller as the warehouse management computer, along with ET 200pro interface
modules and motor actuators with IP65 protection

can be positioned on standard mounting rails with-
out a switch cabinet. Unique connectors and cou-
plings connect the modules to the power and data
network. This minimizes the assembly work, reduces
costs and allows rapid, flexible installation. The same
applies to the modular construction, particularly of
the input/output modules from the ET 200 family.
The Simatic ET 200pro has proved to be particularly
flexible. It enables bus, electronic, connection and
load modules and motor starters to be combined
into flexible, compact units for each of the individual
functions required.
Controllers networked using Profinet
with Safety Integrated
The routes taken by the racks through the flexible
store are controlled and monitored by distributed
stations with a total of seven Simatic S7-416 PLCs,
networked via Industrial Ethernet. For the first time
in a system of this size, a Simatic S7-417 is being
used as the warehouse management controller. The
subordinate Simatic S7-416 PLCs act as data collec-
tors. They are also used for data storage and to re-
generate data if there is a temporary failure of the
warehouse management controller.
With this pioneering system concept for a compact
flexible store, Siemens and its regional system part-
ners, Staudinger GmbH in this case, is once again dem-
onstrating its leading position when it comes to com-
plex automation solutions. Sophisticated components
from the Totally Integrated Automation system also
contribute to its flexible operation and outstanding
safety. p
i n fo www.siemens.com/automotive
c o n t ac t schulzudo@siemens.com

move up | 2-2008 15
Te c h n o l o g y Profinet CBA
p ThyssenKrupp Krause, USA
Faster
Commissioning
A new transmission line for a US automotive
manufacturer was up and running in no time
thanks to Profinet and Component-Based
Automation (CBA).
T hyssenKrupp Krause, an assembly line special-
ist based in the US city of Auburn Hills, Michi-
gan, has developed and installed a new auto-
matic transmission line for a US car manufacturer.
The line comprises 60 stations, each with its own
automation system, as well as ten zone controllers
for the assembly line sections. ThyssenKrupp Krause
found Profinet, the industrial Ethernet standard for
automation solutions, to be the perfect choice to
manage the data and signal exchange between all
stations and the zone controllers. The project also
utilized Simatic S7-300 PLCs with Profinet interfaces
and Scalance switches.
Optimized communication
The cost and duration of commissioning depends on
how quickly and correctly the individual stations of a
plant can be connected to form an efficient, interact-
ing line. In addition, it is common for assembly lines
in the automotive industry to require the integration
of other automation components such as camera sys-
tems, RFID or automatic tightening stations. Profinet
offers an advantage here with the ability to transfer
non-time critical data asynchronously alongside
automation-specific, real-time data and signal ex-
change. Each assembly station was modeled as a
self-contained component with a logic interface. This
approach enables all units at the communication
level to behave uniformly. The component-based
16 move up | 2-2008
A US car manufacturer commissioned a new transmission
line much quicker than usual thanks to Profinet
Profinet approach also makes it possible to simplify
machine function engineering by replacing pro-
gramming with graphical configuring. The associ-
ated standardization of the interfaces and the ability
to duplicate data and signal exchange to neighboring
stations in the same engineering environment mean
that each machine can be commissioned in advance
and autonomously.
Extensive standardization
Thanks to the defined component interface to the
other items on the plant floor, the engineering of a
machine function now needs far fewer cross-links
to other machines than in the past. The mechanical
engineering, control technology and user programs
of a machine or intelligent machine module are com-
bined using their standardized component descrip-
tion. A machine function “encapsulated” in this way
can now not only be developed and maintained inde-
pendently of other stations in the line; it can also be
replaced with a completely different solution – with-
out any effect on the communication relationships in
the higher-level production line.
The decisive advantage for Profinet and CBA is the
ease and simplicity in creating a formal description
of the signal and data interface of a machine or ma-
chine module. In terms of the communication rela-
tionships that control the interaction of the individ-
ual production stations, a CBA component describes
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Siemens AG

The individual automation stations are exposed

as a Profinet component

the machine in full. It is presented as an easy-to-

use library element for all other engineering steps
and provides a manufacturer-independent, machine-
readable and self-documenting interface. In practice,
the abstraction function performed by CBA permits
a high degree of standardization.
Plant view in the
SIMATIC iMap
Graphical configuration rather than configuration editor
programming
The definition of each component and its communi- faces between all parties concerned and on-site com-
cations interface and the configuration of communi- missioning of the assembly line.
cation between components is fully integrated in the The typical commissioning risks associated with
Simatic engineering environment. All automated, in- programming communication between machines
dividual tasks on a plant floor can be combined with and stations have been reduced using Profinet. Com-
standardized data and signal relationships to form a munication within the assembly line was established
production chain. Graphical configuration using a once the PLCs on the Profinet backbone of the assem-
drag-and-drop method replaces detailed knowledge bly line were deactivated and the station addresses
of communication tasks. The engineering system adjusted. The developers maintain that using Profinet
automatically generates routines that perform the was a considerable boost when it came to meeting
communication over the available network and loads the client’s ambitious deadline. p
them as configuration information into the auto-
mation devices. This makes the devices ready for
communication.
Using the experience gained by ThyssenKrupp
Krause from the transmission line project, Profinet
and CBA have continued to improve development re-
liability and accelerate engineering and commission- i n fo www.siemens.com/profinet
ing. Particularly important in the critical phases of c o n t ac t dirk.joschko@siemens.com
this complex project: the initial mapping of inter-

move up | 2-2008 17
 In Brief

Kaluga Volkswagen Plant, Russia

Infrastructure Success

In Kaluga, 150 kilometers southwest of

Moscow, Volkswagen is currently build-
ing a plant with body shop, paintshop and
final assembly. Up to 150,000 different
VW and Skoda models are expected to roll
off the production lines from 2009.
As the general contractor, Siemens will
be supplying the entire electrical infra-
structure for the plant. This will include
power supply and distribution from sub-
station to socket.
Siemens will supply all of the low-volt-
age distribution boards, Sivacon bus bars,

as well as a monitoring system for opera-
tional data.
The brief also includes design moni-
toring for the grounding, installation of
equipotential bonding, as well as pro-
tection of the plant against lightning.
Siemens will also carry out the installa-
tion and commissioning of the power sup-
ply by the diesel generators and illumina-
tion of all buildings – including general,
Volkswagen AG
Over 150,000 vehicles are set to roll off the production lines
in the new buildings at the Kaluga plant beginning in 2009
escape route and emergency lighting. The then be installed and operated without
work is expected to be completed on any hitches. p
schedule by May 2008 so that the process
technologies of the individual plants can www.siemens.com/automotive

Tata Motors India

New Segment – New Drive

Tata Motors Limited, the biggest car man-
ufacturer in India, has expanded its ca-
pacity at the Udham Singh Nagar site in
the state of Uttarakhand with a second
body shop and will be employing Siemens
automation and drive technology for the
first time.
In the southern Himalayas, Tata Motors
will, from March 2008, be producing the
new ACE mini-truck – a small transport
vehicle custom-made to cater to local
needs. Under the overall control of gen-
eral contractor ThyssenKrupp Drauz Not-
helfer, Siemens has equipped the body
shop’s entire materials handling technol-
ogy with the latest Sinamics G120D-series
converters designed for local use. Just
under 130 of these IP65 protection class
converters are installed directly on the
conveyor belts, ensuring problem-free
transportation of the body shells on skids
through the halls. Siemens fail-safe con-
trollers (S7-300F) and input/output mod-
ules ensure compliance with occupational
health and safety requirements. p
www.siemens.com/drives

Small, light and all-terrain: the

Tata Motors

Tata ACE mini-truck is perfectly

suited to meet needs in India

18 move up | 2-2008
Dialogue

infos library
Further information about our concepts, solutions and
systems in the automotive industry can be found at our
Automotive Internet portal. There you will also find your
personal Siemens contact.

www.siemens.com/automotive
If you want to know more about Siemens automation and
drives technology, log on to our online information hub in
the Internet:

www.siemens.de/automation/newscenter

Pigan, Raimond; Metter, Mark

online Automation with PROFINET

Under the address
www.siemens.com/read-moveup
you can download the latest issue as a PDF file. The elec-
tronic archive also gives you access to all previously
published issues.
Furthermore, you will find a form in which you can write
your suggestions and comments on the issue and the in-
dividual articles. Your feedback will be included in the next
issue of move up. Finally, you can also inform us of any
changes to your subscription.
Profinet is the first integrated Industrial Ethernet
standard for automation and uses the advantages of
Ethernet and TCP/IP for open communication from
the company management level through to process
level. The book describes the network technology
used with active network components; access and
connection technology and assembly guidelines
specifically adapted for industrial use.
The second edition will be released in July this year.
Automation with PROFINET; second revised
and extended edition, 2008, appr. 475 pages,
271 figures, hardback, ISBN 978-3-89578-294-7

move up 2-2008
Publisher Concept © 2008 by Siemens Aktiengesellschaft Munich and Berlin.
Siemens Aktiengesellschaft, Christian Leifels
Gleiwitzer Str. 555, 90475 Nuremberg, All rights reserved by the publisher. This edition was printed
Publishing House on environmentally friendly chlorine-free paper.
Germany
Publicis KommunikationsAgentur GmbH, GWA
Division Drive Technologies
Corporate Publishing The following products are registered
CEO Klaus Helmrich
P. O. Box 32 40, 91050 Erlangen trademarks of Siemens AG:
Division Industry Automation Telephone +49 (0) 9131 9192-501 BERO, ET 200, MICROMASTER, MOBY, MP177, S7-300, S7-400,
CEO Anton S. Huber Telefax +49 (0) 9131 9192-594 SCALANCE, SIMATIC, SIMATIC HMI, SIMATIC iMap, SIMATIC IT,
SIMATIC IT Framework, SIMATIC Multi Panel, SIMATIC Panel PC,
publishing-magazines@publicis-erlangen.de SINAMICS, SINUMERIK, SIRIUS, SIVACON, STEP 7, TOTALLY
Editorial Responsibility in Accordance
with the German Press Law INTEGRATED AUTOMATION, WinCC
Editor: Christoph Manegold
Peter Miodek Layout: Jürgen Streitenberger
Copy editor: Daisy Kraus If trademarks, technical solutions or similar are not included
Responsible for Technical Contents Jobnumber: 002800 12222 in the list, it does not imply that they are not protected.
Thomas Schott DTP: der Döss für Kommunikation, Nuremberg
Printed by: Wünsch, Neumarkt The information provided in this magazine contains merely
general descriptions or characteristics of performance which
In-house editorial staff
move up is published quarterly in case of actual use do not always apply as described or which
Kathrin Brämer
may change as a result of further development of the products.
E-mail: kathrin.braemer@siemens.com
Circulation: 6,500 An obligation to provide the respective characteristics shall
Jürgen Nolde
ISSN 1610-7802 (Print) only exist if expressly agreed in the terms of contract.
E-mail: juergen.nolde@siemens.com

IWI: TMOV
Order No.: E20001-M4208-B100-X-7600

move up | 2-2008 19
There are many ways to increase
the productivity of your company.

Here is the short cut.

Our innovations combine virtual product planning with state-of-the-art factory automation
for more flexibility in production. This also allows individual customer wishes to be realized
cost efficiently. You are also welcome to visit us in hall 9 booth A72.

Answers for industry.