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Case studyPLC programming
MB
Marko Bratković··1 min read

PLC programming of production lines for Valeo Siemens in Veszprém

As a subcontractor to SAR Electronic, we programmed and commissioned four high-tech lines for the production of electric vehicle components for Valeo Siemens in Veszprém.

Valeo Siemens logo
Production line for Valeo Siemens in Veszprém
Client
Valeo Siemens
Location
Veszprém, Hungary
Industry
Automotive industry (EV components)
Platform
Siemens S7-1517F / S7-1512SP, TIA v14
01 - Project context

PLC programming of four lines for Valeo Siemens in Veszprém

As a subcontractor, ENSO worked with SAR Electronic on a project integrating production lines for electric vehicle components for Valeo Siemens in Veszprém. The engagement covered the programming and commissioning of four high-tech production lines, synchronising the central control system with a number of specialised units within the process.

Every workpiece carrier (Werkstückträger) on the line carried an RFID tag holding the part data, which was sent to the higher-level system at the end of the line - the basis for traceability throughout the process.

02 - Technical scope

Master-slave architecture with a Siemens S7-1517F and integration of multi-vendor equipment

The control structure is a master-slave architecture - a central Siemens S7-1517F processor connected to distributed intelligence on the stations with S7-1512SP controllers (ET200 I/O), programmed in TIA Portal v14.

The lines integrated a wide range of process operations: plasma cleaning, robotic pick-and-place, automatic screwdriving, pressing, adhesive application and optical inspection. A key part of the work was programming the sequences and the handshake communication between the PLC and equipment from different manufacturers.

Integration of multi-vendor equipment

Epson SCARA robots with Weber screwdrivers, a Kistler press for the parts, KUKA robots for adhesive application and Festo pneumatics - all synchronised through a single PLC logic.

RFID traceability and vision systems

Cameras and QR code readers integrated for traceability and quality control, with RFID data written on the workpiece carrier that follows the part through the whole line.

Cycle time optimisation

By analysing communication delays and parallelising process steps, we ensured maximum line throughput while meeting the quality standards of Mercedes and VW.

03 - Scope of work

Four lines commissioned to Mercedes and VW standards

4
high-tech lines commissioned in Veszprém
S7-1517F / S7-1512SP
master-slave control architecture
TIA v14
programming platform
Epson, Kistler, KUKA, Festo
integrated multi-vendor equipment

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