AGV – automation of transport on the production line – Man Niepołomice
Implementation of a comprehensive Automated Guided Vehicles (AGV) system replacing traditional transport on key production lines in a truck manufacturing plant.
Client
Man Niepołomice
Scope of cooperation
AGV system implementation, PLC programming, technical support
Implementation period
Multi-stage project
Project languages
Polish, English, German
About the project
The project aimed to replace classic internal transport on the production line at the Man Niepołomice plant with a modern AGV system. The aim was to increase efficiency, precision and safety of assembly processes in the production of heavy trucks, aligning with the trend of AGV integration. Collaboration with a renowned German manufacturer of innovative transport solutions provided access to the latest technologies in the industry.
Scope of work
Our company was responsible for the comprehensive commissioning of the AGV system on two key sections of the production line. The scope of work included programming PLC controllers, including programming of Siemens S7-1500 controllers, the configuration of HMI panels, the integration of communication systems, and technical support in the commissioning and servicing of vehicles. We also participated in the initial start-up in Germany, verifying the readiness of AGV vehicles prior to their transport to Poland.
Key elements of the scope
1) Start-up of key production lines
Implementation of an AGV system on the cockpit subassembly line and on the main cabin assembly line with full equipment.
2) Integration of AGV vehicles and higher-level systems
Commissioning of nearly 90 AGVs and three supervisory systems based on Siemens S7-1500 controllers with HMI Comfort Panels, controlling the entire process.
3) Ensuring operational flexibility
The implementation of functions enabling operators to make real-time modifications to parameters, such as speeds, stop locations, working tool positions, or height, which provided full operational flexibility.
4) Advanced communication and navigation
Implementation of Siemens Scalance Wi‑Fi communication and a navigation system based on transponders, magnetic lines and feedback from encoders for precise positioning.
5) Specialized AGV functionalities
Vehicles on the cockpit line with automatically adjusting mounts and vehicles on the main line with hydraulic systems for adjusting cabin height, optimizing work ergonomics.
Project challenges
The AGV system implementation project at Man Niepołomice was characterized by technological and logistical complexity. Key challenges included the integration of multiple subsystems, ensuring high precision in positioning and synchronization of nearly 90 AGV vehicles across extensive production lines, and maintaining operational continuity in the dynamic factory environment.
Main challenges
Technologies and solutions used in the project
| Supervisory control | Siemens S7-1500 (3 controllers) |
| Operator interface | Siemens TP1200 Comfort Panel (3 panels), HMI on each AGV (87 panels) |
| AGV control | ET200SP modules with built-in PLC controller (87 modules) |
| Network communication | Siemens Scalance (WiFi) |
| Safety | SICK safety scanners, safety curtains |
| Drives | Servo drives of proprietary design, ELMO controllers |
| Movement systems | Hydraulic systems |
| Power/Charging | Inverters for inductive power supply, Frequency converters for AGV charging |
| Positioning/Identification | Magnetic antennas, RFID antennas, Transponders, Encoders |
| Superordinate system | Proprietary MES system |
Effects and benefits for the client
The most important results
• Significant increase in the efficiency of internal transport through process automation.
• Improvement of operators’ work ergonomics thanks to automatically adjusting mountings and adjustable cabin height.
• Increased safety on the production line through the use of scanners and safety curtains.
• Increase in production flexibility through the ability to make ongoing modifications to AGV operating parameters.
• Minimizing downtime and maintenance costs thanks to a reliable inductive charging system.
• Precise monitoring and control of each AGV vehicle, which resulted in higher assembly quality.
• Integration of production data with the MES system for better management and analysis of processes.
Added value for the Man Niepołomice factory
The implementation of the AGV system at Man Niepołomice delivered long-term benefits to the client in the form of optimized operating costs associated with internal transport and a significant increase in production line throughput. Full flexibility and the system’s ability to adapt to changing production needs ensure scalability and readiness for future challenges, enhancing the plant’s competitiveness in the market.
Why do clients choose us for projects?
Our experience in advanced industrial automation projects, in particular in the area of PLC programming For internal transport systems, it was crucial to the success of this project. The ability to comprehensively manage the project – from verification in Germany to commissioning and on-site support – and proficiency in integrating complex technologies (such as the Siemens S7-1500, Scalance communication, and advanced AGV navigation systems) allowed us to meet the high requirements of the client Man Niepołomice.
Summary
The project to implement an AGV system at Man Niepołomice is an example of effective large-scale internal transport automation that has significantly improved production efficiency, ergonomics, and safety. Thanks to the use of advanced technologies and precise programming, a flexible and reliable solution was created that serves as a model for modern assembly lines in the automotive industry.
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