Electric motor assembly line – preparation of stators for BMW
Programming and commissioning of six stations of the automatic stator assembly line, ensuring Series 0 production of the new generation of electric motors in accordance with BMW GSC standards.
Client
BMW
Scope of cooperation
PLC programming, vision systems, MES integration, commissioning
Implementation period
2024
Project languages
German, English
About the project
Project carried out for BMW focused on the key stage of stator preparation in the assembly line of the new generation of electric motors. Our goal was the comprehensive commissioning from the programming side of six highly automated stations: three robotic and three process stations, responsible for the precise joining of the stator with the sleeve. The entirety of the work included advanced PLC programming, integration of vision systems, drives and supervisory systems, with the final aim of achieving series 0 production while maintaining rigorous process parameters and optimal cycle time.
Scope of work
Our role in the project included comprehensive support in commissioning key stations of the assembly line. A three-person team of engineers was responsible for offline preparation and online programming of PLC controllers, strictly according to the BMW GSC programming standard. The scope of work also included operation and integration of advanced Keyence vision systems, configuration and programming of SEW drives, precise calibration and programming of the Kistler press, and HMI visualization. A key element was also ensuring integration with BMW’s higher-level systems: IPM, IPSC, IPST, followed by supervision of the start-up of pre-production (series 0).
Key elements of the scope
1) PLC programming compliant with the BMW GSC standard
Implementation of advanced programming for Siemens S7-1518F controllers in the TIA Portal environment, fully adapted to the stringent guidelines of the BMW GSC standard, ensuring high reliability and process optimization.
2) Integration of KUKA robotic stations
Programming and synchronization programming of KUKA robots responsible for precise parts logistics, warehouse management, cooperation with GLT transports, and integration with the component cleaning module before assembly.
3) Start-up of stator assembly process stations
Configuration and programming of processes for joining the stator to the sleeve, including precise feeding of components by robots, control of the sleeve’s induction heating, and programming and calibration of the Kistler press to ensure optimal force and connection accuracy.
4) Vision systems and peripherals
Configuration and integration of Keyence cameras for quality control and precise positioning of components, as well as support and integration of IO-Link peripherals, increasing communication efficiency on the line.
5) Configuration and programming of SEW drives
Implementation and optimization of control of SEW Movidrive MDX61 B drives, key to the smoothness and precision of movements in transport and assembly processes.
Project challenges
The project was characterized by a high level of complexity, resulting from the need to meet the rigorous standards of the automotive industry and the specific requirements of the end customer BMW. Key challenges included the integration of diverse technologies, the need to maintain extreme precision in assembly processes, and optimization for a short production cycle time necessary for efficient serial production.
Main challenges
Technologies and solutions used in the project
| Control | Siemens S7-1518F |
| PLC software | TIA Portal |
| Robotics | KUKA |
| Drives | SEW Movidrive MDX61 B, SEW Movisuite |
| Vision systems | Keyence cameras, Keyence software |
| Pressing technology | Kistler press |
| Peripheries | IO-Link |
| MES Integration | BMW SmartAutomationSuite, IPM, IPSC, IPST |
Effects and benefits for the client
Most important results
• Successful start of production of Series 0 of the new generation of electric motors.
• Maintaining the established, stringent process parameters at all stations of the line.
• Achieving the required production cycle time, crucial for line efficiency.
• High precision of stator assembly with the sleeve, confirmed by quality tests.
• Stable and reliable integration with BMW’s higher-level systems.
Added value for the BMW factory
Thanks to comprehensive automation and precise integration of all components, the client gained a production line capable of manufacturing a new generation of electric motors with the highest quality and repeatability. The shortened cycle time and process optimization contributed to increased efficiency and throughput. Compliance with the rigorous BMW GSC standards guarantees long-term reliability and ease of servicing, building solid foundations for further production development and strengthening the client’s position in the innovative automotive industry.
Why do clients choose us for projects?
Our experience in implementing complex projects in the automotive industry, combined with specialized knowledge in the field of programming Siemens S7-1500 controllers in TIA Portal, was crucial to the success of this project. We have documented skills in integrating a variety of technologies – from KUKA robots, through Keyence vision systems, to SEW drives and Kistler presses – into one coherent and efficient system. Our team of engineers met the challenge of fulfilling the rigorous BMW GSC standards, delivering a solution that not only met but exceeded the client’s expectations in terms of precision, reliability and efficiency.
Summary
The stator assembly line project for BMW was a demanding undertaking that confirmed our comprehensive competencies in implementing advanced industrial automation systems. We successfully met the challenges related to precision, integration and rigorous automotive standards, delivering a solution enabling the production of Series 0 of a new generation of electric motors. This achievement highlights our ability to transform stringent engineering requirements into efficient and reliable production systems, strengthening the client’s position in a dynamically changing industry.
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