Electromagnetic Coil Assembly Line – Hilite
The project involved the commissioning of an assembly line for an electromagnetic coil used in the camshaft module of the VW MDB EVO engine.
Client
Hilite International – Czech production facility
Scope of work
PLC programming
Project duration
Q2–Q3 2021
Project languages
Polish, English, Czech
About the project
The project involved the commissioning and optimization of an assembly line for an electromagnetic coil used in the camshaft modules of the VW MDB EVO engine. The work had the nature of a re-commissioning process, as the entire line had been transported from China and required complete reassembly, verification, and configuration.
Scope of work
Our task was to provide comprehensive industrial automation support during the re-commissioning of the line. This included both PLC/software engineering activities and close on-site collaboration with the assembly teams — electricians and mechanical technicians.
Key scope elements
1) PLC programming and control diagnostics
– execution of a complete I/O check,
– signal mapping in the Siemens 1517F controller,
– error analysis, diagnostics, and implementation of program code fixes,
– configuration of communication with the AIS supervisory system.
2) Support for mechanical and commissioning teams
– collaboration with mechanical and electrical teams during equipment setup,
– testing in manual modes,
– configuration of Siemens V90 servo drives and Festo valve islands.
3) Process optimization
-testing of automatic sequences,
– improving control logic to increase cycle stability,
– eliminating issues resulting from instability in component assembly.
4) Integration with supervisory systems
– verification of data transmitted to the AIS system,
– communication testing under production conditions.
Project challenges
The commissioning of this particular line imposed high demands on our team due to the very small, precision components used in the assembly process. Any misalignment could lead directly to assembly errors.
Main challenges
This phase required extensive iterative testing and advanced error analysis within the PLC software.
Technologies and solutions used in the project
| PLC controller | Siemens PLC 1517F |
| Programming and HMI | TIA Portal V15, WinCC, mobile operator panels |
| Drives | Siemens V90 servo drives, Lenze rotary tables |
| Pneumatics | Festo valve islands |
| Process technology | Kistler press-fit system |
| Identification / quality control | Keyence laser for DMC code marking |
| Supervisory system | AIS |
Project outcomes and client benefits
Thanks to the implemented improvements and the comprehensive reconfiguration of the assembly line, the client achieved:
Key results
Fully stable and repeatable production of electromagnetic coils.
Minimization of assembly errors caused by motion desynchronization.
Complete and reliable communication with the AIS system.
Optimization of the automatic sequence, resulting in a shorter and more stable cycle time.
Increased process reliability despite working with very small and precise components.
Added value for the Hilite factory
Reduced time required to bring the line into full serial production.
Lower production downtime costs.
Scalability of the process for future projects.
Comprehensive documentation and modernization recommendations.
Why Clients choose Us for commissioning projects?
– extensive experience in deploying and optimizing industrial production lines,
– strong expertise in Siemens PLC programming (S7-1500, S7-1200, Safety),
– deep knowledge of precision assembly technologies and drive synchronization,
– proven ability to operate within international project environments,
– capability to support additional areas such as industrial robot programming, Eplan design, and control cabinet manufacturing.
Project Summary
The project for Hilite in Ostrava is an example of an effective combination of programming expertise, technical automation knowledge, and the ability to work with precision assembly processes. Thanks to comprehensive support, the production line was successfully commissioned and brought to full, stable performance.
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