HEAT2 Electric Motors Assembly Line – BMW
Comprehensive commissioning of automated and manual stations for an advanced electric motor assembly line in the electromobility sector.
Client
BMW
Scope of cooperation
PLC Programming, Robotics, Commissioning, Systems Integration
Period of implementation
2021
Project languages
English, German
About the project
In mid-2021, the company Amister undertook the implementation of the HEAT2 project. The goal was to launch an advanced line for the final assembly of electric motors for the electromobility and automotive sector. This project, constituting a response to the growing demand for precise and efficient production processes, involved the integration of both automatic and manual stations, which ensured the optimization of the entire production process. Our activities fit into the trend of increasing robotization of production, crucial for maintaining competitiveness in a rapidly changing industry.
Scope of work
Our key task was the comprehensive commissioning of both automated and manual stations on the final assembly line of electric motors. The Amister team, consisting of three experienced PLC programmers and two robotics specialists, was responsible for the integration and configuration of nine robots deployed across six workstations. The project execution encompassed the full cycle of engineering works, from the functional testing phase (FAT/SAT) to final commissioning and optimization. Our competencies in programming PLC controllers Enabled effective management of complex processes on the line.
Key elements of the scope
1) Installation of the motor inverter
Precise tightening of the inverter, a key component of the electric motor.
2) Sealing and preliminary assembly of the cover
Automatic application of a sealant to the upper cover, visual verification of the application, and preliminary fastening of the cover to the engine.
3) Final assembly of the top cover
Final tightening of the cover while maintaining the required force and sequence.
4) Tightness test
Comprehensive leak test of the entire engine, guaranteeing its trouble-free operation.
5) Mounting and test of the membrane
Automatic installation of a dustproof membrane and verification of its tightness.
Project challenges
The HEAT2 electric motor assembly project was characterized by a high degree of complexity and stringent quality requirements typical of the automotive industry. The main challenges included the integration of diverse systems and devices from multiple manufacturers, the necessity of ensuring extreme precision in assembly and testing processes, and the optimization of the production cycle to meet the planned line takt time.
Main challenges
Technologies and solutions used in the project
| PLC controllers | Siemens (S7, TIA Portal) |
| Industrial robots | KUKA |
| Screw fastening systems and feeders | Weber |
| Dosing systems | Dobotech |
| Vision systems | Visiontool |
| Tightness testers | Zeltwagner |
Effects and benefits for the client
The most important results
• Significant reduction in the assembly cycle time of electric motors thanks to effective automation of key processes.
• Increased precision and repeatability of assembly, which translates into higher quality of the final product and reduction of defects.
• Successful commissioning of nine robots at six stations, which optimized assembly and testing processes.
• Effective integration of systems from different manufacturers, ensuring the smooth operation of the entire production line.
• Fulfillment of the rigorous quality and technical requirements of the automotive industry, confirmed by positive test results.
Added value for the factory
The implementation of the HEAT2 assembly line provided the client with long-term benefits, including increased production efficiency, reduced operating costs through the reduction of manual labor and the elimination of errors, as well as an improvement in the overall quality of the electric motors produced. The scalability of the solution and its compliance with the highest industry standards strengthened the client’s position in the dynamic electromobility market.
Why do clients choose us for projects?
Our experience and specialist knowledge proved to be crucial in such a complex project. The Amister team, composed of certified PLC programmers and robotics engineers, possessed the necessary competencies to integrate advanced systems. The TMO 3.0 certificates held by our engineers enabled the smooth fulfillment of the end customer’s requirements, ensuring compliance with industry standards. Flexibility in adapting to diverse technologies and manufacturers such as Weber, Dobotech, Visiontool and Zeltwagner, as well as advanced skills in programming of KUKA robots, guaranteed effective and timely delivery of the project.
Summary
The HEAT2 electric motor assembly line project was an example of successful cooperation and a confirmation of Amister’s competencies in automating assembly processes for the demanding automotive industry. Thanks to precise PLC programming, advanced robotics and effective system integration, we achieved all the set goals, delivering to the client an efficient and reliable production solution that meets the highest quality and operational standards.
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