Production line of the eATS2.0 engine – Daimler A.G.
Implementation of comprehensive production line software for the new Mercedes-Benz electric motor, including PLC and KUKA robot programming according to the Powertrain standard.
Client
Daimler A.G. StarAssembly
Scope of cooperation
PLC and KUKA robot software, systems integration
Implementation period
III quarter 2023 – III quarter 2025
Project languages
English
About the project
This project constituted a key investment in the development of Mercedes-Benz production, focusing on the launch of an assembly line for the new electric motor eATS2.0. The objective was to create an advanced, automated production environment meeting the highest standards of quality and performance. Programming work began in the third quarter of 2023, and full commissioning and optimization continue to this day, providing support through the third quarter of 2025.
Scope of work
Our role in the project included comprehensive PLC programming controllers of the Siemens company and programming KUKA robots. All work was carried out in accordance with the Powertrain standard required by the client. The scope also included integration and technical support for a variety of devices and technological systems, which enabled the smooth operation of the entire production line of the new electric motor.
Key elements of the scope
1) Programming Siemens S7-1500 PLC
Development of control software for 25 production stations in accordance with the Daimler Powertrain standard, including communication with the higher-level systems ZellSystem, Prisma and PLA.
2) Programming of KUKA robots
Implementation of robotic applications ensuring precision and efficiency of assembly processes, including in the Powertrain standard.
3) Integration of Cleco screw-in technology
Support in the implementation and calibration of screwdriving systems.
4) Integration of Kistler press-in technology
Implementation and support for press-fit systems, crucial for assembly precision.
5) Vision inspection Sensopart
Integration of vision sensors and DMC scanners to ensure quality control and component identification.
Challenges of the project
The project was characterized by a high level of complexity due to the need to integrate many advanced technologies from different manufacturers within the strict guidelines of the Powertrain standard. Additionally, the international and multi-stage nature of the implementation, spread over time and involving offline and on-site work in two countries, required precise project management and team flexibility. A key aspect was also maintaining the highest quality standards so that the final product – the eATS2.0 electric motor – met the expectations of the premium Mercedes-Benz brand.
Main challenges
Technologies and solutions used in the project
| PLC control | Siemens S7-1500, Siemens Sinumerik HMI (HMI Pro) |
| Robotics | KUKA |
| Screw insertion technology | Cleco |
| Press-in technology | Kistler |
| Visual inspection | Sensopart vision sensors, DMC scanners |
| Weighing technology | Minibea Intec |
| Drives | Siemens Sinamics S120 servo drives, SEW inverters and motors |
| Security | ProfiSafe |
| Communication | ProfiNet |
| Programming environment | TIA Portal |
Effects and benefits for the client
Most important results
• Successful implementation of software for the production line of the new eATS2.0 electric motor for Mercedes-Benz.
• Effective integration and commissioning of 25 advanced production stations.
• Implementation of complex technological systems within the strict Powertrain standard.
• Ensuring stable and efficient operation of the line, supporting the production of high-precision components.
• Smooth coordination of an international team of developers, ensuring the timely completion of the project.
Added value for the Daimler A.G. StarAssembly factory
Thanks to our commitment, the client Daimler A.G. has gained a modern, fully automated production line capable of manufacturing the innovative electric motor eATS2.0. The implementation of the rigorous Powertrain standard guarantees the highest quality, process repeatability and global compatibility, which translates into reduced risk of errors, optimized operating costs and increased overall production efficiency. The project also provides scalability for future production needs, strengthening the client’s position in the electric vehicle market.
Why do clients choose us for projects?
Our experience in programming Siemens S7 controllers and programming KUKA robots, combined with specialized knowledge regarding the Powertrain standard, was crucial to the success of this project. We have a documented ability to manage complex, multi-stage implementations in an international environment, engaging large, distributed teams. Our flexibility in working at various stages of the project – from off-line programming to start-up and on-site optimization – and our comprehensive approach to the integration of diverse technologies, allowed the delivery of a solution meeting the highest quality and technical requirements.
Summary
The implementation of the eATS2.0 engine production line project for Daimler A.G. was a confirmation of our competencies in advanced industrial automation. We successfully integrated a variety of technologies and control systems, delivering to the client a fully functional and efficient solution compliant with global standards. This success underscores our ability to execute strategic projects that contribute to innovation and development in the automotive industry.
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