Relocation and modernization of assembly machines – Mercedes Arnstadt
The project involved the relocation, structural modification, and recommissioning of assembly machines on an engine block production line.
Client
MDC Power GmbH (Mercedes-Benz) – Arnstadt, Germany
Scope of work
PLC Recommissioning • Robotics • Modification of Conveyor Systems • Integration of Higher-Level Systems
Project duration
2025
Project languages
Polish, German, English,
About the project
The main objective of the project was the relocation and modernization of three key machines. Due to production floor optimization requirements, the machines underwent significant structural modifications: their overall footprint was reduced, internal material handling systems were redesigned, and the component picking process was simplified (including the removal of the robot handling crankshaft bridge blister packs).
Our team was responsible for the programming and technological aspects of recommissioning the processes in the new system configuration.
Scope of work
A team of two PLC programmers was responsible for the complete recommissioning scope, including:
– adaptation of PLC software to the modified mechanical design,
– synchronization of four KUKA robots with the new machine cycles,
– configuration of an extensive drive network (approx. 50 axes),
– commissioning and parameterization of pressing, tightening, and leak testing systems,
– final integration of the machines with the PRISMA higher-level system.
Key scope elements
1) PLC Recommissioning and Modifications
– Logic adaptation: Reprogramming of Siemens S7-300 PLC controllers to support the new, compact machine design.
– Conveyor system modifications: Redesign of part flow logic following the physical downsizing of the machines.
– Process optimization: Removal of software sequences related to the robot handling crankshaft bridge blister packs, resulting in a simplified process flow.
2) Robotics and Drive Control
– Recommissioning and optimization of motion paths for four robots after structural modifications to the production line.
– Configuration and synchronization of an extensive drive system consisting of approximately 50 SINAMICS S120 axes.
3) Advanced Assembly Technologies
– Integration of KISTLER pressing systems and CLECO tightening systems.
– Marking and identification: Operation of BORRIES engraving systems, Siemens DMC scanners, and Zebra label printers.
– Power hydraulics: Control of two hydraulic power units executing the rivet breaking process.
4) Quality Control and Leak Testing
– Commissioning of an engine block leak testing station based on the Bayer DLP system.
– Integration of the NeuroCheck vision system for final engine block validation.
– Operation of two measurement stations verifying crankshaft bridge tolerances.
5) IT Integration (Higher-Level Systems)
– Final connection of the machines to the Mercedes-Benz PRISMA higher-level system for production data reporting and full traceability.
Project challenges
The main challenge of the project was adapting the existing software to the modified mechanical design of the machines. The removal of one robot and changes to the material handling layout required deep modifications to the control logic, while maintaining full compliance with Mercedes-Benz operational standards. An additional challenge was the coordination of hydraulic power units with high-precision pressing processes.
Main challenges
Technologies and solutions used in the project
| PLC Controller | Siemens SIMATIC S7-300 |
| Robotics | KUKA – 4 units |
| Drives | SINAMICS S120 (approx. 50 axes) |
| Press-Fit Systems | KISTLER press-fit systems |
| Tightening Systems | CLECO tightening systems |
| Vision and Identification | NeuroCheck, Siemens DMC scanners |
| Leak Testing | Bayer DLP |
| Engraving | BORRIES |
| Higher-Level System | PRISMA |
Project outcomes and client benefits
Key results
Successful recommissioning of the modified machines at the new location.
Optimization of production line floor space through reduction of machine footprint.
Seamless data exchange with the PRISMA system, ensuring uninterrupted production reporting.
Maintenance of high efficiency in engine block assembly and leak testing processes.
Added value for the MDC Power (Mercedes-Benz)
Elimination of unnecessary robotic operations simplified machine operation and reduced the risk of failures.
Thanks to the team’s experience with Mercedes-Benz standards, the machines were restored to full production readiness in minimal time after physical installation at the new location.
With KISTLER and NeuroCheck systems, every press-fit operation and vision inspection is monitored in real time.
Integration with the PRISMA system provided immediate production visibility within the manufacturer’s global reporting network.
Why Clients choose Us for commissioning projects?
– Experience in modifications (Retrofit / Relocation): We efficiently modify PLC code developed by third-party suppliers, adapting it to new technical and process requirements.
– Expertise in measurement technologies: Advanced handling of KISTLER systems and leak testing technologies.
– Understanding of Mercedes-Benz specifics: Proven experience with the PRISMA system and the group’s communication and reporting standards.
– Effectiveness of small teams: The high efficiency of two dedicated PLC engineers enabled on-time delivery of a complex project scope.
Project summary
The project for MDC Power in Arnstadt confirms our flexibility in delivering relocation and recommissioning projects. Combining expertise in legacy control systems (S7-300) with modern drive technology (S120) and IT systems (PRISMA) enabled the efficient return of modified machines to serial production of Mercedes-Benz engine blocks.
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