AFT Schopfheim receives order for restructuring of EMS-Systems for components.
Because of some automation measurements at door assembly, rebuilding and expansion of EMS-Systems are required. The doors are transported through the assembly lines via EMS vehicles with height-adjustable hangers. In addition, there are extensive changes and expansions of the EMS-Systems for the transport and assembly of floor trim panel and front ends.
Planning and assembly of the works presented a special challenge at “Gläserne Manufaktur” in Dresden, Germany.
For the production of the new e-Golf several conversions in the VW plant “Gläserne Manufaktur” in Dresden, Germany were necessary.
At the beginning of January first pre-production models will be produced, in April the first customer vehicles will be finished. After the conversion, which costs according VW about 20 millions €, it will be possible to produce different models because of the flexible assembly lines.
AFT is significantly involved in these conversions. The oval circulating production lines covered with wooden parquet, where the luxury limousine Phaeton was assembled, are retrofitted by AFT Bautzen. For this purpose, underneath the assembly line a new rail system is installed, a corresponding new roller concept is used and the entire system is modernized in many other areas and thus fits the new requirements.
For the first time, Mercedes-Benz has planned to automate the transportation of components of carcass at the commercial vehicle plant in Ludwigsfelde, Germany.
An EMS-System will buffer the prefabricated body parts and transport them precisely to the welding lines. AFT Schopfheim will be responsible for delivery and installation of this EMS-System as general contractor.
In order to integrate a new car type at the plant in Zwickau, Germany, VW ordered the needed modifications of the skid conveyors used in the paint shop from AFT Bautzen.
After approx. three weeks the structural alternation works were completed successfully. AFT Bautzen delivered conveying systems for body shop, paint shop and assembling at the plant in Zwickau several times.
VW contracts AFT in order to deliver numerous new production lines and upgrading several, already exisiting, installations in their Bratislava plant, Slovakia.
Three more line installations will be delivered and an already exisiting light EMS-system will be upgraded in order to transport chassis side parts. One light EMS system type 200-2 and two more inverted EMS (running on floor) are implemented for the transportation of body parts and logitudinal supports.
VW is planning to modernize their, Zwickau based, JIT production of wheels, seats and cockpits.
They accepted AFT´s submission comprising dismantling of the exisiting machinery, delivering new replacements for the JIT production lines and the extension of an EMS system. The delivery scope includes several vertical lift conveyors as well as roller-, chain- and belt-conveyors connecting to the EMS-system.
AFT provides the mechanical components for the AWT system extension at the New Surgery of the University Hospital Heidelberg.
With Siemens as general contractor, AFT Schopfheim is responsible for delivering and installing the AWT system extension (approx. 800 m rails). The delivery scope comprises various single and double (rail) switches, an empty vehicle storage area, a container storage area (12 places) directly preceded by a transversal shuttle, plus a large number of floor conveyors. This expansion completes the so called “Ring Closure”, creating a shortcut between the Women’s Clinic and the Medical Clinic.
AFT recently received the order for the extension of the vehicle final assembly at the BMW Leipzig plant.
The order includes the expansion of the EMS-driving course in connection with the redelivery of EMS heavy duty vehicles. Additionally, maintenance and extension of two plastic modular belt conveyors were ordered, which are directly related to the capacity expansion. The delivery of these conveyors is handled by AFT Bautzen within an intercompany project.
BMW is expanding capacities at their production plant in Regensburg, Germany.
Therefore AFT will extend the floor conveying system for seats in the final assembly line. Additionally, a two-story truck loading deck with chain conveyors will be delivered. Furthermore, the roller conveyor storage, where seat-sets are going to be sorted and transported to the line in the right assembly sequence, will be expanded. In scope of delivery of this order is also the retrofit of the drive and control technology of the existing production facility.
AFTeco drive
AFT Schopfheim and Volkswagen Slovakia in Bratislava agreed a field test cooperation for the new developed AFTeco drive system for the EMS 200-2.
AFT Schopfheim provides VW Slovakia with five control units and motors, in order to achieve maturity phase of the new drive system concept for the EMS 200-2. Current EMS 200-2 vehicles had been taken out of the operating system and were equipped with a new AFTeco drive unit. These modified vehicles are now running in mixed operation on one of Volkswagen Slovakia body shop plants alongside with the approved common three-phase drive vehicles. The cooperation with VW Slovakia enables AFT to gain unique experiences and realistic results, which are not achievable under conditions of a practically completed long term prototype-test on the test track circle at AFT`s development centre in Schopfheim.
The EMS 200-2 system with AFTeco drive is mechanical identical with the best practice three-phase drive of EMS 200-2 system. Nevertheless, the difference is the drive system concept which is applied for patenting by AFT. An alternating current motor is used as travelling device, its rotor shaft – without intermediate transmission- serves the power transmission straight to the drive wheel.
This drive unit is much smaller and of half weight compared to the common three-phase drive with gear. Previous tests have shown that the new drive system concept is more energy efficient than three-phase drives.
AFTeco offers additional valuable side effects for AFT`s customers as there are a step by step exchange from EMS 200-2 with common three-phase drives to AFTeco drive and a superior effective power result. Further advantages are less maintenance efforts by avoiding oil check, oil exchange and gear breakdown and easy dismantling of the drive unit for maintenance purpose because of less weight.
