Plant automation

Plant automation at EDAG

Optimise production with robotics and automation

With the aid of robotics, automation and application technology, simulation techniques (e.g. digital twin and virtual commissioning) as well as modern process and control technology, we help you to automate, optimise and validate your production sequences - even with complex production processes. Our engineering package includes all mechanical, mechatronic and electrical components.

In robotics, we have been providing defining impetus for the workplace of the future for many years, e.g. in the realisation of new fields of application such as human-robot collaboration (HRC). We work independently of various robot manufacturers, which allows us to deliver cost-optimised results for our customers.

Advantages for the customer

  • Planning of electrical and mechanical automation from a single source.

  • Virtual commissioning means that the new or optimised plant is completely "validated" prior to commissioning: it has successfully completed all virtual tests and test runs.

  • We achieve real cost advantages through manufacturer independence and the increased use of automation and robotics.

  • Thanks to planning and design from a single source, possible problems are identified early and resolved in the best possible manner.

  • With the aid of our know-how, manufacturer independence and many years of experience with all relevant robot types, we develop the best solution for you.

Automation is the art of manufacturing products with minimal manual intervention, high quality and low costs. In this regard, all maintenance groups should be perfectly coordinated. We achieve this high level of automation by using state-of-the-art, innovative tools, experience and methods from the digital factory.

Principal areas of automation:

  • We take responsibility for electrical design including the PLC and robot programming for your systems according to your specifications. We guarantee high quality through close networking with mechanical engineering. This includes:

    • Hardware design
      Generation of complete wiring diagram documents, construction plans for control cabinets and cable and network overviews, including the associated parts lists.
    • Software development
      PLC sequence and safety programming, engineering for visualisation equipment, field bus and network structures, powertrain engineering and intelligent actuators and sensors from different manufacturers.
    • Robot programming
      Virtual or real with robots from various suppliers and for different OEMs.
    • Virtual commissioning
      The PLC and robot programs created for the equipment are tested on the virtual kinematic and behaviour model and validated with all functions before the real commissioning begins. See also digital twin
    • Setup
      Installation of all control and safety-related PLC, bus and visualisation components and interfaces to plant-wide systems.
    • Real commissioning, project management and documentation
  • Virtual commissioning is the ideal quality assurance for the mechatronic components and the production process. We want you to save valuable time in the project as well as modification costs. With the help of suitable kinematic and behaviour models of your plant, the simulation of material flow computers and by connecting to the ERP, we can carry out the programming and first tests, including employee training on the virtual model, long before "steel and iron" create reality on site, which is then expensive to change.

    Your advantages:

    • Lower commissioning costs due to shorter commissioning times and reduced on-site attendance
    • Early development and commissioning of the control system under real conditions
    • Reproducible tests of the real control system (stress tests, failure scenarios)
    • Quality assurance of control system development
    • Reduction of errors in the real control system
    • Training of operating personnel on the real control system in conjunction with the simulation - without affecting the real system.

    More about this under Software & Digitisation

  • The close integration of mechanical and electrical processes in combination with digital methods is an important basis for the creation of a smart factory and its operation with the possibilities of Industry 4.0. Here we focus on:

    • Interdisciplinary cooperation (simultaneous engineering)
    • Modular systems of mechatronic components
    • Consistent data models
    • Manufacturer-independent data structures

Automation across all maintenance groups with no interface losses

Robotics: the mainstay of the engineering process

Robotics includes the design, control and operation of robots and thus acts as an important link between engineering and implementation. It combines the virtual with the real world. With robotics, we ensure that the requirements of your production plant are met. It is integrated in all engineering phases. For this purpose, our employees create 3D simulation cells in which the planning and design concepts are implemented in line with process requirements.

As a manufacturer-independent provider, we have acquired extensive knowledge of robots over the years, especially in programming and control.

The supported systems include:

    • KUKA and KUKA LBR
    • ABB
    • FANUC
    • COMAU
    • MOTOMANN
    • Universal Robots
    • Kawasaki
    • KRC 2/4, Java Sunrise
    • VKRC
    • IRC 5, S4
    • RJ 3, R-30iB
    • ABB Safe Move
    • KUKA Safe Operation
    • Fanuc DCS SAFE

Application technologies

In material processing, especially when joining workpieces, subjects such as lightweight design, material mix, energy and resource efficiency play an important role and place high demands on production plants. Gluing and spot welding are often no longer sufficient. We have extensive knowledge that allows us to bring new technologies to series production maturity.

    • MIG / MAG welding, resistance spot welding, laser beam welding (also scanner-guided), friction welding (friction stir / friction spot welding), stud welding, Weldfast®, Variopicker®
    • Laser beam brazing
    • Roller hemming
    • Clinching, flow drilling, flow drilling screws
    • Hole punch riveting (semi-tubular riveting, solid punch riveting)
    • Gluing
    • Hybrid joining technology
    • Laser beam cutting
    • Laser cleaning
    • High-speed joining process
    • Electrode tip changing device (stationary)
    • Inline process monitoring

In our technical centre, we can map your test scenarios and bring new technologies or the processing of new materials to series production maturity.

Instrumentation and control engineering: the IT behind production

Automated systems require the right process and control technology. We are happy to undertake the conceptual design, planning and implementation of new control technology, and for the migration or functional expansion of existing plant.

At EDAG, automation engineers work hand in hand with software developers to plan and implement integrated control concepts. We are experts in production control systems such as SCADA (Supervisory Control and Data Acquisition) and MES (Manufacturing Execution System), which read out and process the data from the production equipment controls. We also link these to ERP (Enterprise Resource Planning) systems, which control and process orders at the commercial level.

All companies benefit from our extensive knowledge of processes, IT and controls in diverse systems in different fields of application.

    • Evaluation of key production indicators
    • Comprehensive visualisation of production
    • Order data management and optimisation
    • Product tracking and identification
    • Version and sequence control, buffer control
    • Smart / predictive maintenance (KI-supported)
    • Process data acquisition, analysis and backup
    • Alarm notification system (e-mail, phone, SMS)
    • Flexible, time-controlled operation
    • Poka-Yoke systems (Pick2Light, Andon Boards etc.)
    • EC screw technology evaluation system
    • Installation testing

NOW LET'S TALK ABOUT YOUR APPLICATION!

Your contact for production IT: Mark Kramer

Your contact for plant automation: Christoph Schultheis

Download further information

LEGAL NOTE:

All registered trademarks and business names mentioned above and any trademarks and business names that may be protected by third parties are subject without restriction to the provisions of the applicable trademark law. All rights related to these trademarks and business names belong to the respective owners. Mention is made for the sole purpose of pointing out the terms and conditions of the programming and control services we offer and must not, in particular, be understood as a reference to the existence of a business relationship between us and the respective owner.

 

 


 

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