2023西门子汽车动力总成解决方案.pdf

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1、Answers for industry.Solutions for PowertrainTRANSLINE汽车动力总成解决方案 TRANSLINE汽车动力总成解决方案 TRANSLINE 动力总成解决方案 TRANSLINE 是一种适用于发动机、变速箱及轴类大批量机械加工和装配的全面解决方案。该系统化的解决方案通过全球范围内的项目管理，凭借显示、操作和诊断功能的标准化，及用于整个加工和装配过程中一致的硬件和软件形成统一的自动化理念，旨在提高工厂的可用性，改善生产能力，降低制造成本。Solutions for PowertrainTransline Solutions for Powertra

2、in-TRANSLINE is a well rounded concept for the mass production in mechanical manufacturing and assembly of engines,gearboxes and axles.The system solutions allow worldwide project management,simple automation concepts thanks to standardization in the visualization,operation and diagnosis,and consist

3、ent hardware and software for complete manufacturing and assembly processes with the aim of increasing the plant availability,improving the productivity and reducing the manufacturing costs.您在汽车动力总成应用上的要求Your Requirements in Automotive Powertrain Applications 提高机床和设备的生产能力 使用高技术部件确保高可靠性 缩短维修时间 快速提升产能

4、 可根据市场需求灵活调节产量 可实现技术升级的开放系统 降低项目周期成本 High productivity of your machines and equipment Superior reliability of all technical components Short repair times in case of failure Fast ramp up of production Easy capacity adjustment according to changing market needs Open system for further technical expans

5、ion Reduction of life cycle costs2汽车动力总成解决方案的突出优势Solutions for PowertrainHighlights西门子动力总成解决方案使您动力总成部件的生产得心应手，该解决方案充分利用了西门子的标准化技术，包括：全球性的技术支持和项目管理 从项目规划至生产运行 统一的设计理念显著降低项目周期成本 基于 PLC 和 CNC 的机床控制具有一致的外观和使用体验 通过采用超薄终端技术，具有操作可升级的设计理念 使用模块化控制理念，灵活性更强，调试成本更低 制造系统信息化解决方案与制造执行系统（MES）的集成Solutions for Powert

6、rain leverages your production of powertrain components.Take advantage of our standardized technical Siemens solutions including:Support and project managementworldwide from the planning through to the operation Consistent concepts reduce the life-cycle costs Identical look-and-feel for PLC-and CNC-

7、based machines Scalable operating concepts by the use of thin-client technology Improved fl exibility and reduced commissioning cost by the use of modular machine concepts Integration into Manufacturing Execution Systems(MES)应用领域 发动机、变速箱、轴类等部件的生产 柔性生产线 传送生产线 装配生产线 转位工作台机床 数控机床 专用机床 装卸机 机械手、装载机、辊道Fie

8、ld of Applications-in the production of parts for engines,transmissions,axles,etc.Flexible lines Transfer lines Assembly lines Indextable Machines NC Series Machines Special Machines Handlings Gantries,Loaders,Conveyors客户受益于 通过标准化和专业的项目管理，实现更高的可用性和生产能力 一个合作伙伴即可完成全部自动化任务 技术复杂性降低 整个生产工厂设计风格整齐划一 调试时间更短

9、 培训成本降低 维护更轻松，停机时间更短 备件需求最小化 高效和专业化的服务 降低项目周期成本Your Benefi ts Increased availability and higher productivity through standardization and professional project management One partner for all automation tasks Less technical complexity One look and feel for all operator interfaces Faster commissioning t

10、imes Reduction of training costs Easier maintenance,less standstill times Minimized need for spare parts Effi cient and professional service Reduction of project life cycle costs3The Solutions for Powertrain-TRANSLINE concept has been designed in a modular way that allows you to take advantage of it

11、s features not only in Flexible Lines or Transfer Lines,also in Assembly Lines,Loaders and Gantries,as well as Special Machines such as grinding or gear cutting machines,the Solutions for Powertrain-TRANSLINE concept is the appropriate solution.The automotive concept“Solutions for Powertrain”is base

12、d on modular components and systems like SIMATIC,SINUMERIK,SINAMICS or PROFINETnames that have set standards in the market.汽车动力总成解决方案 TRANSLINE 的理念Solutions for PowertrainTRANSLINE concept合理的组合使每个客户从中受益该理念的意义在于：当今的汽车工业生产对自动化解决方案的要求是既要符合一定的规则又要具有多样性，即一方面需要根据需求量身定制，另一方面又需要以经过验证且具有创新性的标准为基础。动力总成解决方案正是兼

13、具上述优点的解决方案，该解决方案在开发、改进和全球推广中均使用“TRANSLINE”这一名称，尤其适合于汽车工业的批量生产。现在，我们将向您介绍一些该解决方案中的控制结构应用实例。柔性生产线Flexible Lines传送生产线Transfer Lines装配生产线Assembly Lines机械手Gantries数控机床/专用机床NC Series MachinesSpecial Machines转位工作台机床Indextable Machines柔性生产线Flexible Line使用柔性生产线加工汽车动力总成部件，这一趋势在过去几年仍在继续。尤其是缸盖、缸体以及齿轮箱壳体，都是在柔性生产

14、线上加工的。其特点是：一个主站是加工中心、机械手及其它辅助机械之上的主控。采用 TRANSLINE 概念实现自动化的柔性生产线使用标准化的硬件，并基于一个统一的软件平台。这使得通过以太网快速传递工件程序、刀具数据、机床参数成为可能。通过PROFINET交换实时数据可以设置柔性生产线的节拍。识别系统允许进行多品种生产。在所有这些情况下，动力总成解决方案 TRANSLINE 都使您的生产线的灵活性最大化。The trend towards using fl exible lines is unbroken during the last years for machining of automob

15、ile powertrain parts.Especially cylinder heads,cylinder blocks and gearbox cases are machined on flexible lines.Its characteristics:One head control is the master on top of machining centers,gantry loaders and additional auxiliary machines.Flexible lines automated using the TRANSLINE concept adopt s

16、tandardized hardware and are based on an uniform software platform.This makes it possible to rapidly transmit part programs,tool data,and machine parameters via Ethernet.Real time data is exchanged using PROFINET setting the pace of the fl exible line.Identifi cation systems allow a mixed production

17、 and in all these cases Solutions for Powertrain-TRANSLINE maximizes the fl exibility of your line.The right combination makes individuality profi tableThe idea makes sense:The objective in production today is a“disciplined versatility”with automation solutions that are,on the one hand custom-made a

18、nd,on the other hand,based on proven,yet innovative standards.Solutions for Powertrain is just such a concept.It has been developed,polished and made universal under the name TRANSLINE specifi cally for mass production in the automotive industry.We would now like to present to you some examples of i

19、ndividual building blocks of this solution.传送生产线Transfer Line传送生产线广泛应用于加工缸盖、缸体、曲轴以及大多数其它汽车动力总成部件。其特点是：用于零部件加工的大多数设备是专用机床，适合大批量生产。在传送生产线上，动力总成解决方案 TRANSLINE 采用标准化的硬件并利用了统一的软件平台。整条线是通过以太网和 PROFINET 从主站进行控制的，主站可以是可编程控制器（PLC）或者是数控（NC）。微型操作面板的使用，可以降低传送生产线设备的初始投资。Transfer Lines are commonly used for the m

20、achining of cylinder heads,cylinder blocks,crankshafts and most other automobile powertrain parts.Its characteristics:Most of the equipment designed for parts machining are special machines and tools,suitable for high volume production.On Transfer Lines,Solutions for Powertrain-TRANSLINE adopts stan

21、dardized hardware and takes advantage of the uniform software platform.The whole line is controlled via Ethernet and PROFINET from the head control,which can be a PLC or NC.The use of slim operator panels even allows reducing initial investment in the Transfer Line equipment.动力总成解决方案 TRANSLINE 的理念采用

22、模块化的设计思路，其特性不仅可以适用于柔性生产线和传送生产线，而且对于装配生产线、装载机、机械手和专用机床：如磨床、齿轮加工机床，TRANSLINE 也是绝佳的解决方案。该解决方案基于模块化的组件和系统诸如 SIMATIC、SINUMERIK、SINAMICS 或 PROFINET 这些名称已经确立了市场标准。46针对独立的数控机床和 PLC 机床的应用实例Application examples for Stand Alone CNC and PLC based machines在整条生产线上采用 TRANSLINE 解决方案，即使是独立的工作单元，也具有相同的控制结构，使您实现统一的操作、

23、维修和人机界面。TRANSLINE has the same control structure even for single working units.Thus the control structure of the whole line is uniform and complete,realizing unity in operation,maintenance and interface.CNC Based machinesPLC Based machines应用清单Overview of Applications装配生产线Assembly Line发动机装配生产线是发动机制造中

24、最复杂的一道工艺。它不仅要求装配生产线能够完成各种型号发动机的柔性装配，还要求能够进行数据归档、操作数据确定、工件信息跟踪等更复杂的任务。TRANSLINE 可以很好的完成上述任务，在装配生产线上 TRANSLINE 采用标准的硬件结构和统一的软件平台，它运用了工控机及操作面板，并与现场的部件如可编程控制器、拧紧机和识别系统等进行联网。通过以太网将各种数据传递给服务器，又通过 PROFINET 进行现场控制，将手动站、自动站、传输控制和工件识别系统有机的结合在一起。The engine assembly line is the most complicated technique in eng

25、ine manufacturing.The assembly line is required not only to realize flexible assembly for all types of engines,but also to fulfill such complex tasks as archiving data,checking operation data,tracing work piece information,etc.TRANSLINE is designed to fulfi ll all the above-mentioned tasks successfu

26、lly.It adopts industrial control computers and operator panels,and connects the fi eld components such as PLCs,Nut Runners,and Identifi cation Systems.Via Ethernet,it transmits various data to the server;via PROFINET,it combines on-site control of manual stations,automation stations,transmission con

27、trols and workpiece identifi cation systems together.79元器件Components操作显示部件O&M控制器Controller驱动器Drive电机MotorPLC 机床PLC machineSINUMERIK OP 08T,OP 012,OP 015A,TCU,PCU 50,MPP 483SIMATIC CE-panelsSIMATICCPU 315-2 PN/DPCPU 317-2 PN/DPCPU 319-3 PN/DPSINAMICS S120SINAMICS 1FK7CNC 机床CNC machineSINUMERIK OP 08T

28、,OP 012,OP 015A,TCU,PCU 50,MPP 483,SINUMERIK 840D slSINAMICS S120SINAMICS 1FT7/1FK7传送生产线Transfer lineSINUMERIK OP 08T,OP 012,OP 015A,TCU,PCU 50,MPP 483SINUMERIK 840D slSINAMICS S120SINAMICS 1FT7/1FK7柔性生产线Flexible lineSINUMERIK OP 08T,OP 012,OP 015A,TCU,PCU 50,MPP 483SINUMERIK 840D slSINAMICS S120SIN

29、AMICS 1FT7/1FK7转位机Indexing machineSINUMERIK OP 08T,OP 012,OP 015A,TCU,PCU 50,MPP 483SINUMERIK 840D slSINAMICS S120SINAMICS 1FT7/1FK7装卸机HandingSINUMERIK HT 8,MPP 483SINUMERIK 840D slSINAMICS S120SINAMICS 1FK7装配生产线Assembly lineSINUMERIK OP 012,OP 015A,PCU 50,MPP 483SIMATIC CE-PanelsSIMATICCPU 315-2 PN

30、/DPCPU 317-2 PN/DPCPU 319-3 PN/DPSINAMICS S120SINAMICS 1FK7TRANSLINE 人机界面：控制过程TRANSLINE HMI:Process under control全面掌控生产过程的进展状况极为关键。因此，在开发“模块化自动系统”时，我们重点考虑了此项需求。TRANSLINE HMI PRO 是一个基于 SINUMERIK 系统的灵活的用户操作界面，可集成到各种基于NC操作的机床中。TRANSLINE HMI PRO 可嵌入到 SINUMERIK 840D sl 或 PCU50 中运行，例如其界面经过优化后可以简单快速地设置工作流程

31、和更换刀具。基于超薄终端技术的可移动式和固定式操作面板，可以低成本的在 SINUMERIK 840D sl 中使用 TRANSLINE 技术。Knowing whats going on is crucial in production processes.Therefore,we paid close attention to this requirement when developing our“modular automation system.”TRANSLINE HMI PRO is a fl exible user interface based on SINUMERIK Ope

32、rate with integrated NC operation for all types of machines.TRANSLINE HMI PRO runs embedded on the SINUMERIK 840D sl or on the PCU50.The screen forms have been optimized for fast and simple set-up procedures and tool changing,for example.Mobile and stationary operator panels,based on thin client tec

33、hnology allow low-cost access to TRANSLINE in the SINUMERIK 840D sl.对于每种应用均配有专用部件：操作 操作界面具备设置、上电、激活和关闭机床单元等功能 通过操作相关界面可以选择机床操作模式(如：工件类型选择、循环类别选择)显示 机床和系统的总览功能可以显示工件和机床单元的运行条件 工件计数界面和循环时间界面 过程特殊信息界面（例如：刀具数据）通过集成的可变布局（Variable Layout）功能实现不同的用户自定义界面诊断 报警和信息可以显示在标题栏、报警界面和历史报警界面中 提供 PROFIBUS、PROFINET、AS-

34、i、RF-300 和 SINAMICS S120 等硬件诊断界面 可供选用的同 S7-PDIAG 和 S7-GRAPH 相连的过程诊断界面There are specifi c parts for every application task:Operation Operation screens for setup tasks,power up,activation and deactivation of machine units Operating screen for selection of machine operating modes (Part type selection,c

35、ycle type)Visualization Machine and System overview to display work piece and machine unit operating conditions Part counter screen and cycle time measurement Process specifi c information screens(e.g.tool data)Customer specifi c screens by using the software function Variable Layout.Diagnostics Ala

36、rm and message display on Header,overview screen and alarm history Hardware diagnostic screens for:PROFIBUS,PROFINET,AS-i,RF-300 and SINAMICS S120 Optional process diagnostics in connection with S7-PDIAG and S7-GRAPH10HMI PRO RTThe runtime software for embedded and PC basedcomponents:PCU 50/NCU 7x0.

37、2 and OP 012/TP 012/OP 015A/TP 015Aand SIMATIC Thin Client Touch(10”and 15”)Screen customization via the confi gurations software HMI PRO CS Integration of third party applications or user screensHMI PRO CSConfi guration software for PG/PC Easy parameterization of HMI PRO RT screens Loading of the p

38、roject to the target panel and/or target control Project data management and archivingHMI LiteThe embedded solution with selected screens For Windows CE based Panels:OP 277,MP277 and OP 177/TP 177 Customization and expansion through WinCC fl exibleHMI PRO RT此运行软件适用于嵌入式或基于 PC 的部件，如：PCU 50/NCU 7x0.2 和

39、 OP 012/TP 012/OP 015A/TP 015A 和SIMATIC 超薄终端触摸屏（10”和 15”）通过 HMI PRO 组态软件（HMI PRO CS）实现用户界面的自定义 支持集成第三方应用软件或用户界面HMI PRO CS运行在 PG/PC 中的组态软件 可轻松实现 HMI PRO RT 界面的组态 可将项目下载到目标面板和/或目标控制器 可实现项目数据管理和归档HMI Lite具有可选界面的嵌入式解决方案 适用基于 Windows CE 系统的操作面板，如：OP277、MP277、OP177 和 TP177 通过 WinCC fl exible 实现自定义和功能扩展11B

40、ased on the well-known software suite MCIS,Manufacturing IT supports the integration of the machine into the IT production environment and offers comprehensive IT and data security consulting.Production data managementThis software enables you to interlink data from planning to production throughout

41、 the factory.The following data is acquired,evaluated and visualized:Machine-related data and informationA multitude of functions provide perfect analysis and evaluation,for example,using the factors for determining machine availability(OEE),cycle times or capacity utilization.Part-related data and

42、informationMachining results from mechanical production and assembly are acquired and evaluated.Contract-related data and informationDefault and feedback data are exchanged between the ERP system and production.This up-to-date information makes it possible to improve the production process quickly a

43、nd easily.制造信息技术 按调度计划组织生产Manufacturing ITfor production according to schedule基于知名的软件套件 运动控制信息系统（MCIS），制造信息技术支持将机床与 IT 生产环境进行集成，提供丰富的 IT 和数据安全方面的查询。生产数据管理该软件可以实现在整个工厂范围内从规划直至生产阶段的数据关联。采集、评估和可视化处理的数据包括：与机床相关的数据和信息众多的功能可以实现完美的分析和评估，例如：通过参数确定机床的可用性（OEE）、循环时间或产能利用等。与零件相关的数据和信息采集并评估设备生产和装配的加工结果。与合同相关的数据和

44、信息在 ERP 系统和生产系统之间交换默认值和反馈数据。根据最新相关信息，可以快速、轻松地对生产过程进行改善。12NC Program ManagementProvides integrated DNC networking of your CNC machines,supports you with the transfer of NC programs to and from the machine and reduces the costs of NC organization.Tool managementWith our tool management you have round-

45、the-clock access to all tool data in the production.The planning module takes you in a position to reduce machine stand-stills in case of missing tools,and the tool handling ensures that the right tool data gets to the right place at the right time.More important,tool statistics give transparency in

46、to your tool management to reduce tool costs.Condition Monitoring delivers efficiencyreliably and safely.Investment decisions are increasingly infl uenced by the costs incurred over the entire life cycle of the machine.Next to consumption-oriented quantities,unproductive times are another major cost

47、 factor.Condition-related inspection and maintenance can minimize those times.ePS Network Services offer a comprehensive range of functions for evaluating machine condition.Using automated test procedures,the machine condition is acquired cyclically and information about the machines real load is di

48、splayed.Knowledge about the condition of individual components is the first step toward increasing productivity.ePS Network Services are available for machine tools and production machines and help machine tool manufacturers,maintenance engineers and service providers to increase plant availability

49、and to take productivity to new levels.NC 程序管理提供集成的 DNC 功能将 CNC 机床联网，实现 NC 程序对机床的下载和上传，从而降低 NC 程序管理的成本。刀具管理借助刀具管理功能，可以随时访问生产中的所有刀具数据。计划模块可以减少因刀具缺失而导致的机床停机时间；刀具控制功能确保正确的刀具数据在正确的时间传输至正确的地点。更重要的是，刀具统计信息使刀具管理完全透明，降低刀具方面的成本。高效、可靠、安全的状态监控投资决策越来越受到机床整个生命周期所产生的成本的影响。另一个主要成本因素是非生产性时间，仅次于以消耗为主的产量因素。与运行状况相关的检查

50、和维护工作可以使上述项的影响降至最低程度。ePS 网络维护为评估机床的状态提供了丰富的功能。通过自动化的测试程序，周期采集机床的状态，显示有关机床实际载荷的信息。了解各个组件的状况是提高生产能力的基础。ePS 网络维护适用于机床和生产机械，可帮助机床制造商、维修工程师和服务提供商提高工厂的可用性，使生产能力提升至新的水准。13西门子提供大量的应用方案，对产品从设计理念到加工制造的整个生命周期提供大力支持。久经验证的软件覆盖了 CAD、CAM、CAE 以及多种级别的工程数据和过程管理。通过集成 PLM 软件，西门子可以为汽车工业提供完善的过程技术支持。通过连接 Teamcenter 和西门子运动