https://www.engineeringnews.co.za

VWSA increases automation at Uitenhage assembly plant

The new AGV line

Photo by VWSA

The new AGV line

Photo by VWSA

The old conveyor line

Photo by VWSA

24th March 2014

By: Irma Venter

Creamer Media Senior Deputy Editor

  

Font size: - +

Volkswagen Group South Africa (VWSA) has installed an automated guided vehicle (AGV) line to replace the traditional roller conveyor used on the VW250 engine line.

An AGV is a mobile robot that follows markers or cabling in the floor, or uses vision or lasers to follow a preset route. AGVs are most often used in industrial applications to move materials around a manufacturing facility or warehouse.

The AGV line at VWSA’s Uitenhage plant, in the Eastern Cape, is located in the engine sub-assembly area, which can be found in the final assembly area.

The line delivers new generation EA211 and EA288 engines, which are being introduced on a number of new models within the Audi, Volkswagen, Seat and Skoda ranges.

The project was priced at R13.35-million. This, however excluded equipment such as controlling systems, bolting equipment, gearbox filling equipment and infrastructure.

The AGV vehicles were delivered by German company Daum + Partner.

Similar AGV systems have been introduced at Volkswagen plants in Wolfsburg (Germany), Chattanooga (US) and China.

What differentiates VWSA’s AGV line from other AGV lines is that it is a completely contactless system. The AGV knows exactly where to go by following induction cables hidden under the concrete floor.

Two of those cables provide enough power to drive the vehicle, so there is no direct contact with cables or tracks, explains VWSA manufacturing planning and plant engineering manager Sarel Breitenbach.

“The cables also give enough power to not only drive the system, but to lift a complete engine gearbox powertrain weighing roughly 150 kg.”

Older versions of AGVs are battery-powered, which means they need to be docked in a charging station at random intervals before being reintroduced into the production line.

The benefits the AGV project deliver are numerous, says Breitenbach.

The biggest improvement has been in the area of ergonomics. For one, there is greater accessibility to the engine and gearbox from all sides, as the power train is on a turn-table which can rotate to suit the operator.

There is also a lifting table on top, making it possible to accommodate different operator heights – the old conveyor system often saw operators climb on steel platforms for proper reach.

The workstation has also been optimised and is now 3 m in length, as opposed to 0.8 m on the old system. This allows for better line-side supply of parts.

The roof structure on the line is also suspended, with no columns obstructing the delivery of parts, adds Breitenbach.

“It was an extremely tough task to have only three weeks to remove the old system and install the new one, and from day one start building 348 cars a day – that was the ask, but I am proud to say we achieved it,” says Breitenbach.

Edited by Creamer Media Reporter

Comments

Showroom

Booyco Electronics
Booyco Electronics

Booyco Electronics, South African pioneer of Proximity Detection Systems, offers safety solutions for underground and surface mining, quarrying,...

VISIT SHOWROOM 
Aqs image
AQS Liquid Transfer

AxFlow AQS Liquid Transfer (Pty) Ltd is an Importer and Distributor of Pumps in Southern Africa

VISIT SHOWROOM 

Latest Multimedia

sponsored by

Option 1 (equivalent of R125 a month):

Receive a weekly copy of Creamer Media's Engineering News & Mining Weekly magazine
(print copy for those in South Africa and e-magazine for those outside of South Africa)
Receive daily email newsletters
Access to full search results
Access archive of magazine back copies
Access to Projects in Progress
Access to ONE Research Report of your choice in PDF format

Option 2 (equivalent of R375 a month):

All benefits from Option 1
PLUS
Access to Creamer Media's Research Channel Africa for ALL Research Reports, in PDF format, on various industrial and mining sectors including Electricity; Water; Energy Transition; Hydrogen; Roads, Rail and Ports; Coal; Gold; Platinum; Battery Metals; etc.

Already a subscriber?

Forgotten your password?

MAGAZINE & ONLINE

SUBSCRIBE

RESEARCH CHANNEL AFRICA

SUBSCRIBE

CORPORATE PACKAGES

CLICK FOR A QUOTATION







sq:0.074 0.125s - 167pq - 2rq
Subscribe Now