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ŠKODA AUTO Vrchlabí Plant Used Digital Twin to Install Robot Station

Auto News - Published on Mon, 27 Jul 2020

Image Source: ŠKODA AUTO Vrchlabí Plant Digital Twin
The Czech car manufacturer SKODA has made use of a Digital Twin to successfully install and integrate a new robot station at the ŠKODA AUTO component plant in Vrchlabí. In doing so, simulations of the equipment and factory were used to run through all processes and scenarios in advance. The use of a digital twin and state-of-the-art technology allowed SKODA to create an extremely detailed virtual image of the plant, simulate processes and procedures, and thus seamlessly add to the production line. The project was therefore fully operational three weeks sooner than a system installed using conventional methods.

Within a cycle time of less than 30 seconds, each gearbox is provided twice with four bearing components at the newly set-up workstation. To guarantee the incredibly high level of precision required for the transmission’s rotating parts to function optimally, this production step is carried out by robots. First of all, a 3D model of the workstation was used to create the digital twin. This also cloned the robot arms, sensor logic and safety components. This allowed all mechanical and kinematic processes at the station to be realistically simulated. The software aspect of the twin ensures smooth communication between all hardware components and the program-based control sequences on the production line. Using this set-up, the technicians developed, tested and optimised the control electronics and determined the space required for the new workstation. They were also able to prevent any chance of the robot arms colliding and calculated the ideal cycle time, the digital twin can also be used to train the workforce for example. By using the digital twin, the robots’ control programs were also developed before the physical robots and their peripherals were even in the factory.

The high-tech Vrchlabí plant plays a key strategic role in ŠKODA’s component production and is one of the most modern sites within Volkswagen Group. ŠKODA AUTO has been building DQ200 automatic 7-speed direct shift gearboxes at the foot of the Giant Mountains since 2012. Approximately 2,200 units leave the production line every day; in 2019 the three millionth DQ200 transmission was produced.

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Posted By : Yogender Pancholi on Mon, 27 Jul 2020
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