Strengthening the PROFIBUS Network in the Paint Shop of an Automobile giant.

  • Introduction

A leading German automotive company, renowned for its luxury automobiles, buses, coaches, and trucks, has a significant presence in India. Celebrating a milestone anniversary, the company has been at the forefront of the luxury car market in the country. With over 130 years of innovation in the luxury automobile industry, it remains a global leader.

  • Customer Problem Statement

In June 2021, during a visit to their plant, We discussed network problems with their team. They reported frequent network failures, causing production stoppages and increased downtime. The primary issue was node failure due to low voltage and device flickering in the paint shop’s industrial automated process, leading to significant production losses

   

  • Proposed Solutions

After assessing the plant, we developed a Bill of Materials (BOM) and proposed a survey visit. By connecting the PROFIBUS diagnostic tool to each

controller on the network, we identified several issues:

– Low voltages in the networks.

– Continuous signal strength drops.

– Double addresses in the diagnostic repeaters.

– Violations of the 1-meter rule.

– Power cables placed too close to three-phase power lines.

To address these issues, we recommended our popular PROFIBUS Multiport Hub along with other products designed to reduce faults and ensure long-term network reliability

Implementation

During our service visit, we implemented the PROFIBUS Multiport Hub and other recommended products on their PROFIBUS networks. We replaced the existing repeater with our solutions, effectively mitigating the identified issues

 

  • Results

The implementation was a success, restoring the machine to 100% capacity and enabling the timely completion of a critical job for a customer awaiting delivery. Additionally, we provided PROFIBUS training and guidelines to help the team troubleshoot future network problems. The network showed no errors and the site was running in good condition.

  • Further Prospects

Our implemented solutions have been working effectively in the paint shop unit. Consequently, we recommended our products for other units, such as the assembly shop and body shop. The automotive company has also expressed interest in scheduling AMC (Annual Maintenance Contract) service visits for all their units.

  • Conclusion

The successful implementation of our solutions in the paint shop has prompted the automotive company to consider applying the same strategies to their other departments and plants, ensuring long-term reliability and efficiency in their production processes.

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