Case Studies
Multi-Platform Battery Assembly Line Upgrade Using Siemens and ABB Technologies
Project Overview
A global automotive OEM required a significant upgrade to an existing battery assembly line to support additional battery platforms while maintaining production efficiency, traceability, safety, and quality requirements.
The project involved modifications across multiple production zones, integrating new robotic operations, fastening technologies, RFID tracking systems, vision inspection systems, conveyor sequences, manual workstations, and production support systems.
Challenge
The existing production line was designed to support a limited battery configuration. The customer required the introduction of additional battery platforms without negatively impacting throughput, quality standards, traceability, or operational reliability.
The scope required coordinated software and controls modifications across six PLC-controlled systems while maintaining compatibility with existing production equipment and manufacturing standards.
Engineering Solution
Tech Automation supported the engineering, development, testing, and implementation of software modifications throughout the battery assembly process.
The solution included updates to Siemens PLC systems, ABB robot sequences, industrial vision systems, RFID tracking, fastening technologies, HMI interfaces, conveyor logic, safety systems, and production workflows.
The project was developed using Siemens TIA Portal and included offline programming, virtual commissioning support, testing, validation, and startup preparation activities.
Project Scope
- Software Design Engineering
- Siemens PLC Modifications
- ABB Robot Integration
- Industrial Vision Integration
- RFID System Integration
- Conveyor Sequence Development
- Fastening System Integration
- HMI Modifications
- Safety System Updates
- Virtual Commissioning Support
- Production Validation
- Documentation Development
Technologies Used
- Siemens S7-1518F PLC
- Siemens S7-1517F PLC
- TIA Portal
- Profinet Networks
- ABB Robotics
- Keyence Vision Systems
- SICK RFID Systems
- Dessoutter Fastening Systems
- SINAMICS Drives
- ET200 Distributed I/O
- Virtual Commissioning
Production Systems Included
- Six PLC-Controlled Production Areas
- ABB Robotic Work Cells
- Battery Handling Systems
- Automated Fastening Stations
- Vision Inspection Stations
- Leak Testing Systems
- Insulation Testing Systems
- Manual Assembly Stations
- RFID Traceability Systems
- Andon Production Support Systems
Results
The upgraded production line successfully expanded its manufacturing capability to support multiple battery platforms while maintaining quality standards, production traceability, safety requirements, and operational reliability.
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The implementation improved manufacturing flexibility and established a scalable foundation for future battery platform introductions within the facility.
The project combined robotics, controls engineering, industrial networking, traceability, vision inspection, and virtual commissioning methodologies to support a modern battery manufacturing environment.
Key Benefits
- Multi-platform battery production capability
- Six coordinated PLC system upgrades
- ABB robotic integration
- RFID-based traceability
- Vision-based verification systems
- Enhanced manufacturing flexibility
- Virtual commissioning support
- Improved production scalability
- Automotive manufacturing compliance
- Future-ready production architecture
Tech Automation LLC
Virtual Commissioning, Digital Twin, PLC Programming, Robotics Integration and Startup Support for Automotive, Battery Manufacturing and Industrial Automation.
Discover how Tech Automation LLC can support your automation journey with their complete range of solutions and expertise.
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Virtual Commissioning, Digital Twin, PLC Programming, Robotics Integration and Startup Support for Automotive, Battery Manufacturing and Industrial Automation.
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