Discover how innovative conveyor technology solutions from Siemens power the production of the Porsche Taycan eCar.
The production facility for the new Taycan eCar was constructed amid the main Porsche plant in Zuffenhausen, despite sports car production running at full speed in parallel.
That’s why Porsche decided to leave the conveyor belt far behind. The short timeline, building requirements and need for flexibility resulted in a new approach to production: Autonomous guided vehicles take the car bodies from one processing station to the next.
Automated guided vehicles increase flexibility in production compared to traditional fixed conveyor belts.
The surrounding structures limit the amount of space available, which was why the production facility had to be arranged on several levels. The Siemens plant assures the best possible use of available space.
Construction and commissioning of the production facility took 4 ½ months, about half as long as comparable projects, thanks to efficient and transparent project management and automation using the TIA Portal.
The main plant at Zuffenhausen represents tradition for Porsche—and it’s also where the move toward electromobility begins with the Porsche Taycan. But space for the new construction was seriously limited by the existing buildings, which had to be partly cut back.
“Zuffenhausen is the heart and soul of the Porsche brand. Setting up a manufacturing plant like this in downtown Zuffenhausen is a major challenge on its own,” says Albrecht Reimold, Member of the Executive Board of Porsche AG.
Building upwards was therefore the order of the day. But there are also height restrictions for buildings in Zuffenhausen, to minimize the impact on air flow in Stuttgart. The result is a unique manufacturing concept that makes the most of every level and doesn’t waste a single centimeter of height.
Customization is very important for Porsche customers. Customers want a car that meets their personal expectations, both inside and out. That means Porsche must ensure every station in the Taycan plant offers flexibility—a huge logistical challenge with production spread over several floor levels.
To achieve the necessary flexibility, Porsche decided against fixed conveyor belts and opted for Siemens’ FlexiLine solution with autonomous guided vehicles (AGV). FlexiLine makes it possible to adapt operating cycles to actual needs, such as stopping an AGV to perform automated tasks and then speeding it up to move to the next processing station. The entire system underwent virtual simulation and testing to prevent clashes and optimize workflows.
Conveyor technology solutions from Siemens are used throughout the vehicle assembly process, linking the individual workstations and transporting the car bodies. Axles and doors are taken to their preassembly locations, completed and returned to the line.
In addition to the automated guided vehicles and the door conveyor system, tilt EMS hangers ensure ergonomic working conditions. These enable the car bodies to be rotated 110 degrees in both directions so Porsche employees can access all parts without difficulty.
Finally, heavy EMS hangers carry the full weight of the vehicle, including motor and high-voltage battery, to the final acceptance point, where it is transported using a conveyor belt. The entire final assembly was automated based on the SIMATIC portfolio from Siemens.
The conveyor technology skills offered by Siemens are the perfect match for an automobile plant. We made extensive use of Siemens technology in the assembly shop.