Audi wanted to virtualize shop floor automation, reduce the number of devices and convert applications to software to make production fast, robust and flexible. This required not only a new, IT-based infrastructure but also virtual PLCs. Siemens provided the key to success with SIMATIC S7-1500V.
The Ingolstadt-based automotive manufacturer’s goal is a stable and consistently available production facility, where as many cars as possible can be built. But to speed up the integration of innovations from the rapidly developing IT world and facilitate the continuous optimization of production — in keeping with the motto “Vorsprung durch Technik” — production needed to become more IT-oriented.
The conversion to IT-based shop floor automation is a huge step forward for production, but has barely been detectable by employees. They continue to have access to familiar functions, user interfaces and tools.
All applications share a common foundation that enables fully digital management. Managing through Edge Cloud 4 Production enhances cybersecurity by eliminating multiple attack vectors from the production environment.
The virtual PLC is downloaded as software and deployed via Industrial Edge, so setup is fast and flexible. Updates from Industrial Edge Management can also be quickly and easily rolled out plant-wide and on a fully remote basis.
Audi is primarily challenged by the number of devices. To adapt production to the increasing demand, more hardware devices must be purchased. However, delivery periods are getting longer. In many cases, updates can only be installed manually and maintenance is extremely costly, but both are necessary to guarantee cybersecurity. Plus, the greater the number of hardware devices in use, the more power is required, resulting in a reduction of the plant’s energy efficiency.
To meet these challenges, IT and OT in production need to be merged. This is made possible by virtualizing the shop floor. That’s why Audi turned to SIMATIC S7-1500V, the first TÜV-certified virtual fail-safe control system, which is setting new standards for flexible and safe production.
To merge IT and OT in production, Audi created a brand-new software-based infrastructure. The lowest level of the infrastructure is always the same, and it lays the foundation for the various applications. With Edge Cloud 4 Production, Audi transferred this principle to production and revolutionized its shop floor automation.
In addition to technological hurdles, there were also organizational challenges to overcome. Employees and management had to be won over and the functionality of the virtual PLC had to be demonstrated. Thanks to extensive testing at the plant and the excellent alignment between the IT and OT teams, Audi and Siemens were able to successfully commission the new technology.
It quickly became clear that a large-scale concept was required. However, it took about three years to define requirements, test conditions and talk to the manufacturers. The technologies also had to be modified: for example, to establish the real-time capability of the lower-level infrastructure.
The virtual PLC via Edge Cloud 4 Production was first successfully tested in the Audi Production Lab. A plant in the Audi e-tron GT production line at Böllinger Höfe in Neckarsulm was selected for the initial commissioning. The plant’s small-series manufacturing was ideal for testing the new technologies.
Working with Siemens, Audi performed tests on the plant in the early stages to learn about the setup on-site and the challenges to implementation. This commitment increased employee acceptance.
With the successful initial implementation of the virtual PLC, Siemens and Audi achieved an important milestone. But this success was just the starting point. Both the virtual controller and the cloud-based infrastructure continue to be developed, tested and rolled out.
The priority in the coming months is to train Böllinger Höfe employees. The first apps from Industrial Edge Management are also being rolled out and tested, including SINEC Traffic Analyzer. The apps can be flexibly downloaded and used.
At the same time, Audi is learning from the initial implementation. For example, a virtual operator panel was tested and to detect hurdles in the plant’s everyday operation. Based on the successful collaboration to date, the project participants are optimistic about the future.
The virtual PLC represents a revolution in automation engineering and industry, making it possible to totally rethink a factory and its infrastructure.
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Standard and failsafe PLCs and applications as software just recently became a reality, thanks to our innovative SIMATIC S7-1500V virtual PLC. Let the experts inspire you about its potential.
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