If cables are breaking... Go wireless!

ThyssenKrupp Automotive (TKA), with sales of Euro 6.3 billion in fiscal year 2000/2001, is one of the world's biggest automotive suppliers. The company has some 38,500 employees and operates from 120 locations in 16 countries. They are world market leaders in body parts, crankshafts, assembled camshafts, and electronic and mechanical steering columns and steering systems.

ThyssenKrupp Automotive also leads the way in air suspension and damping systems, axles and complete chassis systems. In their UK factory, machine downtime was a problem as the conventional network cables kept breaking after many rotations. 

The ThyssenKrupp factories in the UK were faced with machine downtime of the rotary welding jigs. Furthermore, they expected more problems in the future as the normal network cables would eventually break after so many rotations. A further complication was the rough operating environment of the machines. Until now no industrial supplier had been able to solve the problem.

Omron proposed a 'wireless' network as a solution, the field bus I/O checks that the jig clamps are in place before welding proceeds and controls valves. After successful trials the system has been expanded to the handling robots. A vital issue in this project was that TKA needed proof that wireless units would operate satisfactorily in such an environment, however, test results were conclusive. Our welding spatter proof IP67 I/O modules were also vital. The operating environment is very hostile, but our products were up to the task.

Omron offered a unique solution, without compromising on functionality. The test results were so impressive that the customer decided to use the same technology for their handling robots.

After installation, communication failure was no longer the reason for downtime.