n TECHNOLOGY BMW HAS IMPLEMENTED A cloud-based tra c system at its Regensburg plant in Germany to control a eet of 140 smart transport robots (STRs) and 50 tugger trains that complete around 10,000 trips daily, delivering parts to production lines. BMW sees the system as a signicant milestone on the road to its digital factory of the future, the BMW iFactory. The Regensburg plant produces up to 1,400 BMW X1 and X2 vehicles every day, including combustion-engined vehicles, plug-in hybrids and electric models. Every 57 seconds, a new vehicle rolls o the assembly line. Each one is unique, built to individual customer specications, from thousands of separate components. The logistics are extremely complex: the components and individual parts need to be delivered “just in time” and in the correct order to the right place in the vehicle assembly process. This task is handled mainly by driverless, automated or autonomous transport systems. In some cases, the loading and unloading of the vehicles is also automated. BMW uses various types of driverless vehicle, depending on the task. For example, the automated tugger trains transport small parts from the warehouse to the assembly line, while larger components, weighing up to a tonne, are handled by at transport robots, known as STRs. These operate autonomously using dedicated AI modules. Sensors and software recognise their surroundings, allowing them to navigate around obstacles autonomously. The vehicles are managed through BMW’s central cloud-based tra c control system. When supplies need to be replenished, assembly line workers rotate change frames with empty parts containers. This operates a “retrieval rocker”. The control system receives a signal telling it that new parts are needed. This results in the smooth, precisely timed delivery of materials, as well as maintaining intelligent tra c ow in the assembly hall. The system also provides optimal route guidance, based on delivery priorities, and ensures that the vehicles’ batteries are charged. “What makes this so unique are the many sequenced parts specically tailored to each customer vehicle,” points out Thomas Dietz, a BMW employee who is responsible for process improvement and quality management in physical logistics. “They must all be delivered in the order they are installed on the assembly line. “Even a brief system failure in the supply of sequenced parts would bring production to a halt – and, of course, that is something we want to avoid,” he adds. “A lot of detailed work on both hardware and software was needed to reach the current status.” The transport eet is being expanded continuously to incorporate additional routes and vehicles. There are plans to integrate additional types of vehicle such as autonomous lifting trucks and automated forklifts. One autonomous vehicle commissioned recently in the Regensburg press shop can carry up to 55 tonnes. “Our vision of intelligently connected logistics, relying on a variety of dierent autonomous transport systems that seamlessly interact with one another – from small to extremely large – is gradually taking shape,” Dietz explains. Cloud-based system controls 190 autonomous vehicles at BMW plant THE US SENSING SPECIALIST, Senva, has announced a technology that, it claims, redefines precision when monitoring electronically commutated motors (ECMs). The company says that its ECMSET Pro current sensor “sets a new standard” in current monitoring for variable-speed EC motors, and addresses common challenges such as low-current sensitivity, false on/off readings, and complex installations. It can be used with lowpower motors in industrial and HVAC applications. The product incorporates a patentpending technology called ECTune, which adjusts its sensitivity dynamically to ensure accurate, reliable detection of motor states, even at extremely low currents. This enables the sensor to differentiate accurately between idle and active motor states, minimising false readings and eliminating the need for wire wraps. The ECMSET Pro is said to simplify the installation, troubleshooting and maintenance of ECMs. It offers: n An adjustable turn-on threshold which can be set as low as 30mA, eliminating the need for wire wraps and simplifying installation. n High-accuracy current sensing with sensitivity down to 5mA for reliable detection in variable-speed EC motor applications. n The ECTune technology which uses advanced waveform analysis to differentiate motor states accurately. It harvests and detects power at extremely low currents, resulting in accurate, reliable detection. n A compact, split-core design that enables quick set-ups without disconnecting wires. n A pre-set adjustable dial that enables quick, safe set-up without live calibration, even in confined spaces. n LED diagnostic indicators that simplify installation, troubleshooting and maintenance. n Support for demand-based control, cutting energy costs. “The ECMSET Pro represents a major step forward in energy monitoring technology," says Senva CEO, Andre Perra. “With the addition of our patent-pending ECTune technology, we remain committed to providing innovative solutions that address the evolving needs of building automation and sustainability.” www.senvainc.com Current-sensing technology ‘rede nes precision’ in ECM monitoring February 2025 www.drivesncontrols.com 20 BMW’s cloud-based system controls a eet of almost 200 autonomous vehicles at its Regensburg plant
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