100% Vision-Guided Inspection Line for Leading German Automotive OEM
Client
Leading Automotive Manufacturing Plant, (part of a global OEM group)
Industry
Automotive Manufacturing
The Challenge
The client needed to automate component loading and unloading for multiple CNC machines in a high-volume aluminium machining line. Manual handling was causing frequent downtime, safety risks, high energy consumption, and inconsistent takt time. The system had to operate 24/7 in a hot, dusty environment while maintaining 99.9% uptime.
Invensys Solution
Invensys designed and supplied a heavy-duty floor-mounted Towline Conveyor System with automated load/unload stations. The system transports fixtures between CNC machines with precise positioning, integrated safety interlocks, and energy-efficient drive technology.
Key Technical Features
- Twin-strand chain towline with 2,500 kg/m load capacity
- 28 automated load/unload stations with pneumatic lifts and RFID identification
- Variable frequency drives and energy-recovery braking
- Dust-proof, heat-resistant design (ambient up to 48°C)
- PLC-controlled zoning with predictive maintenance sensors
- Full integration with client’s existing MES
Measurable Results
- 35% energy savingcompared to previous system
- 9% uptimeachieved in first 12 months
- 62% reduction in manual handling labour
- Cycle time consistency improved by 41%
- Zero safety incidents since commissioning
Products & Systems Delivered
Industrial Conveyor System, Heavy-Duty Towline Conveyor with Automated Load/Unload
Proven Results. Trusted by Global Automotive Leaders.
Client Voice
Invensys delivered exactly what we needed, a robust, energy-efficient towline system that runs 24/7 with almost no downtime. The 35% energy reduction was a pleasant surprise and helped us meet our sustainability targets.
Plant Manager
Major GCC Automotive Facility