Comprehensive Automotive Solutions For Smarter Factories

The pandemic has rendered automation and process reliability a necessity for industrial continuity and growth.

The production line of the future will not only be networked and intelligent; it will possess some self-control and self-optimization capabilities, making it resource-efficient. For the transformation to an “intelligent factory,” the existing processes will be networked, and all products, machines and process data will be recorded.

Automation solutions, such as the WAGO I/O System 750, are available for capturing and securely transferring data into a “Manufacturing Execution System” (MES) or product management system.

IoT Solutions

Besides software, WAGO also supplies the right hardware: PFC Controllers and WAGO Touch Panels 600 with cloud connectivity.

Record, digitize and link data profitably – this is the core of Industry 4.0. Both the WAGO I/O System 750 and 750 XTR connect to the field level, and a WAGO PFC Controller or Touch Panel 600 sends data to the cloud or a local MQTT broker, where it can be aggregated and used for analysis. This capability creates true added value for your company whether for increasing the efficiency of in-house production, implementing energy management in buildings or developing additional end-customer services.

Benefits that come with WAGO’s automotive IoT solutions

  • Connect the field level directly to the cloud
  • Expand existing systems with the PFC and Control Panel as an IoT gateway
  • Distributed data acquisition and visualization from anywhere
  • Connect to Microsoft Azure, Amazon Web Services, IBM Cloud or other MQTT brokers via standardized MQTT protocol High level of security thanks to TLS encryption 

Engineering Software Capabilities

Linux® and WAGO – Automation for the Future

WAGO’s Microsoft Windows-based engineering software perfectly dovetails with our controller portfolio that features the Linux® operating system. In addition to their scalability through the open-source community, the Linux®-based controllers boast a code base that can rise to any future challenges. WAGO’s controllers offer programming in either IEC 61131 with CODESYS or directly in Linux® to create complex tasks.

CODESYS – for an Integrated Operations Environment

All WAGO Controllers are equipped with the high-performing CODESYS industry-standard development environment. This enables software development in the IEC 61131-3 PLC programming languages (ST, FBD, LD, IL, SFC and CFC). As a trusted programming environment, CODESYS guides developers, enabling them to reuse and further develop existing programs without learning new software. This means that advanced paradigms, such as Object-Oriented Programming (OOP), or modern visualization technologies, are available.

High-Reliability Automotive Line Components

Removing human factors from the automotive production line reduces any chances of errors, downtime or malfunctions caused due to human limitations. However, automation can be truly relied upon only if its ‘cogs and gears’ are well aligned, reliable and work like a clockwork.

This is the value WAGO’s component essentially bring-in to any automotive line!

High-fidelity Solutions for Assembly line by WAGO

Press Shop

Ensuring stable processes through high-performance components.

High-Current, Rail-Mount Terminal Blocks with POWER CAGE CLAMP

The key to WAGO’s success: springs, not screws. This design gives POWER CAGE CLAMP the appropriate clamping force for 35, 50, 95 and 185 mm2 (2, 2/0, 4/0 AWG and 350 kcmil) conductors.

WAGO’s high-current, rail-mount terminal blocks meet the most stringent requirements. They resist heat and cold – even under the heaviest of loads. The terminal blocks can be quickly wired – no time-consuming preparation with ring terminals or ferrules required. WAGO’s blocks offer perfect clamping force, independent of operator skill.

In short, they are: vibration-proof, fast and maintenance-free

Body Shop

High-performance automation for high system uptime

The molded sheet metal parts undergo additional processing in the body shop. The body shells are assembled by gluing, welding or press-fitting techniques that use highly automated equipment and stationary industrial robots. Producing a body in white places maximum demands on system availability, precision and the protection of human and machine.

Paint Shop

Perfect surfaces through seamless processes

An automotive paint shop has several different steps. For a trouble-free process and perfect paint finish, the continuous supply of required lacquers and foaming materials is a must.

In some paint shops, there are typically areas where there is a danger of explosion, and these must be protected by appropriate measures. The WAGO I/O System 750 is ideal for exchanging signals between the PLC and the field level. The blue, intrinsically safe Ex i modules can easily be integrated into a standard I/O node. This enables the direct connection of sensors and actuators from Zones 0/20 and 1/21. Even the otherwise difficult safety connections are possible directly in and out of the Ex-i area.


Complex value creation needs high reliability

The term “powertrain” describes all the areas where components for the powertrain are produced. This includes the production of engines, gearboxes, clutches, axles, batteries and electric motors. When all these elements are unified, the entire powertrain of a vehicle is formed. Finally, the assembled components must be available at the right time at the correct location of the engine or gearbox assembly. This precision requires an absolutely reliable automation solution.

For assembly lines or processing centers used in powertrain areas, safe system startup – as well as safe system shutdown and restart of a defined condition – must always be ensured. The goal of this requirement is preventing avoidable errors in the power supply and associated downtime. Here, too, the production costs must be kept in mind and efficiency must be increased. WAGO’s power supplies and circuit breakers were engineered to readily meet these requirements.

WAGO’s 787 Series electronic fuses help prevent accidental tripping that results from high switch-on currents or the unintended startup of equipment that’s triggered by a fault. Function blocks for ECB monitoring that use the WAGO I/O System, or other control systems, are available for free. Electronic circuit breakers (ECBs) have digital inputs and outputs that communicate via Manchester protocol.

All channels can be diagnosed and switched remotely, and independently, of each other. These options allow plant operators to implement preventive maintenance and reduce costly production downtime.

Closing Note

As global industries revive and pickup the pace while fending-off unprecedented threats, WAGO and its team stands strong in the electrical technology domain to ensure reliable, safe and highly efficient automotive production. Visit WAGO’s website to know more!

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