Project Description

The J74 VW Transporter Floor Panel Line was delivered as a turnkey project
for Ford Otosan Yeniköy Plant for the automated welding and laser processing
of vehicle floor panel assemblies.

The system is based on Siemens S7-1500 PLC architecture and integrates a total
of 18 KUKA and ABB industrial robots. The line combines resistance spot welding,
automated sealing, and laser cutting operations to ensure high precision and
flexibility in floor panel production.

Designed for a 115-second cycle time, the line was digitally validated using
Siemens Process Simulate prior to commissioning. The project scope included
mechanical design and manufacturing, electrical design with EPLAN, pneumatic
design using FESTO FluidDraw365, PLC programming, robot integration, installation,
commissioning, and production ramp-up. The project was completed within
1.5 years in compliance with PL-d safety standards, with 24/7 technical support
during stabilization.

Case Details

Client
Ford Otosan
Project Type
Turnkey Welding & Laser Processing Line
Application
Floor Panel Laser Cutting Processes
Location
Turkey
Project Duration
1.5 Years
Safety Level
PL-d

Important Facts

  • 18 industrial robots (KUKA & ABB)
  • Laser cutting + spot welding + sealing processes
  • Siemens S7-1500 PLC platform
  • 115-second production cycle time
  • Digital validation with Siemens Process Simulate
  • Electrical design with EPLAN
  • Pneumatic design with FESTO FluidDraw365
  • Installation & commissioning
  • 24/7 technical support during ramp-up

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