Audi, in partnership with Siemens, is transforming industrial automation with the pioneering implementation of virtual programmable logic controllers with safety functions in production.
The innovation was implemented at the Böllinger Höfe facility in Germany, where Audi is using a virtual programmable logic controller from Siemens on the Edge Cloud 4 Production (EC4P) platform in the body shop area. The network of virtual programmable logic controllers, certified by TÜV, operates with a safety function specifically developed by Siemens.
With this solution, Audi is setting new standards in fully connected industrial automation. The German brand had previously successfully tested the local server solution EC4P in the assembly of the Audi e-tron GT.
“The use of virtual programmable logic controllers in the body shop area represents a significant leap in productivity in our 360factory strategy, focused on efficient and data-driven production,” said Gerd Walker, Member of the Board of Management of Audi for production. “We want to expand the local cloud for production to all factories and take advantage of advancements in digital control systems.”, added the same executive.
As a technology partner, Siemens is responsible for the virtual control system, which offers certified safety features for use in a production environment.
The EC4P platform with Siemens’ virtual programmable logic controllers is being used in the production of a Lamborghini model, whose body is produced at the Audi Sport facility in Böllinger Höfe. These controllers replace the previous hardware-based control systems.
With the new certified virtual control system, Audi is laying the groundwork for flexible, data-driven production, with the ability to control and monitor production processes in real time and remotely.
The virtual controllers also allow for rapid implementation of software and new features, which can be updated and managed centrally. Through the EC4P, it is possible to significantly increase the efficiency and speed of production processes.
Audi also revealed that the development of the virtual programmable logic controller for the bodywork area comes from a technology partnership between Audi, Broadcom, Cisco, and Siemens.
Broadcom provided the virtualization software for the servers, with a new “industrial virtual switch” capable of real-time operation. This software component allows real-time communication with industrial protocols between the platform and the systems. To meet the demands of the automation sector, Cisco provided the “Software-Defined Access” network infrastructure, now extended to the industrial network.
Following the successful implementation of virtual controllers at the Böllinger Höfe unit, Audi is preparing to expand the technology to the Neckarsulm factory. Preparations for this are already underway, including the use of the technology on the assembly line of the new Audi A6.
