Jungheinrich Automates Production for Audi Hungaria

Jungheinrich automates the material supply for the engine production at Audi in Györ, Hungary. Six driverless tugs of the type EZS 350a are used for this purpose. Along their 1,000-meter route, the automated trains serve 57 stops, enabling particularly efficient and reliable transport.

(Hamburg/Györ) Audi Hungaria develops and produces drives for Audi AG and other brands of the VW Group in Györ, Hungary. Since its founding in 1993, over 39 million engines have been manufactured at the plant. Now, with the help of the Hamburg intralogistics specialist Jungheinrich, the automobile manufacturer has automated the previously manual material supply for its engine assembly.

The automation solution from Jungheinrich relies on the use of six driverless transport vehicles based on the proven Jungheinrich electric tug EZS 350. Equipped with modern navigation technology and safety components, the tugs are used to reliably and process-safe automate routine transports in engine production. Along a 1,000-meter route, the automated trains autonomously serve a total of 57 stops in various hall areas – 50 of which are located along the assembly line. The use of the automated tugs is planned in mixed operation with manual forklifts in three shifts, seven days a week.

Automated Trains Operate Independently in the Assembly Area

Each trip, an EZS 350a can transport up to 5,000 kg of various parts for the assembly of four-cylinder gasoline engines. Different trailer variants are used for this purpose. At three stations, these are manually loaded with full goods. Afterwards, the automated trains independently traverse the assembly area and unload at the various stops. On their return journey, they transport empty goods back from production to the logistics area.

“Audi Hungaria is the largest drive plant in the world and the central drive supplier for many brands of the Volkswagen Group. Therefore, we are always required to use the latest technologies, and we are constantly working on increasing efficiency and optimizing processes. At our location, we promote both ‘smart’ production and ‘smart’ logistics. The automation of our logistics processes is an important step that contributes to increasing our competitiveness through greater efficiency,” says Robert Buttenhauser, Board Member for Production Drives at Audi Hungaria.

Commissioning During Ongoing Operations

“The commissioning of the automation solution took place during ongoing production operations. This makes the project complex,” explains John Erkenbrecher, who is responsible for technical sales at Jungheinrich Logistiksysteme GmbH as project manager. “In principle, the integration is realized as a stand-alone system with a special train app and a graphical user interface for schedule management. The assignment of driving tasks is done via the Jungheinrich Logistics Interface, which captures the barcodes of the train trailers through the integration of handheld scanners.” The integration of the system into the Audi system landscape is done via the Audi Traffic Control interface, which controls external peripherals such as traffic lights and fire protection gates.

In the development, Jungheinrich designed the system so that the EZS 350a can be easily integrated into the existing IT and network landscape of each customer. For communication with the vehicles, the existing WLAN structure can be used, for example. If an existing host system such as the Jungheinrich WMS or another WMS/ERP system is to be used, the driverless transport system can connect to this system via the Jungheinrich Logistics Interface.

Orientation Using Laser Navigation

For the navigation of the EZS 350a, no ground work is generally necessary. The vehicle navigates using laser navigation. Reflectors are attached to suitable objects along the route – such as shelves, columns, and walls – or natural landmarks are used. This allows for millimeter-accurate positioning of the vehicles at the pre-defined stations.

The EZS 350a is powered by a 24-V drive motor in three-phase technology. The motor is completely maintenance-free and particularly energy-efficient. The EZS 350a is available with modern lithium-ion technology, ensuring fast charging times, maintenance-free operation, and a long service life.

Photo: © Jungheinrich