The Porsche AG assigned Aberle Steuerungstechnik GmbH as general contractor for the realization of the
central receipt of goods in plant 2 in Stuttgart-Zuffenhausen. Due to the upcoming change of model of type
series 911 a new organisation of the physical flow of material in the area of control to the high rack warehouse
became necessary. The conveyor technique played a significant role here, which conveys the pallets to be
stored to the high rack warehouse – from receipt of goods until storage.
Integrated components
The new receipt of goods G01 is controlled with an up to date control of the Simatic-family S7 414-3DP. The
new stock level for the high rack warehouse G13 also got a separate control with a S7 414-2 DP. Due to the
enlargement it became necessary to replace the existing S5 high rack warehouse data concentrator by a new
high rack warehouse flow of material system. The connection from the new Aberle-high rack warehouseflow
of material system to the customers’ warehouse management system (WMS) was reproduced on the
existing serial interface. The connection to the completely subordinate old and new control level of the conveyor
systems G01-G13 and the S/R machines 1-5 was changed parallel from H1 to TCP/IP communication via Ethernet.
Solution
In order to increase the efficiency of the conveyor system two fully automatic depalleting stations were integrated. Due to the different kinds of pallets and stacking patterns an ultra-modern laser system was applied for the identification of the pallet type. Thus the complex depalleting could be granted.
For the whole plant a decentral drive concept with external SEW-Movimot frequency controllers was chosen. Thus individual adjustments of each drive are possible
on site. By the crosslinking of the SEW-Movimot with the according group control differentiated status- and error messages are relayed to the visualization.
By the new portable Siemens MP170 with touch screen today a continuous and easy-to-understand manual control of the plants is possible.
Advantages for the customers
Due to the high grade of decentralization the plant could be started up in time after the reconstruction in between
the Christmas holidays.
The new high rack warehouse-flow of material system was constructed as powerful and highly available Hot-
Standby client-server solution. In this configuration several emergency strategies were considered. If single
plant parts are faulty the computer will bypass them. Due to this solution and the efficient new conveyor
technique Porsche is in a position to react flexibly to future increases in production.
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