Temperature Control – Daimler Chrysler

10. September 2004

A revolutionary evolution happens in automotive industry. New materials introduce new methods of processing. The importance of glueing is just one example that is continuously increasing. This applies as well over many years for the referring market segment or FELLER ENGINEERING. The adhesive process materials like Epoxy resin, Buthyl-adhesive a.s.o. have the common demand to get handled with the right temperature. There is a high requirement of stable temperatures for the spreading between 30°C and 120°C. This is the section for the well known precise temperature controllers of FELLER ENGINEERING.

The new A-series

The new SLK

Since several years the DaimlerChrysler AG relies on the components of FELLER ENGINEERING for temperature control. The internal construction department responsible for the glueing installation. 50 employees like mechanics, electricians, specialists for hydraulic and pneumatic as well as programmers design the technique for the worldwide plants of DC. The scale of 2003 was more than 150 plants for the A- and the SLKseries.

200 L twin barrel glueing installation

The sequence of the process is mostly the following:

  • the adhesive is pumped out of the barrels (volume 20 –
    200 L)
  • transported via heated tubes over a length up to 12m
  • to the robots (6 or 7 axels, make KUKA)
  • which spread the material with heated nozzles of
    different profiles (round, wide or specified)
  • at max. 40 cm³ per second.

KUKA robot system

60 m glueing profile under the bottom of the A-series

These plants of the DaimlerChrysler construction department are placed all over the body making and the assembly. 98% of these plants are linked to robots, either robot-controlled or with guided nozzles. The applications are designed to seal the welding seams of all known sheet-metals or to stick body parts together (screens, tanks, roof and cockpit panels a.s.o.). Depending on the type and size of the car component the application-cycle has a time of 30 seconds to 5 minutes. One example is the cycle time of 5 minutes for a glueing profile of 60m length at the actual A-series of DaimlerChrysler.

A new glueing control system has been installed in 2003. It bases on a touch-screen panel with an own DC control software. An industrial PC for intuitive operation (setting of doser- and temperature setpoints as well as parameters enables a selectable connection with all parts of the plant via 2 bus-systems. Interbus or Profibus work within the plant, any bus-systems are available for external. The software solves all demands of functions as storage of settings and alarms, diagrams, recipes and archieving.

Operation software from DC

The function of heating is a taken over by the multi channel controller, type FP16. Referring to the size of the plant it is designed for 32 or 64 control loops with Pt100 sensors and linked to the master IPC via WAGO terminals by Profibus DP. Einsatz bei DC unterstreicht.

There is no requirement left to fulfil the sophisticated tusks of the temperature control and supervision by this approved control system.

Even regarding the costs the technology of FP16 is able to convince by the successful application standards at DC.

Temperature-Multichannel Controller FP16/64 control loops

FI-modules AT095/8 control loops

Special FI-modules were designed by FELLER ENGINEERING for manifold leakage-current circuitbreakers in the robot controlled dosing systems of DaimlerChrysler AG.

These modules detect leakage current immediately and indicate the source of failure. This way the service staff will be  informed for a direct fast repair.

Additional features and lower costs than single circuitbreakers are further advantages of these modules.

The optimisation of costs and functions will be the
basis of future cooperation of DaimlerChrysler andFELLER ENGINEERING sein.