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Reference Project · Automotive

Process Control System: Tyre Intermediate Storage

Just-in-sequence control of a fully automated tyre buffer warehouse for a major truck manufacturer — 4 robots, 400+ storage positions, in 24/7 operation since August 2018.

Project Overview

Just-in-Sequence Production

This plant is part of the just-in-sequence (JIS) production line of a major truck manufacturer. Tyres are held in an intermediate storage facility before being retrieved in a predefined sequence (pearl chain) for the next production step — the complete wheel assembly (tyre + rim mounting).

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4 Robots

Retrieval via 4 robots for uninterrupted assembly supply.

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400+ Storage Positions

Over 400 storage slots with automated put-away and retrieval strategies.

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2,000 Movements/Day

Approx. 2,000 inbound and outbound movements per day in live operation.

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Since 08/2018

Stable 24/7 operation since August 2018.

JIS Tyre Intermediate Storage Web Frontend System Overview

Web Frontend — system overview with inventory levels and order status

Web Application

Process Control in the Browser

A complete web application was developed for operating the plant. Operators see the current inventory, order status, module states and can manage the plant from a central interface — without any local software installation.

  • Start retrieval sequences and manage orders
  • Plant overview: orders, module states, inventory levels
  • Block individual storage zones during maintenance
  • Troubleshooting directly via the web application
Web-based terminal for goods receipt and rim assignment

Touch-optimized terminal — tyre/rim assignment for assembly

Terminals

Goods Receipt Terminals & Rim Terminal

The feed to the goods receipt terminals is handled by Fanuc robots. At the robot gripper, each tyre is scanned and identified via image recognition; the captured data is made available to the operator directly at the goods receipt terminal.

Using master data transferred from the WMS, the matching rims are displayed for retrieved tyres. Employees assign the rims and confirm the feed. The information is transmitted to the assembly system via REST.

  • Feed to the goods receipt terminals via Fanuc robots
  • Tyre identification via scan and image recognition at the robot gripper
  • Touch-optimized rim terminal at the assembly line
  • Tyre label printing directly at the terminal
  • Confirmation transmitted to assembly system via REST
Interfaces & Integration

External System Connections

The PCS is embedded in a complex system environment
from WMS to assembly system.

WMS (Oracle)

Inbound movements transferred to the WMS via Oracle interface.

OMS (SOAP)

Pearl-chain sequence and orders received from Order Management System via SOAP. Retrieved sequences are acknowledged.

Assembly System (REST)

All required data for the tyre/rim assembly is transmitted via REST.

Diverters (OPC UA)

Control commands to diverter units for tyre routing.

Robots (TCP/IP)

Retrieval commands to 4 robots via TCP/IP datagrams.

Technology Stack

Technologies Used

Contact

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