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Robotics, assembly & logistics

Automotive & Assembly Lines

Servo pressing, screwdriving and transfer; every part measured and recorded.

  • Typical axes4
  • NetworkEtherCAT
  • Control modeCSP / CST · CST · CSP · CSV / CST
  • Recommended seriesSDU3 · SM13 · SD24-LP · SM06
Start Product Selection See the solution
01
The sector at a glance

Automotive & Assembly Lines

Servo presses, screwdriving and transfer stations make the motion and also measure and record each part's result.

Three things that decide it on the shop floor

  1. 01

    Force-displacement curve

    The part is good if the curve stays inside a window.

  2. 02

    Traceability

    Each part's result goes from the PLC to the plant system.

  3. 03

    Manned stations

    Where an operator reaches in, STO and the safety circuit are designed together.

02
Our advantages

Why SMB TECHNICS?

One set, controller to cable

Controller, drive, motor, cable and connector arrive checked against each other; interface problems are solved at the desk, not on the shop floor.

Open standards

EtherCAT, CANopen, Modbus RTU, CODESYS and CiA 402: your machine is not tied to a closed ecosystem.

Engineer-to-engineer support

The same team from sizing to commissioning, on site and remotely.

Documented products

Manuals, CAD, ESI/EDS and firmware in the Document Centre; every product you choose comes with its documents.

Our application know-how for this sector
  • Force-displacement monitoring and good/bad judgement
  • Per-part traceability and data transfer
  • Safe stop at manned stations
03
How we build the system

From control chain to commissioning, which product goes where

3.1

The control chain and the recommended products

How the machine is driven and the SMB products we choose for it.

Automotive supplier and assembly lines run servo presses, screwdriving stations, transfer lines and test benches. Here, proving and recording that every part was made right matters as much as the motion itself.

On an assembly line every part is a record: force, position and result are kept together.

The control chain

A servo press or assembly station is run from a MAT-LC CODESYS CPU; high-force axes are driven by SDU3 380 V drives with SM13 130 mm motors, and small axes by SD24-LP. The operator picks the recipe and sees the result on an HMI-R9 panel.

What decides the result

  • The force-displacement curve. In press-fitting, force is tracked against position and the part is judged good or bad by whether the curve stays inside a window.
  • Traceability. Each part's result goes from the PLC to the plant system, and a bad part is separated before it leaves the line.
  • Manned stations. Where an operator reaches in, the safe stop is designed from the risk assessment; STO is the drive's part of it.

Sizing it

We need the peak press force, stroke, speed and cycle, and the transmission (ball screw, gearbox). The selection guide and the sizer start there.

Select the products for this machine Enter power, torque and network; compare compatible drives and motors and add them to your basket. Selection guide
3.2

The architecture: which product goes where

The boxes show the real products; click one to open the series.

EtherCAT Operator panel HMI-R9 Controller · CODESYS MAT-LC CPU I/O and sensors MAT-LC I/O · PNP / NPN Safe stop STO · brake Supply protection EMI · braking resistor Servo press Drive · SDU3 CSP / CST · EtherCAT Motor SM13 Screwdriving Drive · SD24-LP CST · EtherCAT Motor SM06 Transfer line Drive · SDU3 CSP · EtherCAT Motor SM10 Test bench Drive · SDU3 CSV / CST · EtherCAT Motor SM13
  • EtherCAT
  • Ethernet
  • Power and feedback
  • Safety
Where this machine sits on the full SMB system map
CPU / PLC & Motion Control 3 series Expansion Rack / IO 10 products Ethernet switch Ethernet Operator Panels 3 series Sensors 3 series EtherCAT Servo Drives 17 products CANopen Servo Drives 6 products Modbus RTU Servo Drives 4 products Servo Motors 6 series Power and Encoder Cables 2 series CODESYS IEC 61131-3 PLCopen Motion Control CiA 402 Drive profile
EtherCAT Ethernet CANopen Modbus RTU Digital I/O Power and feedback

CPU / PLC & Motion Control

Expansion Rack / IO

Ethernet switch

The industrial switch distributes Ethernet traffic between the controller, the operator panel and the engineering PC. It is part of the architecture, not part of the SMB catalogue.

Operator Panels

Sensors

EtherCAT Servo Drives

CANopen Servo Drives

Modbus RTU Servo Drives

Servo Motors

Power and Encoder Cables

CODESYS

SMB controllers are programmed in CODESYS: the IEC 61131-3 languages, integrated motion and a single project covering both machine logic and the axes.

PLCopen

PLCopen Motion Control function blocks give every axis the same standard interface, so proven machine code carries over from one project to the next.

CiA 402

SMB servo drives implement the CiA 402 drive profile: the same state machine and the same operating modes over EtherCAT and over CANopen.

3.4

The build, step by step

From requirement to support; the SMB products and tools each step uses.

  1. 1

    Requirements and sizing

    The motion profile, load and cycle time of every axis are collected; torque, speed and inertia ratio are calculated per axis.

    • Peak and RMS torque, top speed
    • Load-to-motor inertia ratio and gearing
    • Supply: 220 V AC, 380 V AC or 24–70 V DC
    Sizer Selection guide
  2. 2

    Architecture and product choice

    The network (EtherCAT, CANopen, Modbus RTU), the controller and the drive–motor pair per axis are chosen; the safety and power side is drawn at this step.

    • EtherCAT for synchronised axes, CANopen for independent ones
    • Drive current covers the motor peak current
    • STO and braked motors come from the risk assessment
    SM13-DIN13-150B0 MAT-LC-C06 MAT-HMI-R9070-WE MAT-SDU3-MP-300-D3-E
  3. 3

    Cabinet, cabling and EMC

    Power and encoder cables run in separate ducts with their shields bonded 360°; an EMI filter goes at the drive input and a braking resistor where the load regenerates.

    • Flexible cable for the cable chain
    • Shields are earthed at both ends
    • The braking resistor is sized from the braking energy
    Power / Motor Cables Encoder Cables SMKP Power Connectors SMKE Encoder Connectors EMI Filters Braking Resistors
  4. 4

    Software and network

    In the CODESYS project the axes are defined with PLCopen blocks; the drives join the network through their ESI/EDS files and run the CiA 402 state machine.

    • IEC 61131-3 languages and PLCopen Motion Control
    • ESI (EtherCAT) and EDS (CANopen) in the Document Centre
    • EtherCAT coupler for remote I/O
    MAT-LC CodeSys CPU MAT-LC I/O Modules MAT-LC System Modules
    CODESYS FAQ Document centre
  5. 5

    Commissioning and tuning

    After wiring and direction checks the gains are tuned and the axes homed; the operator panel carries the machine recipes.

    • Direction, limit and emergency-stop tests
    • Speed and position loop gain tuning
    • Backing up the parameter sets
    HMI-R9 Series
    Commissioning FAQ Troubleshooting
  6. 6

    Support and lifecycle

    Alarm codes, spare parts, firmware and training, from the same engineering team.

    • Alarm-code and troubleshooting guides
    • Manual, CAD and firmware downloads
    • Remote and on-site support
    Technical support Document centre
3.5

The solution package: what comes with the product

Hardware, software, engineering and lifecycle.

02

Software and know-how

The CODESYS project, PLCopen motion blocks and know-how specific to this machine.

  • Force-displacement monitoring and good/bad judgement
  • Per-part traceability and data transfer
  • Safe stop at manned stations
03

Engineering support

Sizing, architecture, commissioning and tuning, on site and remotely.

  • Motor and drive sizing per axis
  • System architecture and network choice
  • Commissioning, gain tuning and homing
04

Lifecycle

Manuals, ESI/EDS files, spare parts and training.

  • Document Centre: manuals, CAD, firmware
  • ESI and EDS files, parameter backups
  • Spare parts and user training
Engineering knowledge base

Commissioning this application

The topics engineers in this industry ask about most, each with answers, checklists and troubleshooting steps.

CODESYS PLC and I/O System design EtherCAT

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