Application client

Fabrication d'armoires de commande chez Ford avec les blocs de jonction WAGO

Avec l'introduction de la chaîne de montage, Henry Ford a laissé une marque indélébile qui a fait de lui l'un des pionniers les plus importants de l'industrie automobile. L'ambition de son entreprise a toujours été d'améliorer le processus de production. Sur son site de production de Cologne, en Allemagne, il a reconstruit l'ensemble de sa ligne de presse qui fabrique des pièces de châssis pour la Ford Fiesta. L'une des vedettes de cette rénovation : le bloc de jonction sur rail de WAGO.

Près de 19 000 employés contribuent à la production de l'un des modèles de voitures compactes les plus populaires de Ford. Depuis 1976, jusqu'à 1 400 Ford Fiesta sortent chaque jour de la chaîne de montage. Ford utilise de gros équipements dans ses installations de production, mais ce sont parfois les petits détails qui font toute la différence. Par exemple, les grandes poinçonneuses et presses utilisées pour fabriquer les composants du châssis ont une durée de vie de plusieurs décennies. Cependant, de nombreux composants et systèmes internes de la ligne de presses ne durent pas aussi longtemps. Pour remédier à cela, Ford installe régulièrement de nouveaux assemblages, met à jour l'électronique et développe la technologie de sécurité de ses lignes de presses. Au cours de ce processus, la technologie de contrôle et d'automatisation ainsi que la distribution d'énergie dans les armoires de commande sont également mises à jour et optimisées.

Vos avantages avec le smartDESIGNER de WAGO

Aucune installation
Fonctionne exclusivement sur un serveur nuage (aucune mise à jour)
Accessible partout
Création d'assemblages personnalisés avec les produits WAGO
Bibliothèques de pièces personnalisables pour les composants courants
Ajoutez des étiquettes personnalisées qui peuvent être envoyées directement à la smartPRINTER de WAGO

Points forts du produit

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L'histoire

Un prestataire au sein de l'entreprise

Le site de l'usine Ford abrite également le département de production interne des équipements. Dans ce département, environ 180 employés réalisent des projets de conversion et de modernisation pour divers équipements de l'usine de production. L'accent est mis principalement sur la fabrication d'armoires de commande. Ce département couvre normalement l'ensemble du spectre, de la planification et la conception électriques à la structure mécanique et au câblage, en passant par la programmation et la mise en service. Les commandes pour la production d'équipements internes proviennent principalement des deux usines Ford allemandes de Cologne et de Sarrelouis. Mais les autres usines européennes ont également déjà mis en œuvre des projets qui doivent résister à la concurrence externe.

Conversion à la technologie de borniers standardisés dans le cadre d'un projet

Les différents clients internes du groupe Ford ont parfois des exigences très différentes pour leurs projets. Cela vaut également pour les composants destinés à être utilisés dans les armoires de commande, par exemple. Par conséquent, dans le passé, différents borniers provenant de différents fournisseurs étaient souvent utilisés dans les armoires de commande. Il y a deux ans, lors de la conversion d'une ligne de presse dans l'usine de Cologne, l'idée est venue pour la première fois de standardiser les borniers en passant exclusivement aux borniers sur rail WAGO pour la conversion de la ligne de presse. L'accord sur un système uniforme basé sur le projet apporte d'énormes avantages pour la logistique, les achats et l'approvisionnement en pièces de rechange.

Pour les personnes concernées chez Ford, le choix des borniers sur rail WAGO s'est basé sur des considérations financières et (surtout) techniques. La concentration spécifique au projet sur un seul système de borniers réduit les volumes de stockage et offre une prévisibilité à tous les employés impliqués dans le processus de planification et de production. La technologie de connexion innovante Push-in CAGE CLAMP® de WAGO offre aux clients finaux une qualité de contact supérieure, même (et surtout) dans des conditions extrêmes. L'un des principaux avantages techniques des borniers sur rail WAGO réside dans la technologie de connexion par enfichage. Non seulement elle accélère le câblage par rapport aux anciens borniers à vis, mais elle offre également l'avantage de ne nécessiter aucun entretien, contrairement aux connexions à vis qui doivent être resserrées à intervalles réguliers. Avec les borniers WAGO, ce travail n'est pas nécessaire. Cela permet de gagner un temps considérable lors de la maintenance. De plus, les défauts sont moins fréquents. Les grandes presses sont soumises à des vibrations très importantes. Cela peut entraîner un desserrage des raccords vissés. Il y a deux ans, le service de maintenance a donc recommandé de passer aux borniers sur rail WAGO, qui étaient déjà référencés comme standard dans l'usine, pour la conversion de la ligne de presses.

Câblage simplifié et marquage clair

La technologie de connexion par enfichage des borniers sur rail TOPJOB® S de WAGO rend non seulement ces derniers exempts d'entretien, mais permet également au personnel du service électrique de réduire le temps de câblage de près de 25 %. Les conducteurs avec embouts sertis s'insèrent facilement, ce qui rend le câblage très rapide et simple par rapport aux borniers à vis. La méthode de marquage permet également de gagner du temps : il existe des bandes de marquage standardisées pour toutes les tailles de borniers, que les employés de Ford peuvent imprimer rapidement et facilement à l'aide de l'une des deux imprimantes achetées à cet effet. Les imprimantes intelligentes WAGO sont contrôlées en ligne, ce qui permet de stocker les marquages créés et de les réutiliser dans des projets ultérieurs. Les bandes de marquage offrent suffisamment d'espace pour étiqueter clairement les points de connexion. Cela permet également de gagner du temps lors du câblage, car les employés trouvent plus rapidement le bon point de connexion. De plus, le marquage clair facilite considérablement la maintenance en cas de dépannage. Outre les borniers pour montage sur rail, l'imprimante intelligente peut également être utilisée pour marquer les conducteurs à l'aide de manchons de marquage ou de marqueurs à visser, ce qui en fait une solution extrêmement polyvalente.

Le bornier adapté à chaque application

Les armoires de commande construites par le service de fabrication interne utilisent principalement des borniers sur rail TOPJOB® S. Ils servent à connecter une grande variété de signaux provenant de capteurs et d'actionneurs. Ford se limite à trois ou quatre séries de borniers sur rail. Cela fonctionne très bien, d'autant plus que les borniers permettent d'accueillir une très large gamme de sections de conducteurs. La distribution de puissance avec des conducteurs de grande section est assurée par des borniers sur rail à courant fort équipés de POWER CAGE CLAMP. Les experts de Ford utilisent également les borniers WAGO pour d'autres applications. L'enregistrement de la consommation électrique est devenu un élément important dans de nombreux projets. À cette fin, Ford utilise des convertisseurs de courant et des modules de mesure de puissance triphasés, ainsi que des modules fonctionnels de la gamme d'automatisation 750 de WAGO.

Au cours des dernières vacances d'usine, une autre ligne de presse a également été convertie. Sur la base des succès passés, l'armoire de commande a de nouveau été équipée de borniers sur rail WAGO. L'utilisation des borniers sur rail standardisés pour les projets de conversion de lignes de presses est désormais devenue une routine. Cependant, lors de la conversion, il était important pour l'unité de production interne que l'assistance WAGO soit toujours disponible pour aider l'équipe Ford à s'y retrouver dans une large gamme de produits. L'étroite collaboration entre le compte clé Ford chez WAGO, le bureau commercial local de WAGO et les conseillers en systèmes industriels a permis de réduire les temps de réponse.

Texte : Lena Kalmer | WAGO Photo : Ford

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Les produits WAGO sont utilisés dans tous les domaines de la construction automobile. Notre technologie de connexion sans vis garantit une disponibilité maximale du système au niveau des conducteurs, tandis que les contrôleurs et les E/S déportées de WAGO prennent en charge la gestion de l'énergie et les processus IIoT. Dans tous les cas, WAGO peut être un partenaire essentiel pour une production efficace dans la construction automobile, aujourd'hui comme demain.