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Référence

12 décembre 2018

Chez Ford, la construction d'armoire de commande mise sur les bornes WAGO.

Henry Ford a sans aucun doute été un des principaux pionniers de la construction automobile moderne et il a marqué le secteur comme aucun autre en introduisant la production à la chaine. Son ambition, améliorer en permanence les processus, figure encore aujourd'hui dans l'ADN de l'entreprise. Pendant les dernières vacances, le site de production de Cologne a réaménagé et optimisé la ligne de presse où sont produites les pièces de carrosserie de la Fiesta. Dans ce cas, un seul petit élément visible a notamment été décisif : un bloc de raccordement de WAGO.

Beaucoup de choses sont importantes à l’usine Ford de Cologne, mais parfois de petits détails comptent :
18 600 collaborateurs travaillent chez Ford à Cologne et y produisent l'un des modèles à succès. Jusqu'à 1 400 unités de la populaire petite voiture Ford Fiesta sortent actuellement des chaînes de montage chaque jour - et ce depuis 1976 ! Les grandes poinçonneuses et presses utilisées pour la fabrication des pièces de carrosserie ont une durée de vie de plusieurs décennies. Cependant, de nombreux composants et systèmes autour des lignes de presse ne durent pas aussi longtemps. Pour la conversion et la mise à niveau, qui est généralement effectuée pendant les vacances d'usine, on installe par exemple de nouveaux groupes électrogènes, on élargit la technologie de sécurité ou on met à jour l'électrotechnique. Les armoires de commande avec la technologie de contrôle et d'automatisation ainsi que la distribution d'énergie sont également renouvelées et encore optimisées.

Prestataire de services au sein de l'entreprise

Sur le site de l'usine Ford se trouve aussi le bâtiment d'équipement interne. Dans ce département, environ 180 collaborateurs réalisent des projets de conversion et de modernisation de différents systèmes de production. La tâche principale est la construction d'installations de contrôle et de commutation. Le service couvre généralement toute la gamme : de la planification électrique et de la construction en passant par la structure mécanique et le câblage, jusqu'à la programmation et la mise en service. Les commandes pour la construction de l'ameublement proviennent principalement des deux usines allemandes Ford à Cologne et à Sarrelouis. Mais d'autres usines européennes ont déjà réalisé des projets qui doivent résister à la concurrence extérieure.

Conversion en fonction du projet vers une technologie de borne uniforme

Les différents clients du groupe Ford ont parfois des exigences très différentes pour leurs projets. Cela concerne également les composants qui doivent par ex. être utilisés dans une armoire de commande. En conséquence, dans le passé, différentes bornes provenant de divers fournisseurs étaient utilisées à plusieurs reprises dans les armoires de commande. Il y a deux ans, lors de la transformation d'une ligne de presse dans l'usine de Cologne, l'idée est née d'unifier la technique de bornes et d'utiliser exclusivement les bornes sur rail de WAGO dans le projet de conversion de la ligne de presse. L'accord sur un système unique en fonction du projet offre d'énormes avantages dans la logistique, les achats et l'approvisionnement en pièces de rechange.

Il y a des raisons économiques et surtout techniques pour lesquelles les responsables de Ford ont décidé d'utiliser les bornes sur rail WAGO. La concentration sur un système de bornes en fonction du projet réduit les volumes de stockage et assure la sécurité pour tous les employés impliqués dans le processus de planification et de fabrication. La technologie de connexion innovante Push-in CAGE CLAMP® offre aux clients finaux une qualité de contact optimale, même ou surtout dans des conditions de d'utilisation défavorables. L'un des principaux avantages techniques de ces bornes sur rail est la technique de raccordement Push-in. Cela signifie que le câblage est non seulement plus rapide qu'avec les anciennes bornes à vis, mais le fait que les bornes ne nécessitent aucun entretien constitue également un gros avantage car les connexions à vis doivent être resserrées à intervalles réguliers. Ce travail peut être supprimé avec les bornes WAGO. Il en résulte des économies importantes dans la maintenance. De plus, les erreurs sont moins fréquentes. Sur les grandes presses, il y a des vibrations très fortes. Il y a donc un risque que les connexions à vis se desserrent. C'est pourquoi le service de maintenance a décidé il y a deux ans de passer aux bornes sur rail WAGO pour le projet de conversion de la ligne de presse, déjà répertoriées comme standard d'usine à l'époque.

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Câblage plus simple et marquage clair

La technique de raccordement Push-in des bornes sur rail WAGO TOPJOB S garantit non seulement une absence d'entretien mais également une maintenance facilité. Les spécialistes du service électrique économisent également jusqu'à 25% de temps lors du câblage. Les conducteurs avec embout d'extrémité peuvent être enfichés facilement - cela rend le câblage très simple et rapide par rapport aux bornes à vis. Mais le type de repérage permet également de gagner du temps : pour toutes les tailles de bornes, il existe des bandes de repérage uniformes que les employés de Ford peuvent imprimer rapidement et facilement avec l'une des deux imprimantes achetées à cet effet. Les WAGO Smart Printer sont commandés en ligne. On peut y sauvegarder des repères déjà créés et les réutiliser pour des projets ultérieurs. Les bandes de repérage offrent suffisamment d'espace pour que les points de serrage puissent être clairement marqués. Cela permet également de gagner du temps lors du câblage, car l'employé trouve plus rapidement le point de connexion adapté. Le repérage clair facilite également grandement la maintenance si une erreur doit être corrigée. En plus des bornes sur rail, Smart Printer permet également de repérer des conducteurs avec des douilles de repérage ou des marquages de fils à enfiler - une solution très variable dans l'ensemble.

La borne adaptée pour chaque application.

Les bornes sur rail TOPJOB® S sont principalement utilisés dans les armoires électriques produites par le service interne de construction des installations. Celles-ci sont utilisées pour connecter une grande variété de signaux de capteurs et d'actionneurs. Ford se limite à trois ou quatre séries de bornes sur rail. Cela fonctionne également très bien car la plage des sections de conducteur possibles pour les bornes est très large. La distribution d'énergie avec de grandes sections de conducteurs se fait via des bornes de puissance POWER CAGE CLAMP . Les spécialistes de Ford utilisent également les bornes de WAGO pour d'autres exigences. L'enregistrement de la consommation d'énergie est devenu un sujet important. Pour cela, Ford utilise des transformateurs d'intensité et le module de mesure de puissance à 3 phases ainsi que des modules fonctionnels de la gamme d'automatisation WAGO de la série 750.

Même dans les dernières vacances d'usine, une ligne de presse a été rénovée - après les expériences positives, l'armoire de commande a été à nouveau équipée de bornes sur rail WAGO. Entre-temps, l'utilisation des bornes sur rail standard est devenue une routine dans le projet de transformation de la ligne de presse. Lors de la phase de transition, il était très important pour l'équipe dans la construction d'installations que l'assistance WAGO soit toujours disponible rapidement pour aider à s'orienter dans la vaste gamme. Ici, l'étroite imbrication entre le Key Account Ford, la distribution locale WAGO et le consultant en systèmes industriels WAGO conduit à des temps de réaction rapides.

Texte : Lena Kalmer | WAGO

Photo : Ford

Aperçu des produits

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