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Customer application 7 October 2020

Round-the-Clock Consistent Brightness Levels

To ensure optimal lighting for its workers in all production areas, the automotive supplier GETRAG FORD Transmission GmbH in Cologne has replaced their fluorescent tubes with modern, energy-efficient LEDs. WAGO Lighting Management ensures consistent brightness levels around the clock.

Good lighting has large effects on productivity, because humans remain highly responsive to visual information. It also creates a comfortable, motivating work atmosphere. Lighting studies show that people are more productive and work with greater concentration under optimal visual conditions. The work quality increases and the error rates drop. Another aspect in industrial production, which should not be overlooked, is that good lighting positively influences worker well-being, and thus their health. This topic is so important that the technical regulations for workplaces include detailed requirements for lighting systems.

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Modernization of Transmission Manufacturing

Die GETRAG FORD Transmissions invests regularly in improvements to production quality. Therefore, the company decided to completely rehabilitate their Cologne facility. New equipment, new floors, fresh paint on the walls and ceiling create bright, comfortable working conditions. And the newly installed lighting system lets the hall shine. Transmissions for different vehicles made by Ford, Volvo, Land Rover and Mercedes-Benz are produced in the freshly renovated building.

GETRAG FORD Transmissions is a product division of Magna Powertrain, a Magna International subsidiary. Under the auspices of Magna, the company develops and produces drivetrain solutions for the automotive sector. Since its founding in 1935, the company has developed from a family-owned enterprise in Swabia to an automotive vendor with global reach. Their broad product portfolio includes manual transmissions, double-clutch and hybrid transmission designs for passenger and commercial vehicles. In order to satisfy specific customer requests, from concept up to series production, the company employs more than 16,300 workers in development and production on three continents.

Quality Factor: Light

During the day, the assembly hall at GETRAG FORD Transmissions in Cologne is quite bright, since a relatively large amount of natural light enters through the skylights. During times of bright natural lighting, the artificial lights are dimmed to support the day light. The highest illumination levels are reserved for the evening and night hours.

“Good lighting is an absolute necessity in transmission manufacturing, explains Walter Focke, the technician responsible for the new lighting system at GETRAG Ford Transmissions. “Light is already a direct factor in quality. It has happened that multiple lights failed in a short period of time in one area, and our maintenance team did not react quickly enough to remedy the problems. This had direct, negative impacts on quality, because the workers could no longer see well.” It is especially important in the assembly areas that there is correct lighting, because the workers have to deal precisely with small distinctions.

New Lighting in a Practical Test

Comprehensive planning and field tests preceded the comprehensive rehabilitation of the transmission building at the Cologne facility. Philips, a long-term lighting provider and partner for illumination questions provided the lighting calculations. Key data were determined from the building circumstances. The positioning and spacing of the individual lights and light strips should not need to be changed, and the number of light inserts was also fixed at 20 lights per strip.

In was important for the company to check the light calculations in a practical test. Walter Focke had the corresponding lights installed on a test surface in order to measure the illumination levels. The occupational health regulations prescribe an illumination level of 500 lux for assembly floors, and 100 lux for walkways and storage areas.

LED lights are, like other illumination sources, subject to aging: thus, they lose luminosity over time. “For this reason,” explains Focke, ”we planned for a reserve in the design. After all, we want to be able to call up the necessary 500 lux in the assembly hall over the entire lifecycle of the lights, so we currently operate the lighting system at 80 percent output.”

Higher Energy Efficiency

The old conventional light with two 49-watt fluorescent lights was replaced throughout the hall with LEDs. The advantage of LED illumination: it requires less power, only 36 watts, and provides a higher light yield.

In direct comparison of energy consumption, there are clear advantages for the new LED lighting systems. GETRAG FORD Transmissions examined two test cases, which correspond to facility use: during the day shift with natural light and in three-shift operation. Operation as a support to natural light resulted in savings of around 70 percent, three-shift operation led to savings of around 30 percent.

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Lighting Management at European Standards

In their selection of lights and control technology, working at a European standard which is mature enough that all well-known manufactures offer it and which will be easily obtainable several years down the road for expansions and replacement parts was important to Focke. Lighting management with DALI lighting control was the ideal solution for the company. WAGO designed and implemented the controller following the lighting concept designed by Philips.

Because no special programming is needed, the WAGO solution provided several advantages to Walter Focke. “We can simply access the bus through a fixed interface, and we can link to lights and sensors using this interface. In addition, WAGO offers a convincing modular construction style. Depending on our needs, we can order the modules individually and plug them together.

The system remains flexible, because it can be expanded with additional modules at any time. Additional modules allow for the implementation of new functions, for example, power measurements.

A complete conversion to LED lights is planned.

“In the first hall section, we concentrated on creating the optimal workplace lighting for our colleagues. The hall lighting incorporates natural light through sensors, and controls the lights according to the brightness. The lights are switched on using a classic tablet provided with luminous buttons,” explains Focke. Today, at the end of shift, the responsible employee walks through the hall and switches the lights off manually. GETRAG FORD Transmissions plans to successively equip the entire hall lighting with LEDs in the coming year. A central lighting control is also under consideration over the course of this project.

Text: Daniel Kocks, WAGO
Photo: Jens Sundheim

Product Overview

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