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Kundapplikation 1 februari 2021

Round-the-Clock Consistent Brightness Levels

För att säkerställa optimal belysning för sina anställda i alla produktionsområden har billeverantören GETRAG FORD Transmission GmbH i Köln ersatt sina lysrör med moderna, energieffektiva lysdioder. WAGO Lighting Management säkerställer jämna ljusstyrkenivåer dygnet runt.

Bra belysning har stora effekter på produktiviteten, eftersom människor fortfarande är mycket lyhörda för visuell information. Det skapar också en bekväm, motiverande arbetsatmosfär. Ljusstudier visar att människor är mer produktiva och arbetar med större koncentration under optimala visuella förhållanden. Arbetskvaliteten ökar och felfrekvensen sjunker. En annan aspekt i industriproduktionen, som inte bör förbises, är att god belysning påverkar arbetstagarnas välbefinnande och därmed deras hälsa positivt. Detta ämne är så viktigt att de tekniska föreskrifterna för arbetsplatser innehåller detaljerade krav på belysningssystem.

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Modernisering av transmissionstillverkning

GETRAG FORD Transmissions investerar regelbundet i förbättringar av produktionskvaliteten. Därför beslutade företaget att helt rehabilitera deras anläggning i Köln. Ny utrustning, nya golv, ny färg på väggar och tak skapar ljusa, bekväma arbetsförhållanden. Och den nyligen installerade belysningssystem låter hallen lysa. Växellådor för olika fordon från Ford, Volvo, Land Rover och Mercedes-Benz tillverkas i den nyrenoverade byggnaden.

GETRAG FORD Transmissions är en produktdivision inom Magna Powertrain, Magna International dotterföretag. Under regi av Magna utvecklar och producerar företaget drivlinelösningar för bilindustrin. Sedan starten 1935 har företaget utvecklats från ett familjeägt företag i Schwaben till en bilförsäljare med global räckvidd. Deras breda produktportfölj inkluderar manuella växellådor, dubbelkoppling och hybridväxellådor för personbilar och kommersiella fordon. För att tillgodose specifika kundförfrågningar, från koncept till serieproduktion, sysselsätter företaget mer än 16 300 arbetare inom utveckling och produktion på tre kontinenter.

Kvalitetsfaktor: Ljus

Under dagen är monteringshallen på GETRAG FORD Transmissions i Köln ganska ljus, eftersom en relativt stor mängd naturligt ljus kommer in genom takfönstren. Under tider med stark naturlig belysning är de konstgjorda lamporna nedtonade för att stödja dagsljuset. De högsta belysningsnivåerna är reserverade för kvällen och natten.

”Bra belysning är en absolut nödvändighet inom transmissionstillverkningen, förklarar Walter Focke, tekniker som ansvarar för det nya belysningssystemet på GETRAG Ford Transmissions. ”Ljus är redan en direkt kvalitetsfaktor. Det har hänt att flera lampor inte fungerat på kort tid i ett område, och vårt underhållsteam reagerade inte tillräckligt snabbt för att lösa problemen. Detta hade direkta, negativa konsekvenser för kvaliteten, eftersom arbetarna inte längre kunde se bra. " Det är särskilt viktigt i monteringsområdena att det finns korrekt belysning, eftersom arbetarna måste hantera små skillnader med exakthet.

Ny belysning i ett praktiskt test

Omfattande planering och fälttester föregick den omfattande rehabiliteringen av transmissionsbyggnaden vid Köln-anläggningen. Philips, en långvarig belysningsleverantör och partner för belysningsfrågor, tillhandahöll belysningsberäkningarna. Nyckeldata bestämdes utifrån byggnadsförhållandena. Placeringen och avståndet för de enskilda lamporna och ljusremsorna borde inte behöva ändras, och antalet ljusinsatser fastställdes också till 20 lampor per remsa.

Det var viktigt för företaget att kontrollera ljusberäkningarna i ett praktiskt test. Walter Focke hade motsvarande lampor installerade på en testyta för att mäta belysningsnivåerna. Arbetshälsoföreskrifterna föreskriver en belysningsnivå på 500 lux för monteringsgolv och 100 lux för gångvägar och förvaringsutrymmen.

LED-lampor är, som andra ljuskällor, föremål för åldrande: de förlorar således ljusstyrkan över tiden. ”Av denna anledning,” förklarar Focke, ”planerade vi en reserv i designen. När allt kommer omkring vill vi kunna hämta de nödvändiga 500 luxen i monteringshallen under hela lampornas livscykel, så vi använder för närvarande belysningssystemet med 80 procents effekt. ”

Högre energieffektivitet

Det gamla konventionella ljuset med två 49-watts lysrör ersattes genom hela hallen med lysdioder Fördelen med LED-belysning: den kräver mindre effekt, bara 36 watt och ger ett högre ljusutbyte.

I direkt jämförelse av energiförbrukningen finns det tydliga fördelar med de nya LED-belysningssystemen. GETRAG FORD Transmissions undersökte två testfall, som motsvarar anläggningsanvändning: under dagskift med naturligt ljus och i tre-skiftdrift. Drift som stöd för naturligt ljus resulterade i besparingar på cirka 70 procent, tre-skiftdrift ledde till besparingar på cirka 30 procent.

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Ljushantering enligt europeiska standarder

I deras urval av lampor och styrteknik var det viktigt för Focke att arbeta på en europeisk standard som är tillräckligt mogen för att alla välkända tillverkare erbjuder den och som lätt kan uppnås flera år på vägen för utvidgningar och reservdelar. Lighting management med DALI belysningsstyrning var den perfekta lösningen för företaget. WAGO designade och implementerade styrenheten enligt belysningskonceptet designat av Philips.

Eftersom ingen speciell programmering behövs gav WAGO-lösningen Walter Focke flera fördelar. ”Vi kan helt enkelt komma åt bussen via ett fast gränssnitt, och vi kan länka till lampor och sensorer med detta gränssnitt. Dessutom erbjuder WAGO en övertygande modulär konstruktionsstil. Beroende på våra behov kan vi beställa modulerna individuellt och koppla ihop dem.

Systemet förblir flexibelt eftersom det när som helst kan utökas med ytterligare moduler. Ytterligare moduler möjliggör implementering av nya funktioner, till exempel effektmätningar.

Ett fullständigt utbyte till LED-lampor är planerad.

”I den första hallsektionen koncentrerade vi oss på att skapa en optimal arbetsbelysning för våra kollegor. Hallbelysningen innehåller naturligt ljus genom sensorer och styr lamporna efter ljusstyrkan. Lamporna tänds med en klassisk surfplatta med lysknappar, förklarar Focke. Idag, i slutet av skiftet, går den ansvariga medarbetaren genom hallen och stänger av lamporna manuellt. GETRAG FORD Transmissions planerar att successivt utrusta hela hallbelysningen med lysdioder under det kommande året. En central belysningskontroll övervägs också under projektets gång.

Text: Daniel Kocks, WAGO
Foto: Jens Sundheim

Produktöversikt

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Belysningsinstallation och Automation som visar sina värden

Intelligent belysningsstyrning från WAGO

WAGO Lighting Management är den raffinerade lösningen för belysningsstyrning i stora utrymmen som produktionsanläggningar och lager. Med hjälp av en kombination av fördefinierad hårdvara och användarvänlig programvara erbjuder WAGO ett belysningssystem som underlättar design och driftsättning av nya belysningssystem, samtidigt som ytterligare driftsfördelar tillhandahålls.

Din WAGO kontaktperson