Smart factory with igus® - VW Golf production on a scale of 1:18 for training in metal and electrical professions

Volkswagen Wolfsburg relies on 12 individual stations for metal, pneumatics, 3D printing, electrics, robotics, PLC and visualisation for the practice-oriented training of new specialists
In the vocational training programme at Volkswagen AG in Wolfsburg, apprentices from a wide range of disciplines work on the simulation of delivering the VW Golf on a scale of 1:18.

The smart factory consists of 12 individual stations that, when pushed together, form two parallel production lines. Golf production is simulated, starting at the press plant, then passing through body construction, paint shop, marriage, assembly and vehicle delivery.

During the production simulation, special attention is paid to ensuring that the drive mechanism is clearly visible, and an electrical solution should be found instead of the previous pneumatic solution. In order to accurately track the movement, the slide was made of transparent Makrolon.

Profile

What was needed: An electric drive mechanism for a production simulation for training purposes
Requirements: A special requirement was a visible drive system, but also the absence of air as a medium
Industry: Automotive industry, education
Success for the customer: The Apiro® rack gear allows for a simple and lubrication-free drive. This solution includes teaching modules for metal workers and electricians. After the conversion there is content for metal workers and electricians. The model includes gearbox technology, mechanics, electrics and programming

Modular automation system with several robot cells in a production hall.

Problem

Volkswagen AG was faced with the challenge of finding a technically demanding, yet cost-effective solution for the slide, its guidance and its drive.
For training purposes, the entire simulation had to be visible from all perspectives.

A special demand was also placed on the gearbox as precise observation of the shifting was important. However, it was also necessary to do away with the medium of air.

In addition, the transport skid and the Golf had to be transported separately so as not to obstruct each other.

Solution

igus® was not only able to provide support in an advisory capacity, but was also convincing in terms of product technology.

The guides were designed with drylin® pillow blocks WR10, which run on single rails WS-10. The movement was driven by an Apiro® rack gear and controlled by a NEMA 17 stepper motor. The factory simulation project was successfully implemented with a D1 motor control system.

Due to the positioning accuracy, lightness and lack of lubricants of the igus® products, the model is ideal for use for various training purposes in various specialist areas.
The “Smart Factory” has since become a successful part of the gearbox course in the training professions at Volkswagen AG.

Apiro wormgear standard gearbox with visible flange and connecting shaft.

Products used

drygear® Apiro® gearbox with hollow shaft

igus dryve D1 control unit with connectors and status display.

drylin® D1 motor control system

Starterkit Apiro: various individual parts of the gantry system on a white background.

Suitable products

Assemble your own robot, including instructions

Robotics kit of the Apiro® modular gearbox system for educational institutions

Roibot test setup with a model car on a conveyor track.

Technical excellence and educational potential
Practical training is invaluable in technical professions. There is no denying that theoretical knowledge and technical understanding are fundamental. However, all theory is only as good as its application in practice.

It is precisely for this reason that apprentices in technical professions should not only be provided with theoretical knowledge during their training, but also have sufficient opportunity to apply and deepen this knowledge in practice. Practical training enables aspiring specialists to test and sharpen their skills and understanding. They will learn what certain technical devices and machines are designed for, how they work and how they need to be maintained and repaired.

Our experts from igus® will be happy to advise you on your individual application.

Apiro® configurator

Kinematics tailored to your needs

Enter your requirements into the Apiro® modular gearbox system online configurator and receive an application overview. The input can be requested as a quotation or you can conveniently download your configuration as a CAD file.