Explore news, case studies, in-depth reports, and much more from the world of VESCON and SCIO - because together, we're shaping the future of automation. 🚀✨

Since 2019, the VESCON brands have been continuing their success story as part of the SCIO Automation Group. Today, SCIO stands as one of the world's leading companies in automation across the entire value chain of the Smart Factory.

The SCIO Group brings together the collective expertise of now 12 corporate brands, each with decades of success in their respective industries. Through this close collaboration, as VESCON Automation, Energy, Process and Aqua, we've not only forged strong partnerships but also ensured our customers benefit from our comprehensive range of services, powered by a strong corporate group.

To immerse you even further into the world of VESCON as part of SCIO, you can now discover the latest news and compelling stories about VESCON and its partner companies on our shared news portal! We invite you on a fascinating journey through the world of intelligent industry of tomorrow - from automated intralogistics and production solutions to accompanying services and beyond.

All news articles are available for you right here: https://www.scio-automation.com/update

For 16 years now, chemical company BASF has been honoring outstanding partnerships and first-class performance at their Ludwigshafen site with the Contractor Award. In July, the award ceremony was once again held in a wide variety of trade categories. 11 trades, 11 winners - including VESCON Process.

This year, our project team was nominated for its outstanding planning services in 2022 while working for our long-standing major client:

“We have been a reliable partner to BASF for a number of years, and support our client in the fields of plant design, strength calculations and periodic inspections, and process engineering and documentation”, explains Stefan Ruthmann, Managing Director of VESCON Process.

What services exactly are we talking about?

"In our services, we encompass our process engineering designs, such as safety valves, equipment calculations, documentation, and P&ID processing. Additionally, our 3D plant planning team creates digital models of facilities using tools like AVEVA PDMS or E3D. This allows us to generate construction plans for piping and steel structures required for production at BASF. Our pipe statics team is responsible for safety assessments within such facilities, ensuring that the piping systems, often subjected to extreme temperatures and high pressures, are sufficiently stable and secure", explains Marcel Claros, Head of department for strength calculations and periodic inspections.

The team deservedly triumphed over two other candidates in the end due to its extensive range of services and great flexibility when it comes to project development. The prestigious prize was proudly received by Marcel Claros and Thomas Wolf [Head of Process Engineering VESCON Process] during the formal ceremony.

"We're truly honored to receive this award. It underscores the incredible results we can achieve through teamwork and unwavering dedication", Stefan Ruthmann concluded with gratitude.

Learn more about VESCON Process services here.

In times when connected and digital production processes are constantly growing, unfortunately, cyberattacks are no longer uncommon. However, the security of our customers' sensitive information is our top priority. In all of our plant projects and company processes, we place the utmost importance on protecting their data. In doing so, we at VESCON Automation adhere to the requirements of major OEMs in the automotive industry, which require the so-called TISAX® certification for collaboration – an increasing number of companies are following this example. As of this year, VESCON Automation is also officially certified to the TISAX® standard.

What's behind the TISAX® certification audit, exactly?

TISAX stands for "Trusted Information Security Assessment Exchange" and is an assessment and exchange procedure for information security in the automotive industry. This standard is based on ISO/IEC 27001 and aims to establish an Information Security Management System (ISMS). The goal is to protect sensitive and confidential customer data of automotive companies and ensure their integrity and availability.

Our journey to TISAX® certification:

What security requirements do we need to meet? How do we ensure information security in project business? What standards do we need to implement for that? These are questions that we at VESCON Automation have been actively addressing in this year as part of the TISAX® certification audit.

Thanks to the excellent preparation and execution by our IT specialists and colleagues involved, VESCON Automation has successfully passed the important TISAX® audit on the first attempt.

"Getting TISAX® certified is a clear sign of our commitment to keeping information secure. It also shows that we're a dependable partner for projects. As a team, we're genuinely proud of this achievement,” Antonio Cavotta, management VESCON Automation.

You can find more about VESCON Automation's services here.

What do a ballet performance and virtual commissioning have in common? At first glance, not much, but they are enormously similar in terms of their approach: planning, rehearsing, correcting - until every detail of the choreography and every dancer’s move has been rehearsed. In the case of virtual commissioning, the installations control software is run, tested and optimized on a virtual model at an early stage of implementation. This is often carried out in conjunction with a cinematic 3D representation of the system. This means the errors can be detected and corrected before actual commissioning, so that the "premiere" is able to go off without a hitch. In our plant projects, such as converting a final vehicle assembly line with an electric monorail system (EMS), virtual commissioning has been an obligatory component for several years. However, many mechanical and plant engineers at mainly medium-sized companies still express their reservations at times:

“Setting up the virtual model is often seen as just an extra expense. We usually hear people saying things like: 'Our plants are too complex or the plant changes too often to model it.' However, this is exactly where the amazing potential of virtual commissioning comes in" - said Ulrich Reiser, CDO SCIO Automation.

What exactly are the benefits of Virtual Commissioning for our customers?

• The ability to validate the plant control system prior to commissioning:

Without virtual commissioning, you can only test the control system on the real plant. But an ensemble would never go on stage without a dress rehearsal, right? This is particularly essential for complex choreographies. Using virtual commissioning as a virtual dress rehearsal, we check especially complex systems for potential logic errors, which, in the worst-case scenario, might result in downtimes for the end customer. After all, no "dancer" is supposed to deviate from the choreography at the grand entrance! This is how we not only ensure the quality of the product and the process, but we can also significantly reduce the work required and thereby keep cost down for any potential adjustments in the program later on. Downtimes are a major issue, especially for series production in the automotive industry. For orders like our EMS project, it was crucial to use virtual commissioning to identify potential problems and logic errors in the plant PLC beforehand, and to properly prevent them by making adjustments. Within the first two days after commissioning, the plant was already running so stably that we were able to exceed all production targets.

• Increased flexibility over the course of the project:

By using virtual commissioning, we can test the plant and its control system in a systematic and efficient way – while also having a great deal of flexibility. For example, if changes to the plant or its environment occur during the project, we can quickly adapt the virtual model at any time and test the changes without taking any unnecessary risks. This is how we can not only prevent costly downstream adjustments on site, but also ensure that the plant performs as expected when it makes its grand entrance on the end customer’s premises - the commissioning phase.

• Shortened commissioning and project lead time:

Last but not least, virtual commissioning also makes it easier to integrate the machine or system into the real production environment. Although you can't do without the on-site programmer completely, there is significantly less work required. This is an enormous advantage, especially in a global industry such as mechanical and plant engineering. As the EMS project shows: Virtual commissioning allows us to successfully overcome challenges, whether that's due to scheduling demands or unforeseen obstacles such as the coronavirus pandemic, and ensure that the project is completed in a short period of time. Instead of being purely sequential, hardware and electrical design, procurement, PLC development and commissioning can also run in parallel. This makes resource planning more flexible, which keeps implementation and project costs low. Small and medium-sized companies in particular are able to hugely benefit from these advantages.

"We are constantly working on increasing efficiency when it comes to setting up the virtual model to establish virtual commissioning in all projects in the future, irrespective of how complex they are and what the customer’s requirements are. We are doing this the moment, for instance, by extending interfaces for data transfer from previous engineering steps. Our goal is to use the virtual model throughout a plant’s life cycle. This gives us the bandwidth to provide the best support to our customers that we possibly can in terms of  carrying out remote servicing and making changes during operation. We have already successfully implemented this system, which is known as a Digital Twin in an initial project," said Ulrich Reiser.

Read more about virtual commissioning here.

Meet our experts at Motek 2023 in Stuttgart. Experience our Virtual Engineering solutions like virtual commissioning up close from October 10-13!

As part of the international automation platform SCIO Automation, the VESCON Group will be showcasing its solutions for production and assembly automation at Booth 5501 in Hall 5 at Motek 2023 in Stuttgart. Visitors can look forward to a variety of exciting solutions, including our tailored production and testing systems, Virtual Commissioning, and the 360° collaboration software SO3.

After their impressive debut at Automatica in Munich, the team is already deep into the intense planning phase for their next major appearance. As an international SCIO team, VESCON Automation and VESCON Systemtechnik, along with MRB Automation, AUTKOM, Industrial Automation, and tmp, will be presenting their portfolio for production and assembly automation, including accompanying service areas, to interested trade visitors at Motek 2023 in Stuttgart.

Joining them are the experts from VESCON Systemtechnik with their custom machinery solutions, ranging from tailored manufacturing and production systems to measurement and testing stations. In their arsenal, they have the BDE and Traceability software SO3 Hiberion, including the innovative Control and Info Tower. Whether it's production status, troubleshooting information, order data, or production statistics, as well as dashboards – the streamlined tower serves as a central information hub at each setup. To demonstrate the tower's interaction with the setups live in action, our experts have something very special in mind… We won't give away too much just yet, but rest assured, there's an exciting energy boost in store!

In addition to their Virtual Engineering solutions, VESCON Automation will also showcase their E-Mobility expertise – for years, they have been collaborating with leading OEMs on battery(module) assembly.

Our accompanying services, such as our 360° Collaboration Software SO3 for demanding project engineering and management, will also be presented at the joint booth.

Learn more about our Motek appearance here!

214.70 km of cable, 2,460 tons of steel components, 200 tons of aluminum pipes, and 90 tons of high-voltage clamps – VESCON Energy GmbH has secured its largest contract to date to renovate the Sarasdorf substation for its long-time client Austrian Power Grid AG (APG). 

The Sarasdorf substation includes a 380kV switchgear and is linked to regional network operator Netz Niederösterreich via a 110kV connection. By expanding the facility as planned, APG will improve this connection, enabling surplus wind energy generated on-site to be efficiently fed into the regional APG grid and distributed nationwide in Austria, right where electricity is needed. The existing substation will need to be dismantled and rebuilt as part of the expansion and the increase in short-circuit strength, while a significant portion of the substation has to remain operational. The total contract is worth EUR 49 million, and this is VESCON Energy GmbH's largest project to date.

"We’ve been working closely and successfully with APG for a number of years now, and we’re delighted to have won them over them with our proposal and earned their trust for this major contract, which far exceeds the scope of all our previous projects," said Erol Pamir, Managing Director of VESCON Energy. The APG project is not only the largest project to date for VESCON Energy but it’s also the biggest that our entire SCIO group of companies has ever taken on. "SCIO’s support means we have the financial stability we need to effectively plan and make this challenging major project a reality," added Pamir.

VESCON Energy's team has been involved in preliminary planning, tendering, and execution planning for primary technology, secondary technology, construction technology, and building services for APG's substations for quite some time, with an average of two to three substations (UW) planned per year. VESCON Energy had already won the planning tender for renovating and expanding Sarasdorf substation just over a year ago, and successfully completed it at the end of last year. Following the planning phase, VESCON Energy has now secured the subsequent project for the entire electrical installation and will implement it in multiple construction phases until the end of 2029.

VESCON Energy has been actively expanding and modernizing power grids for over 20 years, working successfully and in trusted collaboration with long-standing customers. Its core expertise is in high- and extra-high-voltage projects for nodal points, feed-in points, and load acceptance points for substations and switchgear up to 380kV.

To find out more about VESCON Energy's services, click here.

The VESCON Group will be showcasing its Virtual Engineering solutions at booth 218 in hall A4 at automatica 2023 in Munich as part of international automation platform SCIO Automation. In addition to Virtual Commissioning, these include 360° collaboration software SO3, which is used to make project engineering and management simpler for plant engineering projects.

It has been part of international corporate platform SCIO Automation since 2019 as a founding member, and will be presenting part of its portfolio at a trade fair for the first time at a joint stand (A4, 218) at automatica.

"We’ve been supporting our customers from various industries in plant engineering and automation on their journey to Industry 4.0 for 30 years now. In the robotics and automation environment, in addition to our integration services, it’s our virtual engineering solutions for digital transformation in particular that greatly appeal to our customers," said Dr. Ulrich Reiser, Chief Digital Officer.

VESCON will present two Virtual Engineering solutions to the automatica trade audience:

Virtual Commissioning has already been successfully used by VESCON in its plant projects for several years, ensuring that on-site commissioning is done on time and on budget. VESCON uses several virtual commissioning software packages from different developers to allow them to offer a customized response to customer needs and requirements. Virtual commissioning has now become a crucial part of VESCON offering’s, paving the way for additional digitalization projects in the company such as the Digital Twin, which has already been successfully developed in initial customer projects.

SO3 cloud software is the 360° collaboration solution for sophisticated project engineering and management. It helps companies in the plant engineering sector to increase production by up to 50 percent and reduce project costs by up to 40 percent. As a centralized communication platform, it not only combines the project data for all trades in one place in real time, no matter where they are, but it also presents the project status, as well as electrical and mechanical data in a visual layout. Each project participant can create, view and edit their individual tasks and is in direct contact with all other relevant participants. This enables the entire plant engineering project to be seamlessly managed on a single, powerful, collaborative platform.

VESCON will be appearing alongside other brands from the SCIO Automation Group at automatica.

Companies like 4am Robotics, with its mobile and application-specific robotics solutions, as well as PrintoLUX with its patented PrintoLUX marking process including its latest printing system development for industrial applications, known as SIGNO, will also be on hand to wow the audience.

Founded in 2019, SCIO Automation Group is an international business platform for end-to-end industrial automation for logistics and production processes. It now includes 10 independent corporate brands at over 30 locations worldwide, which pool their expertise in intralogistics, production and process automation as part of SCIO. This gives SCIO the ability to support its customers by providing a bespoke, holistic service, with customized solutions for the entire smart factory, including product innovations that are uniquely tailored to each customer.

Cable harnesses are still assembled manually because they’re so unique and complex? Production is relocated to low-wage countries as well to keep costs low? Numerous manufacturers are familiar with these problems. This is a risky strategy for manufacturing companies given the accelerating rate of climate change worldwide and uncertain political events.

In order to protect a well-known supplier to the automotive industry from these problems, the experts at VESCON Systemtechnik are relying on innovative and customized automation solutions in a joint project, that allows their customer to benefit in a variety of ways. How do our experts make this possible?

1. They declaring war on non-rigid components

Non-rigid components such as cable harnesses can stop automation solutions becoming a reality for your cable assembly due to unwanted deformations. This is where customized workpiece carriers are massively needed! These helpful tools enable:

• The cables to be guided into the best position
• The cables to remain in the desired position during the entire assembly process
• The cable harnesses to be connected at specially defined fixed points

Our company brand VESCON relies on 3D printing to produce ideal workpiece carriers for the customer. Using 3D printed molded parts, our experts first create models for the workpiece carriers. Using these models, they can then the cable’s position and alignment, as well as their connections. If the cable routing is not yet as effective as it can be, the 3D models are improved upon. This is done in a kind of feedback loop:

First, a digital 3D model is constructed, the position of the cable in it is simulated and then 3D printed. By repeating this process, an ideal model is produced at the end. The finished workpiece carrier is manufactured based on this.

What benefits do they offer customers through 3D printing?

• Saving an enormous amount of time and money:

Cheaper and quick to produce 3D models, instead of costly/time-consuming conventional manufacturing in the optimization phase.

• Conserving resources:

By eliminating the need for numerous prototypes

• Making the best use of the available space:

This is made possible by ensuring the cables remain in the ideal position

• Optimizing accessibility for automatic processes:

Critical points for automatic testing and assembly are clearly visible and easily accessible due to the cables being in the ideal position

2. Our experts always keeping product quality in mind

Guaranteeing that the wiring harnesses remain in the ideal position and are properly fixed is essential for ensuring that a wiring harness can be installed and connected without any issues in the confined installation space of the car. Incorrect processing can create in sharp edges and, in the worst case, result in dangerous short circuits.

Most camera systems are designed to detect deviations down to the smallest millimeter. However, they can tolerate minimal deviations due to the fact that the components are flexible. The focus in this case is on inspecting the position, the rotations as well as the crossings of the cable harnesses. This is easy to recognize for the human eye, but for but it’s a huge challenge for automated systems, our automation specialists at VESCON Systemtechnik apply an innovative method, giving our cameras the tools to make intelligent decisions in the same way as humans do:

Machine learning

By teaching different product images into the specially developed camera system, knowledge is generated on how to assess the cable routing. Based on negative and positive examples, the system searches for a comparison to the object being tested, making a decision on its quality. These form a kind of progression in terms of their tolerance to the best position, to enable a step-by-step approach to be taken. In other words, there are images that show a very poor cable position, images that are already slightly better, and then sample images that show the best possible position.

3. Many years of experience and expertise

VESCON Systemtechnik is on hand to help as an experienced partner in this project with comprehensive expertise in developing process- and cost-optimized special machines. As a manufacturer and automation service provider, they rely on a winning combination of integration, innovation and mechanical engineering expertise, and offer a vast suite of services from developing your solution concept, to production.

The result? An automated cable assembly plant that is ready for the challenges of the future.

Learn more about the innovative solutions here.

Independent work, a high degree of personal responsibility and personal development across departmental and company boundaries. A dual study program at the VESCON Group is so much more than the link between practice and theory. You can try yourself out, go new ways and shape your career start individually. Rico, dual student of electrical engineering at VESCON, is one of those who should know. During one of his practical phases, he took the opportunity to participate in the student exchange program between our partner company tmp GmbH automation & engineering and VESCON. At tmp, Rico went through the "Knowledge-Base" training program for interns and students and got to know PLC programming better in all its facets - from the basics to the realization of his own project, everything is included in the training program. 

"My goal is to join the project management team later on. For this, it is necessary that I acquire in-depth know-how in the area of PLC programming. The exchange at tmp has given me another perspective on possible solutions and approaches, while at the same time deepening my knowledge through active exchange with colleagues on site," says Rico. 

With the help of the knowledge base and the close cooperation with the team, the students can quickly build up competencies and work independently in a very short time.

"I immediately felt at home in tmp's familiar environment and was able to immerse myself in the world of PLC programming. After going through the first two modules of the knowledge base - the basics and commissioning - I was already able to tackle my first own task: The development of a device module for the Cognex camera of a training cell. Despite the short time, I learned an enormous amount."

Fun was not neglected either: the team went on excursions together, went out to eat, and even went water skiing. For Rico Großmann, this was a great way to balance out the stressful university and work routine, and it was also a great place for private exchanges with colleagues. 

"Working at eye level and team spirit is really important here" - with these words Rico said goodbye to tmp.

VESCON and tmp both belong to the international automation platform SCIO Automation. The 10 medium-sized companies in the group to date rely on very close cooperation and the exchange of knowledge across company boundaries. This results in a variety of opportunities within the group to get a taste of other companies (cultures) and to individually shape one's own career entry during the dual study program.

In close cooperation with the Baden-Württemberg Cooperative State University and the Munich University of Applied Sciences, you have the chance to study with us in an exciting way, with great colleagues, a lot of know-how, different companies and a lot of fun.

Starting in October 2023, we are looking for dual students in the fields of electrical engineering and applied computer science.

Click now here for your application!

A German car manufacturer approached VESCON Automation with the request to convert an existing car final assembly and to expand the load capacity of the electric monorail system. The challenges that arose during the course of the project and how they were mastered are reported by our specialist departments involved. The end result was a system with brilliant production performance.

But what was actually to be done?

For a German car manufacturer, an existing final assembly line for passenger cars was to be rebuilt and the load capacity expanded in order to be able to produce further vehicle types (e-mobility) in the future. The conversion involved these three areas:

1. heavy-duty EMS with upstream conveyor belt

2. assembly crosshead final assembly

3. crosshead return transport

After the so-called marriage, where body and chassis are joined together, a conveyor belt takes over the body. The cross members to which the vehicle is attached are no longer needed. They are therefore dismantled and transported back. On the conveyor belt, the vehicle is then prepared for attachment to the heavy-duty EMS. The vehicle then hangs in the EMS for the final assembly of further parts (are mounted from below).

Each EMS chassis can carry a load of 2.6 tonnes when converted. There are a total of 95 hangers and each trolley has its own control system. The big advantage: each trolley can be maintained individually. This means that individual trolleys can be taken out of the train so that the EHB can work without interruption at any time.

The EMS is one of the established in-plant and floor-free transport systems. Particularly in final vehicle assembly, EMSs are preferred because the employees have barrier-free access to the lower area of the vehicles.

What challenges were encountered and how were they dealt with?

This was a highly challenging project, both technically and in terms of deadlines. It could only be completed within a narrow time frame because the production could only be shut down for a certain period of time for cost reasons. In addition, limited space made project execution difficult. Another challenge: the project was implemented during the height of the Corona pandemic and related Corona requirements influenced the implementation.

Our Virtual Commissioning, Hardware Design and PLC Programming with Commissioning departments worked closely together to successfully implement the project.

To shorten the on-site commissioning time, the existing plant was converted into a virtual model. Specifically, the hardware and the entire PLC programming were imported and subsequently simulated. This meant that it was not necessary to wait until on site to find out:

• Where the plant does not run properly
• Where bottlenecks and problems occur in later operation
• Where new programming and design is required

From a software point of view, this was probably the biggest project ever for VESCON Automation. There were the following challenges in programming:

• Only one employee could effectively work on each PLC at a time, which made it difficult to distribute tasks as well as progress over time.
• Converting an existing plant always means familiarising oneself with existing software programming, which was originally built by another manufacturer.

On site, all parts were first commissioned in another hall, connectors pre-installed and all cables attached. Only then was everything assembled in the actual production hall. Another important point, so that the conversion could take place in the previously defined time window and production in the existing EMS did not come to a standstill for too long.

"Without the great team that worked on the project in this constellation and without the untiring personal commitment of each individual, it would not have been possible to realise this project! But this is how we managed to have the plant running so stably (heavy-duty EMS and upstream conveyor belt) in just the first 2 days after the expansion that all production targets were exceeded. I have never experienced that up to this point."

Christian, Project Manager

The customer now has a plant for final car assembly that is now fit and running robustly for the next few years and the team has another successfully completed project whose implementation has welded them together.

Learn more about the automation services.

Any company with international operations is familiar with the hurdles in everyday project work - time differences, lack of clarity in coordination and confusing project boards. They make international project work difficult.

Despite well-coordinated colleagues and digitalised communication processes, which are supposed to eliminate challenges, optimisation in everyday project work fails to materialise. That is why GE&PM relies on VESCON's project management software SO3 to significantly increase their communication and visualisation.

"The company is involved in plant construction and technical planning and was looking for a tool to successfully handle projects worldwide. Among other things, SO3 can offer exactly that," explains Alexander Isakov, SO3's technical contact.

Our client's manufacturing is primarily located in China. An advantage of this international set-up, besides great cost savings, is the time difference between China and Germany. Internationally active companies use this time difference to work on orders 24 hours a day.

One challenge with this way of working: Every task has to be coordinated. For project communication, GE&PM has relied on email or phone communication until now. Several thousand emails exchanged during different phases of projects showed the inefficiency of this method of communication. The result was an overcrowded inbox and no overview of current project phases and status messages. Consequently, the calls for a solution have become louder.

In addition to the desire for a solution to the international communication barrier and confusion about document versions, the new solution should preferably offer a cloud application and at the same time fulfil the requirement that the data fed into the projects be stored in a secure place. VESCON’s client also sought a tool that would function as a design database.

With SO3, VESCON offers software that is precisely customised to these requirements and fully covers the needs in international project management.

"One of the main reasons we went for SO3 was VESCON's area of activity in the industrial plant business. The software was developed to meet the demands specifically in this area," explains Ronny Teutsch, Senior Electric Engineer at GE&PM.

In addition to the possible area of application in process engineering, SO3 also supports customers in other versatile industries: automotive industry, process industry, pharmaceutical industry and in technical building equipment. An added value that was an important factor for the cooperation. The parallel use of a database in which everyone can enter their data in real time and work independently is fulfilled with SO3.

"With SO3 we work with software that is perfectly tailored to our needs. This is due to the individual database with its own master data and individual configurations. We can use it with great freedom and we can independently add things that we need," says Daniela Stirn, Head of Mechanical Engineer at GE&PM, describing the use of the software.

The VESCON software offers the advantage of working directly with intelligent graphics. Whereas in previous GE&PM projects work was done without the use of professional project management tools, SO3 makes it possible to link intelligent 2D and 3D plant layouts with synchronised lists. This provides a data layer from which important information can be directly derived. In this way, typical questions of the daily project business can be answered quickly in the simplest way, which would otherwise have to be worked out in a time-consuming manner. At the same time, all project participants can work in one database. Everyone can enter and manage data themselves. In doing this, everyone involved in the project is integrated in real time. 

Now the company relies on the help of the VESCON software SO3 from the start of the project to the end of commissioning. Due to its flexibility, the tool is applied differently in the different project phases. At GE&PM, SO3 is used wherever electrical components are used and where teams work together, especially on an international basis. In process engineering, conveyor technology as well as in workplace equipment. Electrical equipment ordering is also handled with SO3.

"Fortunately, we have found a way to manage communication effectively and stay up to date with the latest project developments despite the distance in time and space," confirms Daniela Stirn from GE&PM.

Learn more about SO3.

Only recently, the German government decided that by 2030, up to ten million electric vehicles should be registered in Germany. In the wake of this, the topic of electromobility is becoming even more of a focus for German automobile manufacturers.

The size and nature of the battery module assembly in particular make the new technology much more complex than bodyshell assembly lines. We asked our control technology experts VESCON Automation for more details.

The colleagues at SCIO's Eching site in Germany are managing a major automation project for battery module assembly at a German car manufacturer.

What is the exciting thing about electrification compared to bodyshell lines?

Let's take battery module assembly as an example. Until recently, this was still completely in the fledgling stage. No one, not even the OEMs themselves, knew exactly what the challenges were and what the automation requirements were. It was new territory for all of us at the beginning. In cooperation with the customer, we approached every single step in the programming of the production line and customized it for this new technology. Compared to the bodyshell lines, the plants take up much less space, but are much more complex in themselves. Great things take place in the smallest of spaces in every process step.

What are the specific challenges in battery module assembly?

We have very low tolerances in the micro range in battery module assembly. This brings new challenges for the programming of the systems.
In addition, there is the short processing time of just under four minutes - within this time, the cells must all be glued and welded together. Any longer and the purity of the battery cannot be ensured, and it becomes unusable. Therefore, every step of the process must be checked and documented to ensure quality. This includes current and voltage measurement as well as checking the thickness of the paint layer and bonding strength.

Career Excursion:

Working as an automation specialist in the field of electric drive technology. In theory, every automation specialist has the basic requirements and knowledge. In the field of electric drive technology, it is mainly about new technologies that are not yet completely developed like the classic bodyshell sector. If you enjoy a challenge, have the technical understanding and are also creative, this field is guaranteed to suit you. Here you can find our current job postings.

Regarding the topic of rejects. What is the procedure?

Waste is regularly produced during the programming and commissioning of systems. This is not particularly expensive in bodyshell assembly, but it quickly becomes pricey in battery pack assembly. A single battery cell alone has a value in the upper three-digit range. And we are talking about a cell here, of which several are processed in a pack. So, a lot of rejects add up quite quickly to a very high amount, which of course should be avoided. Also, there are hardly any available resources to resupply new cells. A battery that has been bonded together once cannot easily be disassembled again.

What about external conditions during production?

External conditions are crucial for battery assembly. Is the temperature right? How high is the humidity? A cooling chain has been specially integrated into the systems for the raw material, in order to keep transport distances short and to ensure the purity of the materials. Also, suitably powerful extractors must be installed to filter the particles out of the air.

Looking back, where are we today in battery module assembly?

The last few years have been a constant learning process for everyone involved. We have acquired new expertise that will be increasingly in demand in the future. Up to now, there have only been a few people with this expertise, and specialists are always in demand.

Thank you for the interesting talk!

Insights: Battery Module Assembly Line Project

Customer: German car manufacturer
Assignment: Complex battery & high voltage assembly line installation of >10 automatic stations with standard and gantry robots
Specifications:
• Fully automated transport system between cells, transfer stations
• various cleaning and joining technologies for battery cells, aluminum, steel and composite materials
• All technologies applied are being verified, falsified by external institutes to assure the process and product are within the specified tolerances
• Buy-off according to specification with additional stand-by and optimization of all technologies incl. cycle time decrease

As of January, 1st, 2021, VESCON Systemtechnik GmbH, based in Gleisdorf, Austria, is under new management. Alois Kien and Sergej Kristal will lead the Austrian VESCON company with immediate effect. 

The two previous managing directors, Heimo Reicher and Peter Bürger, handed over a solidly positioned company to their successors at the turn of the year. For almost 20 years, they led VESCON Systemtechnik GmbH in Austria. They built up and expanded the two business areas of special machinery and software development. The new management team will now continue and further expand this.

As a trained engineer, Mr. Kien brings 25 years of experience in the field of automation and special machinery. During these years he held various management positions in a leading automation company in Austria and will in future contribute his experience to the operational business of VESCON Systemtechnik. In addition to his current functions as CFO of the entire group of companies, Sergej Kristal will take over the commercial management of the Austrian company.

We would like to thank Mr. Reicher and Mr. Bürger for their dedicated and successful cooperation and wish them all the best.

We welcome Mr. Kien to the VESCON Group and wish him and Mr. Kristal all the best in their new and extended tasks.

The VESCON Group expands its process technology portfolio with the acquisition of AQUA (formerly Bilfinger GreyLogix Aqua GmbH). AQUA specialises in control and process control technology for drinking water and wastewater treatment plants.

The company AQUA (formerly Bilfinger GreyLogix Aqua GmbH) is part of the VESCON Group as of December 15th, 2020. In the future, the company will operate under the brand name VESCON AQUA GmbH (AQUA). AQUA is now a subsidiary of VESCON Process and strengthens the business unit with its automation and programming services for drinking water and wastewater treatment plant, mainly for customers in the public sector.

Climate change and the associated water scarcity require solutions: In this context, automation and process technology know-how for drinking water and wastewater treatment plants is becoming increasingly important. Acting sustainably in the long term, reducing energy consumption and constantly improving water quality are strategically important in our globalised world. "The drinking water and wastewater sector is one of the most important components of the German infrastructure. With the acquisition of AQUA, we are expanding our process technology know-how in future-oriented and sustainable environmental applications,” says Stefan Ruthmann, Managing Director of VESCON Process.

AQUA, headquartered in Flensburg, was founded in 1998 by Olaf Kremsier and had been part of Bilfinger SE as a subsidiary of Bilfinger GreyLogix GmbH since 2013. AQUA acts as a system integrator with a focus on project management and specialized automation and programming services. Across its seven locations, AQUA ensures highest service levels and customer proximity.

More about our Process portfolio.

VESCON is a member of the SCIO Automation Group. Please find SCIO’s press release about the acquisition here.

A transformer station that was no longer sufficient for the rapidly increasing feed-in of renewable energies and therefore had to be replaced. In addition to that, it is located at one of the most important energy junctions for the north-south connection. 

Our VESCON Energy team was involved in this major project for the customer TenneT TSO GmbH at the transformer station Wilster-West in North-Germany. It took four years until the old plant was completely disconnected from the grid and the new extra-high voltage switchgear could be put on stream.

The million-euro project is considered the core of the German energy transformation center:

Watch the video of TenneT in the column on the lef. Source: TenneT, shortened version

The existing 380 kV switchgear at the transformer station Wilster-West had reached its capacity limit. Moreover, the important energy hub should be able to receive and distribute the future transmission capacity of NordLink, SuedLink, the West Coastline, the central axis and the offshore connections in the North Sea. TenneT TSO GmbH therefore decided to renew the switchgear and brought VESCON Energy into the project. The two companies have already been working together for 17 years.

The colleagues of VESCON Energy are specialists in the high and maximum voltage environment. They conducted the complete electrical assembly for this major project. VESCON Energy initially planned the primary technology and provisional arrangements for the primary technical construction of the high and maximum voltage stations. In the secondary technical expansion, it carried out cabling work as well as the installation and connection of all control, protection and general plant components such as auxiliary power and transmission technology. A 380kV switchgear with a triple busbar, designed for up to 8,000A, was installed. The new switchgear covers an area of 18 hectares, which is the same as 25 football pitches. VESCON Energy rebuilt the plant and created the connection to the distribution network of SH-Netz with two large transformers.

"A challenge in the implementation of the project was certainly that the existing plant was already an important north-south junction. The new construction therefore had to take place without any significant interruption of the north-south connections. For that reason, we initially installed several 380kV temporary installations. In doing so, we were able to ensure that operations continued almost without interruption," says Olaf Baumgartel, Head of Business Unit Energy, explaining the complexity of the project.

Over the years, around 100 employees of VESCON Energy and subcontractors coordinated by us have been involved in the renewal. One of these employees is Stefan, who was part of the project as senior fitter. In the video (see column on the left)  he gives an insight into his daily work routine.

At the beginning of October 2020, the new transformer station Wilster-West was commissioned by TenneT. The next order is already in line for VESCON Energy: The 110kV system of the SH-Netz at the Wilster site is also to be expanded.

Technical project data:

• Switchgear with 31 fields triple 380kV busbar
• 2x 380kV cross coupling
• 8x 380kV line fields
• 2x 380kV cable fields
• 3x 380kV transformer panels
• 2x 380/110/30kV transformers
• 1x 380/20kV transformer
• 4 fields double 110kV busbar

More about the portfolio of VESCON Energy.

This year’s motto was developed jointly by the Vitamin V Scouts and our Management at the periodic kick-off workshop. Vitamin V fitness and health trainer Nina Gösele explains: "We want to continue to focus on the team, which is why we are keeping the theme 'Stronger Together' from last year. At the same time, we added 'for you' to express the importance of everyone taking care of themselves".

In 2020 we had originally planned to promote the theme through a variety of classes including TOSO, Aqua Cycling as well as Pilates and various events, such as archery, and participating in the initiative 'Helden. Retten. Leben.' (Heroes.Save.Lives.). Due to Corona, these planned events had to be postponed indefinitely.

At the same time, the current situation leads to the birth of new ideas and solutions - Vitamin V was quickly converted to a digital format. For example, Nina Gösele now offers fitness courses twice a week via video conference and is planning further online seminars. Other members of the SCIO Group, such as the Schiller Group or tmp GmbH, have also joined the digital Vitamin V platform. "With the new digital program, we can easily connect our employees at different locations with each other and create a community of our colleagues", explains Nina Gösele.

An example of this networking success, outside of the digital world, can also be seen in our Step Challenge, which ran in May: a total of 83 employees took part in the program across different SCIO-wide locations.

More information about Vitamin V can be found here.

Jobs, Flyers and other marketing material have been hinting towards the change in VESCON’s corporate design. In the last step, the website has been relaunched and can now be seen with its sleek and modern new design.

The large header pictures with our colleagues, which are seen consistently throughout all pages, are especially notable. These headers have also been placed on other marketing material in the past few months.

For these headers, about 100 employees were photographed at different VESCON locations. “It was important to us to give VESCON a face instead of presenting only facts and figures,” says Dietmar Haubenhofer, VESCON General Manager.

With the new website we are primarily targeting candidates and future employees and are aiming to provide them with a deeper and more personified insight into VESCON, showing what it’s like to work here. At the same time, our business units and services are presented in great detail. The connection between the technical and the personal side of VESCON is also mirrored in the colour scheme, combining cool technical blue-grey hues with a warm and emotional red tones.

Know-how successfully shipped: About 30 Software Developers from the Rhein-Neckar region were hosted by VESCON last Wednesday. Within the scope of a "Docker Beginners Workshop" the interested participants ventured into the topic of Dockers with five mentors.

In addition to a lively discussion about the beginners' impulse lecture by Robert Reiz, the participants also tested the theory themselves. Under the guidance of experienced mentors, the interested participants were able to gain their own first-hand experience in working with Docker. Docker is a software for container virtualization, i.e. applications or services are packed into an isolated environment. Docker is used to synchronize development with the production environment. We would like to particularly thank our two in-house Docker experts Martin and Marcel, who were able to directly answer any technical questions.

Along with the professional exchange, delicious pizza and drinks were served in an open atmosphere, so that at the end of the four-hour event all participants and mentors started their way home having gained new skills and acquaintances.

Many thanks also to Jens Doose, who organized this event using the Meetup.com platform and actively supported us on site. We are looking forward to further events of this kind!

Gleisdorf.

This past November, the VESCON Systemtechnik in Gleisdorf finished commissioning on the first 10 Production Data Logging Towers with VESCON-produced hardware at their customer's site. This is yet another milestone for the SO3-HIBERION PDL system, which was developed in collaboration with selected customers.

Behind SO3-HIBERION you will find a production data acquisition system developed by VESCON, constructed in a modular structure and can be implemented in any industry.

The recently commissioned SO3-HIBERION BDL-Towers combine a 24″ touch PC and a large 42″ display screen built into a slim tower, which serve as a centralized information hub in every plant. The production status can be checked at any point in time and in the event of errors, information is immediately displayed on the screens. On the touch PC, all order details including recipes and material details can be managed and Dashboards can be accessed.

The collaboration between VESCON and the client started 5 years ago with the integration of SO3-HIBERION at four plants and has since been continuously further developed. The current expansion with their own PDL-Tower and the integration of 10 additional plants were planned in 2018 and called into life this year.

"With this system, we offer our clients a future-oriented option for production optimization, thanks to absolute transparency and complete traceability," says Martin Feichtgraber, Division Manager Software Development at VESCON Systemtechnik. "All Smart Production features are integrated here, and the system can be adjusted individually to our customers’ specific needs".

Further companies have already expressed interest in the new tower and first orders have since been given to VESCON Systemtechnik.

For more information on Digitalization and Production Data Logging (PDL) please watch this Austrian TV Report: https://www.atv.at/road-to-digital-austria/folge-17/d2667042/ (Due to Data Protection Law, this report is only available in Austria.)

The VESCON health initiative Vitamin V is starting the new year with the motto “Stronger Together”. The new motto was presented at the end of May in the Vitamin V room at our Frankenthal office. The Vitamin V steering committee had previously developed the theme and the related activities with the input from the Vitamin V scouts.

With “Stronger Together” the focus lies on solidarity and teamwork. The sum of individuals is decisive for the company’s success. “With this new theme we would like to strengthen the teams from within and promote group activities,” says Nina Gösele, Vitamin V Fitness Coach.

The planned activities include, among others, team events like SCRUM-Cooking, a blind walk, the participation in the BASF initiative Helden.Retten.Leben (Heroes.Save.Lives), Stand-Up Paddling and a team step challenge.

 In addition, the Vitamin V activities will be reinforced with a variety of courses and online training videos. Relaxation and muscle-building exercises can therefore be done easily from home or on the road. The offered course plan targets especially those VESCON employees who spend a large portion of their time working on construction sites or in factories, and therefore are not able to join the courses offered at our offices.

More information on Vitamin V can be found here. 

From now on it is official: The VESCON Group (Headquartered in Frankenthal) and the Schiller Group (Headquartered in Osterhofen) are moving towards a promising future with Quadriga Capital Consulting (Headquartered in Frankfurt). The antitrust authorities have agreed to bundle both Corporations into a joint holding under the leadership of the majority Shareholder Quadriga Capital. The holdings appointed management team includes Michael Goepfarth (CEO) and Peter Bürger (CFO).

With the entry into the commercial register, the integration process has now begun. Both companies, VESCON and Schiller, will remain operationally autonomous. Strategic leadership and cultural governance will take place through joint projects and the through the holding. During the upcoming weeks the first steps will be taken in order to implement the future strategy.

“We are very pleased that we can fully concentrate on the common future of both companies from now on”, says VESCON Manager Peter Bürger. “In the upcoming weeks and months, we will already be making the first joint decisions to strengthen future development.”

The closing is also the official starting shot towards a promising future for Michael Goepfarth, who joined the Management team next to Peter Bürger and Dietmar Haubenhofer von December 1st, 2018:“VESCON and Schiller complement each other optimally. Together with Quadriga Capital, we will now begin to leverage the extensive potential this merger poses across all business areas.”

With Schiller and Quadriga towards a leading Platform.

As of December 1st, 2018, VESCON and Schiller have announced the bundling of competencies and skills in a  joint holding company, with Quadriga Capital as the majority shareholder. Schiller Automatisierungstechnik GmbH and Schiller Engineering & Maschinenbau GmbH, with more than 200 Employees, are successful in the fields of Automation, Intralogistics and Clean Rooms. Spanning over 5 locations, including a site in Shenyang, China, the company develops systems, machines and solutions that aim to set new standards. One of the most important innovations is the autonomous tugger train, which has great potential as a breakthrough in logistical solutions of the future.

“With Schiller and Quadriga by our sides, we will build a leading platform of medium-sized companies for Industrial Automation Solutions and for other Plant Construction and Engineering Services”, summarizes Dietmar Haubenhofer, VESCON’s CEO. “We are confident that we will be able to announce further milestones throughout this year.”

Profile: The new Group.

With the unification of Schiller Automatisierungstechnik, Schiller Engineering & Maschinenbau and the VESCON Group, the new conglomerate now has more than 700 employees at 16 locations in four European countries and in the People’s Republic of China. Among its customers, who we support in the fields of Automation, Intralogistics, Process, Special Machinery, Energy and Software, are medium-sized companies as well as international corporations. One important focal point is on the area of Automation for automotive customers, which not only include automotive manufacturers but also their suppliers. The turnover of the entire conglomerate is estimated to amount more than 100 million Euros.

Exciting News from Frankenthal: As of December 1st, 2018, VESCON and Schiller have joint their competencies in a holding company. At the same time, the investment company Quadriga Capital has come on board as the majority shareholder. 

For VESCON this merger is a decisive step, which established the basis for its continuous growth. The merger also has a significant strategic importance for Schiller. “VESCON and Schiller complement each other perfectly,” says VESCON CFO Peter Bürger. “Both companies are in a similar growth spurt and will benefit from this merger in numerous ways, while the range of the service portfolios is mainly complimentary. This results in some overlap but also leads to many additions and expansions, which in the future can and will provide even greater resources and services for our customers.”

With more than 200 employees, the Schiller Automatisierungstechnik GmbH and the Schiller Engineering & Maschinenbau GmbH, both headquartered in Osterhofen, are successfully active in the fields of Automation, Intralogistics and Clean Room technology. At five locations, including a site in Shenyang, China, the company develops standard-setting systems, machines and integrated solutions. One of the most important innovations that Schiller has developed is the Autonomous Tugger Train, which has great potential as an intralogistical solution of the future. “Together with VESCON we are growing to a size which gives us entrepreneurial security for future development of our products and innovation. At the same time we can expect synergy effects from which both companies will benefit”, the founder and Managing Director of Schiller, Ewald Schiller, summarizes the advantages of the merger.

In order to formally justify the joint venture, VESCON and Schiller have established a holding company and at the same time opened themselves up to the Quadriga Capital GmbH, headquartered in Frankfurt, as majority shareholder. Quadriga Capital not only strengthens the financial side but also brings extensive know-how from the Automation Industry to the table: “We are pleased that we could gain a strong partner with Quadriga Capital, who would like to promote the successful development of our companies, while representing the entrepreneurial values that we endorse. Quadriga will endorse us in expanding our growth strategy sustainably,” says VESCON Managing Director Dietmar Haubenhofer.

In addition to these steps, the management itself has also been strengthened. Since December 1st, 2018, Michael Goepfarth, together with the previous Managing Directors Peter Bürger and Dietmas Haubenhofer, leads the newly formed conglomerate. Michael Goepfarth has many years of experience as CEO and Managing Director at technology-driven industrial companies: “I am very much looking forward to the challenges and opportunities that lie ahead of me, and I have great respect for what has been achieved so far. I am convinced that we will continue to expand our position within the market, we have a clear vision: With Schiller and Quadriga Capital we want to build a leading medium-sized platform for Industrial Automation and other Engineering services together.”

With this newly established course, VESCON has set itself up for a promising future. During the upcoming year, Peter Bürger’s long-awaited switch into the advisory board of the holding company will be completed: “I will continue to be available to the company on the advisory board and will help advance our joint vision.”

The aforementioned transactions are still subject to approval by the responsible antitrust authorities.

Profile: The new Group.

With the unification of Schiller Automatisierungstechnik, Schiller Engineering & Maschinenbau and the VESCON Group, the new conglomerate now has more than 700 employees at 16 locations in four European countries and in the People’s Republic of China. Among its customers, who we support in the fields of Automation, Intralogistics, Process, Special Machinery, Energy and Software, are medium-sized companies as well as international corporations. One important focal point is on the area of Automation for automotive customers, which not only include automotive manufacturers but also their suppliers. The turnover of the entire conglomerate is estimated to amount more than 100 million Euros.