Engine Assembly Automation · Vietnam Project

Vietnam 14/16-Cylinder Diesel Engine Assembly Line Automation Control System

A new full-line automation project for marine power generation and medium-to-large diesel generator manufacturing, integrating EPLAN cabinet design, Siemens S7-1500 PLC control, HMI, SCADA, G120C VFDs, V90 / S120 servo control, KUKA robot loading and on-site commissioning.

Vietnam Project14/16-Cylinder Diesel EngineSiemens TIA PlatformSystem Integration

New diesel engine assembly line automation project for marine power generation and generator set manufacturing.

Application

Marine power generation

Full-line automation for 14/16-cylinder diesel engines used in marine power generation and diesel generator set applications.

Customer Type

Engine machinery OEM

The customer is an intelligent equipment company serving engine manufacturing and powertrain-related production lines.

Project Type

New production line

This was a new production-line project, designed to support a new-generation automated engine assembly process.

VectorTech Role

System integrator

VectorTech supported cabinet design, cabinet build, PLC / HMI / SCADA engineering, drives, commissioning and delivery.

Project Background

New diesel engine assembly line automation for Vietnam

The project was developed for a Vietnam-based new diesel engine assembly line serving marine power generation and medium-to-large diesel generator applications. The production concept covers multiple automated sub-lines working together to complete engine assembly through final line-off.

Instead of only supplying control cabinets, VectorTech worked as a system integrator, combining electrical cabinet engineering, Siemens PLC / HMI / SCADA software development, drive control, FAT support and on-site commissioning.

Customer Requirements

Engineering challenges behind the assembly line

The customer needed to overcome previous line-development limitations, reduce dependence on manual operations for heavy engine assembly, and support new process requirements across a connected multi-line production environment.

Challenge

Multi-station coordination

Multiple automated stations needed to work together across sub-lines, conveyors, handling equipment and final assembly processes.

Challenge

Heavy engine handling

Large engine components required reliable automatic handling, turnover and positioning control to reduce manual workload.

Challenge

Automatic tightening

Bolt tightening stations needed to be integrated into the line control concept and coordinated with upstream and downstream process steps.

Challenge

Robot loading

KUKA robot loading and robot vision-related handling needed to connect with the production control and product data workflow.

Challenge

Distributed PLC control

The system required a main PLC station, multiple remote stations and multiple HMI stations for line operation and status visibility.

Challenge

Data and quality status

HMI / SCADA functions needed to support OK / NG status display, QR-code-based product information, recipe parameters and production records.

VectorTech Scope

From EPLAN cabinet design to PLC, HMI, SCADA and commissioning

This case shows an integrated control-system delivery scope, covering both electrical hardware and production-line software engineering.

View Related Service

EPLAN electrical control cabinet design and electrical drawings
Control cabinet assembly and manufacturing
Siemens TIA Portal PLC programming and HMI engineering
SCADA engineering for production data and process supervision
Siemens G120C VFD commissioning and motor control
Siemens V90 and S120 servo control for station-level motion
FAT support, status monitoring, on-site commissioning and final delivery
Remote support, program delivery, new-function development and remote debugging

Control Architecture

Siemens S7-1500 main control with distributed stations

The control architecture uses Siemens S7-1500 as the main PLC platform, with distributed remote stations and multiple HMI stations engineered through Siemens TIA Portal. VFD and servo control coordinate conveyors, handling devices, positioning, turnover and station-level motion.

Main PLC

Siemens S7-1500

Remote Stations

Distributed I/O

HMI Stations

Siemens KTP1200

SCADA Layer

Data supervision

Production Line Scope

Automated sub-lines connected for engine assembly to line-off

The automation scope covers important engine components and assembly steps, including piston and connecting rod assembly, cylinder head assembly, cylinder block assembly, final engine assembly, gantry turnover, automatic bolt tightening, overhead travelling crane coordination and robot loading stations.

Sub-line

Piston and connecting rod assembly

Automated assembly-line equipment supports controlled production flow for piston and connecting rod-related processes.

Sub-line

Cylinder head and cylinder block lines

Cylinder head and cylinder block assembly lines are integrated into the overall control and station coordination concept.

Sub-line

Final assembly conveyor

The final assembly chain conveyor links key workstations and supports the engine assembly process through line-off.

Equipment

Gantry turnover machine

Multi-axis gantry turnover equipment supports heavy engine handling and positioning during assembly.

Equipment

Automatic bolt tightening station

Automatic tightening workstations are connected to the line sequence and production status workflow.

Equipment

Overhead travelling crane control

PLC remote control and interlocked operation support safe handling of heavy engine components.

Cabinet Configuration

Siemens PLC, VFD, servo and low-voltage components

The control cabinet scope combines PLC control, industrial communication, VFD motor control, servo motion control, safety functions and Siemens low-voltage components for a serviceable production-line control system.

Configuration

PLC Platform

Siemens S7-1500 main control platform for production-line sequence control and distributed station coordination.

Configuration

Drive Control

Siemens G120C VFD control for motor-driven equipment and Siemens V90 / S120 servo systems for positioning and multi-axis motion.

Configuration

HMI Stations

Siemens KTP1200 HMI stations for line operation, process status messages and operator interaction.

Configuration

Low-voltage Components

Siemens MCBs, contactors, thermal overload relays, relays, safety relays, MCCBs, isolator switches and push buttons.

Configuration

Robot Loading

KUKA robot loading integration for cylinder head and engine assembly-related material handling.

Configuration

Engineering Platform

Siemens TIA Portal for PLC, HMI, VFD and servo-related engineering work, together with EPLAN electrical documentation.

HMI / SCADA / Data

Production data, OK / NG status display and QR-code process records

The SCADA layer is used for production data and process supervision. After robot vision loading and product identification, QR-code-based records can help bind product information with workstation process parameters, inspection status and production status.

Data Layer

QR-code product data binding

Product and process information can be associated with QR-code records across the line.

Data Layer

Workstation parameter package

Process parameters for each workstation can be stored, adjusted and recalled according to production needs.

Data Layer

OK / NG management

HMI and SCADA functions support OK / NG status display, process status visibility and exception handling.

Data Layer

Deviation reports

SCADA can support error and deviation data reporting for production review and continuous improvement.

FAT & Commissioning

Testing, status monitoring and on-site delivery support

VectorTech supported FAT testing, status monitoring and commissioning together with Siemens engineering resources on site. The delivery scope also included later program handover, new-function development, remote debugging and technical support.

Customer name, exact plant address, production capacity, takt time, torque data, complete drawings, I/O lists, source code and protected engineering parameters are not disclosed.

Project Photos