The document provides an overview of a project to replace the control system for a tri-axis press and feedline at a BMW factory that produces pressed parts for Mini vehicles. The original control system was outdated and needed to be replaced with a modern Siemens-based system that met BMW's standards. The project objectives included replacing the electrical drives and controls, safety systems, and operator interfaces to bring the press and feedline up to current safety regulations. The project was successfully completed on time to support production demands and the launch of a new Mini model.

1. CS0020Iconsys, Iconsys House, Hortonwood 33, Telford, TF1 7EX, UK
T +44 (0)1952 607300 F +44 (0)1952 607333 info@iconsys.co.uk www.iconsys.co.uk
PROJECT OVERVIEW
BMW Swindon produces pressed parts for the original and recently
released second generation Mini.
The GP531 Tri-axis press was originally installed around 1990. The
original control system was based on an Allen Bradley Pyramid
integrator and a Unico digital DC drive system. Both these items
are now unsupported and required replacing with a system which
meets BMW’s equipment standards.
The Stacker control is PLC based using a Siemens S7 400 standard
PLC and a Pilz PSS 3006 safe PLC. The variable speed drives are
Rexroth Indra M and SEW Movitrac drives.
The Bandteiler control is PLC based using a Siemens S7 315
standard PLC and a hard wired safety system. The variable speed
drives are Rexroth Indra M and Siemens Micro Master 440 drives.
The Swing Shear is PLC based using a Siemens S7 315 standard
PLC and a hard wired safety system. The variable speed drives are
Rexroth ECO drives.
Much of the Line & Press safety related parts of the control system
did not meet current legislation, so required Risk Assessing and
bringing up to the latest PUWER regulations.
PROJECT OBJECTIVES
To manage the project as Principle Contractor under CDM and HSE
Regulations and included engineering, materials, manufacture,
installation, obsolete equipment disposal, training and production
standby.
This included:
Replacement feed line & press
Electrical Drive & Control panels.
VS DC motors with new AC technology
Complete new Power & Control Cabling
SCADA / HMI Control Desks & Operator Stations
Machine Terminal Boxes
Safety Gate Locks
New feedback sensors
Flexible conduit
Interface to:
Bandteiler
Swing Shear
Stacker
Installation
Commissioning
Operator and maintenance training
24 / 7 post commissioning support
GP531 Tri-Axis Press & Feedline
Continued on next page...

2. CS0020Iconsys, Iconsys House, Hortonwood 33, Telford, TF1 7EX, UK
T +44 (0)1952 607300 F +44 (0)1952 607333 info@iconsys.co.uk www.iconsys.co.uk
PROJECT SOLUTION
The overall project comprised of a complex multi drive and control
system designed on a Siemens Totally Integrated Automation (TIA)
product platform.
The control system consisted of S7 Safe and Standard PLC’s
with multiple Remote I/O nodes as shown above. These PLC’s
controlled a Siemens Sinamics and Simotion Servo drive System.
Operator Controls were provided by multiple operator stations
utilising WinCC SCADA clients communicating on Profinet to a
WinCC Server.
Also interfacing to existing BMW control systems, such as the
Stacker, Bandteiler and Swing Shear systems and mechanical
enhancements were also incorporated.
In addition to this, state of the art safety systems utilising Fortress
Locks, Light Guards, Euchner Switches, Leuze Lasers and Mobile
HMI Panels were also implemented to bring the machine up to the
latest safety legislation.
The project coordination and implementation was managed by
Iconsys as Principle CDM Contractor, as well as the management
of BMW and other contractors and activities, under the CDM and
HSE regulations.
PROJECT FEEDBACK
The project was brought in on time to meet the growing demands
of the BMW Mini product and also in time for the launch of the
second generation BMW Mini.
The high quality standards set by Iconsys and the commitment to
complete the project to meet the demanding standards of BMW,
have been commended by BMW and will be used as a benchmark
for future projects within BMW Swindon.