Audi Brussels: Dual-track electrified monorail system

  • Factory work floor with orange-painted, dual-track electrified monorail system behind a curve

On the new assembly line, the Audi e-tron handles the curve with ease

Quiet, safe, and always at just the right speed: At Audi in Brussels, sophisticated MAXOLUTION® technology permits particularly flexible and ergonomic assembly of the new Audi e-tron electric vehicle fleet. Smooth, silent motion has taken the place of rigid cycle timing and rattling chain drives. This is made possible by perfect synchronization of all AGV frames and maximum safety.

The project at a glance

  • Dual-track electrified monorail system for heavy loads on the assembly line:
    • 96 vehicles over a length of 1,100 meters, carrier payload of 3,200 kilograms for each vehicle
    • 2 travel drives for each unit: one heavy-duty electrified monorail system gearmotor for each track, with electronic motors (HK60 DRC2), efficiency class IE4, frequency inverter integrated into the motor
    • Curved track: the two widely separated travel drives are coupled using a function called "electronic differential"
    • 2 lifting drives on each unit: one R107 DRN132 helical gearmotor for each track, efficiency class IE3
    • One MOVIPRO® decentralized drive, positioning and application controller for each EMS vehicle
    • Positioning using a DataMatrix barcode system (PXV)
    • MOVISAFE® HM31 safety controller for each EMS vehicle
    • Safety functions: Safe Positioning, Safely Limited Speed (SLS), Safe Direction of Movement (SDI), Safely Limited Position, (SLP), Safe Stop 1 (SS1), Safe Torque Off (STO), Safe Distance Monitoring, switching on/off of the battery charging device, monitoring of the brake test
    • All modules and performance features are scalable, quick to start up, and can be combined with the simulation and startup software MOVIVISION®.
  • Single-track electrified monorail systems for the Cockpit area of the plant (length 330 meters, 43 carriers)
  • Single-track electrified monorail systems for the Doors area of the plant (length 390 meters, 40 carriers)
  • Electrified monorails move as necessary at any given moment, always in synchrony with the skillets on the floor and the lifting stations
  • Each transport unit knows its position in the plant at all times and reports its state parameters continuously to the stationary segment controllers, which exchange data among themselves and pass on the position information to the plant control system
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Workplace safety maintained between the suspended loads, even in curved sections

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Video: In use at Audi Brussels

Smooth motion, safe positioning, and a curved track like none ever seen in the industry: At Audi in Brussels, every step in the production of the e-tron electric car is perfectly synchronized – without rigid cycle times. Watch our video to find out for yourself what drives Audi's new assembly line and those responsible for it – and why SEW‑EURODRIVE is the ideal partner for the project.

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Quote: Dominik Adam, project supervisor at LogSystems, the main contractor for the Audi Brussels project

A curved track like none ever seen in the industry

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Quote: Tom Timmermann, project and technical manager at Audi Brussels

SEW‑EURODRIVE helped us greatly.

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Quote: Andreas Cremer, general secretary at Audi Brussels

We're not trying to be "fast followers" – we want to be trend setters.

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Quote: Patrick Danau, plant manager at Audi Brussels

Any downtime costs money and must be avoided. That's why we chose SEW‑EURODRIVE.

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Impressions of the project

The project in detail

The future of mobility in the factory of the future

No rigid cycle times – smooth, uninterrupted motion

Heavy loads on dual tracks safe in the curves

Safety and ergonomics first

Only ever as fast as necessary

Virtual startup reduces the actual costs

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