As Siemens’ first native digital factory in the world, the new Siemens Numerical Control (Nanjing) Co., LTD. (SNC) factory is not only a useful practice for Siemens on the road to smart manufacturing, but also sets a new benchmark in the industry in terms of efficiency, quality and sustainable development.

During the Expo in November 2022, Siemens SIMOTICS high-performance permanent magnet synchronous motor obtained the “carbon neutral verification statement”, becoming the first “carbon neutral product” in the new SNC plant.

“Carbon Neutral products” – Siemens SIMOTICS high-performance permanent magnet synchronous motors

Today, we focus on the production line of this star product and reveal the scientific and technological power behind the process innovation!

Xijia investigation “carbon”, help precise emission reduction

In order to achieve the goal of “carbon neutrality”, every energy-intensive production process needs to be improved. Then the first problem to be solved is to find out these high energy consumption links.

The new SNC facility deploys SiGREEN, Siemens’ trusted actuarial and traceability solution for carbon footprints. Using innovative technologies such as energy management, industrial edge computing and digital experience gained in manufacturing,

EPL10200-W

SiGREEN enables factories to accurately calculate and trace the carbon emissions of products during manufacturing.

In addition, the team also helped supplier partners including Datong Gear Transmission (Kunshan) Co., Ltd. and Jiangyin Huaxin Precision Technology Co., Ltd. also deploy SiGREEN solutions to build a crypto trust network based on blockchain technology, and achieve transparency of the carbon footprint of the entire life cycle of products “from the cradle to the door.”

By tracking and analyzing the carbon footprint of SIMOTICS high-performance permanent magnet synchronous motors, the team found that the stator machining process has large energy consumption and high carbon emissions, and there is a large room for optimization, so there is a process innovation from dipping to dropping paint.

SiGREEN makes it possible to accurately calculate and trace the carbon footprint of products.

From dip paint to drop paint: Small change, big effect!

In the original dipping process, the paint tank was filled with resin insulating paint, and as the resin rose, the suspended stator was completely covered, and then the resin fell. Then three times of heating to promote the resin gel and curing, thus forming a complete stator dipping process. Among them, the process of resin flowing in and out will cause waste. In addition, multiple heating and curing processes are complex, occupy a large area, and consume time and energy
Dipping process

So, how does the improved drop paint process exist? First, the stator is precisely fixed, and with the cooperation of the Siemens industrial control system and the industrial robot, the robot can move the resin drip nozzle to the desired position, so that the resin fills the entire stator drop by drop, thus greatly reducing the resin waste. Not only that, the drop paint process only needs to be heated once, and the use of inductance heating, fast, less energy consumption, carbon emissions are also reduced.

Paint drop process

From dipping to dropping, a process improvement resulted in four significant effects: the production unit’s footprint was reduced from 191 square meters to 35 square meters, the time required to produce a stator was reduced from 540 to 32 minutes, the electricity consumed was reduced from 2.58 KWH to 0.25 KWH, and the carbon emissions were reduced from 2.68 kg to 0.26 kg.