Welcome to VESCON

How do our customers achieve Industry 4.0? Using our tailored solutions.

As an engineering service provider and plant manufacturer, VESCON's top priority is supporting our customers on their journey to Industry 4.0 and to ensure their sustainable success. To this end, we support our customers with integration services that are fit for the future, as well as customised product solutions in our Automation, Special Machinery, Software, Process, Aqua and Energy business units. VESCON is fully focused on building the smart factories of tomorrow, as we are a member of the SCIO Automation international automation platform.

What you can expect from us:

  • value-added system integration and innovations that are tailored to your specific needs
  • automation and process technology expertise that ensures your processes are as efficient as they can possibly be
  • planning, implementation and after-sales service from a single source
  • almost 30 years of experience in a wide range of engineering services and plant engineering sectors
  • close collaboration based on a partnership model, and trust at all levels
  • extensive international expertise in a vast array of industries

Our employees are always there when you need them, and are the key to your success. Their expertise, dedication and service with a smile is what makes the VESCON Group special. More.

 

Six business units are not all we have to offer: Please visit the website of our affiliated company PrintoLUX GmbH to learn more about future-oriented solutions in industrial labelling.

News

Successful conversion of a vehicle assembly with electric monorail system

A German car manufacturer approached VESCON Automation with the wish to convert & expand an existing car assembly line with an electric monorail system. The challenges that arose during the course of the project and how they were overcome are reported by the departments involved. The end result was a system with brilliant production performance.

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.

Project management software SO3 simplifies the handling of global projects

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.

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.

Big things in the smallest of spaces: Battery module assembly

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.

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

Careers at VESCON

We don’t just offer jobs, we offer perspectives.

VESCON was founded in 1993 and has been part of the SCIO Automation international automation platform since 2019. Approx. 500 VESCON employees at 11 European locations plan and implement challenging projects for global players and hidden champions in a wide range of industries. Our business areas include Automation, Special Machinery, Software, Process, Aqua and Energy.

We are focused on the needs of our employees*. We promote personal strengths and involve all colleagues* in decisions such as when it comes to distributing projects.
We are not dominated by rigid structures but by flexible opportunities, for example with regard to working hours and locations. Also, because we attach great importance to an excellent work-life balance.
Fewer supervisors, more opportunities At VESCON we are on equal footing with each other when it comes to work and make most decisions together in a team so that everyone can contribute their ideas.
Mutual appreciation is our top priority. We see ourselves as a team, support each other and stand up for each other. That’s because only by working together can we be successful.
Taking the initiative and a high degree of personal responsibility are very important to us. No supervisor who constantly looks over your shoulder, but projects that you can take into your own hands.
Many different customers, many specialist areas, a wide range of tasks: Employees who work at VESCON have a very interesting job – and with it all the opportunities for further development.
Having many customers presents many challenges. That's why hardly any of our projects are alike. Variety is guaranteed and boring routine is guaranteed not to come up.

The VESCON Group

As a system integrator, VESCON plans and implements projects in the automation, special machinery, software, process, Aqua and energy fields to sustainably support customers on their way to Industry 4.0. More than 500 employees at multiple European locations are committed to working with our customers (planners, suppliers and operators) in a wide range of industries:

  • Automotive industry
  • Machinery and plant engineering
  • Electrical industry
  • Chemical industry
  • Medical technology & pharmaceuticals
  • Energy sector
  • Drinking water and wastewater plants

Our customers include companies of all sizes, renowned international industrial groups and ‘hidden champions’ from the SME sector.

VESCON Process GmbH
Waltherstraße 80, Building 2007
D-51069 Cologne

Phone: +49 221 1207169-0
Fax: +49 221 1207169-88
Mail: koeln@vescon.com

VESCON Slovakia s. r. o.
Minská 7/5 
SK-036 08 Martin

Phone: +421 43 42815-21
Fax: +421 43 42815-44
Mail: m.galcikova@vescon.com

VESCON Automation GmbH
H-9027 Györ

Phone: +49 8165 90516-120
Fax: +49 8165 90516-130
Mail: vca.eching@vescon.com

VESCON Automation s. r. o.
Stará  Prievozská 2
SK-821 09 Bratislava

Phone: +421 2 58104 -111
Fax: +421 2 58104 -129
Mail: bratislava@vescon.com

VESCON Systemtechnik GmbH
Industriestraße 1
A-8200 Albersdorf-Prebuch

Phone: +43 3112 36006-0
Fax:  +43 3112 36006-88
Mail: gleisdorf@vescon.com 

VESCON Energy GmbH
Merkurring 110
D-22143 Hamburg

Phone: +49 40 18138418-0
Fax: +49 40 18138418-88

Sales:
Toni Werner
Phone: +49 40 18138418-30
Mail: toni.werner@vescon.com

Maik Karge
Phone: +49 40 18138418-33
Mail: maik.karge@vescon.com

VESCON AQUA GmbH
Heidenkampsweg 101
20097 Hamburg
Mail: aqua@vescon.com

Sales:
Maik Bösch
Phone: +49 40 2364854-60 
Mail: maik.boesch@vescon.com

VESCON Energy GmbH
Welfenstraße 19
D-70736 Fellbach

Phone: +49 711 6733160-0
Fax: +49 711 6733160-188

Sales:
Toni Werner
Phone +49 40 18138418-30
Mail: toni.werner@vescon.com

Maik Karge
Phone: +49 40 18138418-33
Mail: maik.karge@vescon.com

VESCON Automation GmbH
Oskar-von-Miller-Straße 1
D-85386 Eching

Phone: +49 8165 90516-120
Fax: +49 8165 90516-130
Mail: vca.eching@vescon.com

VESCON GmbH
VESCON Automation GmbH
VESCON Process GmbH

Dürkheimer Straße 130
D-67227 Frankenthal
Phone +49 6233 6000-0
Fax: +49 6233 6000-800
Mail: frankenthal@vescon.com

PrintoLUX GmbH
Dürkheimer Straße 130
D-67227 Frankenthal
Phone +49 6233 6000-0
Mail: info@printolux.com

VESCON AQUA GmbH
Conrad-Röntgen-Straße 1
D-24941 Flensburg

Olaf Kremsier
+49 171 1455009
olaf.kremsier@vescon.com

Mail: aqua@vescon.com

VESCON AQUA GmbH
Gadelander Str. 172 
D-24539 Neumünster

Mail: aqua@vescon.com

VESCON AQUA GmbH
Westerbreite 7
D-49084 Osnabrück

Henning Pohlmann
+49 541600187-33
henning.pohlmann@vescon.com

Mail: aqua@vescon.com

VESCON Energy GmbH
Hans-Grade-Allee 1/1a
D-12529 Schönefeld

Sales:
Toni Werner
+49 40 18138418-30
Mail: toni.werner@vescon.com

Maik Karge
+49 40 18138418-33
Mail: maik.karge@vescon.com

VESCON Process GmbH
Am Holzweg 26
Gebäude A
D-65830 Kriftel

Markus Hartmann
+49 1522 2559029
markus.hartmann@vescon.com