Mobility starts in the head.

The Automotive Industry is subject to very specific dynamic processes. Globalisation, shortening product life-cycles and increasing costs demand more and more flexibility and efficiency of all those involved in the market. This is where VESCON steps in: We are a solution-oriented partner, not only to big groups, but also to medium-sized suppliers who plans, designs and realizes projects in a future-oriented manner.

Our profound sector-specific knowledge forms the basis for our in-house developed software solution Material Data Manager (MDM) and the engineering tool SO. In addition, VESCON's experts not only know and master the major projecting guidelines of our automotive customers, but also develop and maintain these guidelines for all other premium manufacturers in Germany.

In other words: We speak your language and know the factors that determine your success.

BMW - Roller control system Dingolfing

Task:Roller test bench, development EPLAN, S7, Visu
Business:Automotive industry
  • Roller test bench
  • development EPLAN, S7, Visu

An easy-to-handle, precise and efficient solution: The VESCON Material Data Manager for application in the automobile industry

Task:suppliers integration on the basis of the Material Data Manager
Business:automobile industry

The Material Data Management system developed by VESCON has been used by a large automobile company in southern Germany since the end of 2006. The online solution which today is being used in many plants worldwide supports the management of approval lists for new plants and machines.

VESCON has continuously improved the software and, what is more, tailored it to the specific needs of the customer. Since November 2012, for example, it has been possible to apply this system for managing project structures including factories, projects and orders - down to the level of plants and machinery.

In addition, the connection of the Material Data Manager to the CAD systems (RUPLAN and EPLAN P8) saves the supplier companies the creation of article data. Parts list information that is written back from the CAD systems to the respective project structure significantly facilitates the acceptance processes and the further processing of the data in the target customer system. The result: an efficient software solution which not only saves time but also minimizes possible sources of error.

Services provided by VESCON:

  • specification, design and programming of the online application Material Data Manager
  • hosting and implementation of application and database (24 x 7 x 365)
  • basic administration of the users
  • hotline and support
  • training
Bernhard Adler
Project Development
Phone +49 6233 6000-640
Karl Heinz Charusa
Head of Business Unit IT & Software
Phone +49 6233 6000-400

BMW - Chassis test bench USA

Task:Chassis test bench, roller test bench, development EPLAN, S7, Visu
Business:automotive industry
  • Chassis test bench
  • roller test bench
  • development EPLAN, S7, Visu

Porsche CMT welding plant for doors, PLC programming and commissioning.

Task:PLC programming and commissioning, assistance and optimization
Department:Electrical engineering | Automation
Business:automobile industry

Customer: IBS Dr. Klaus Schürer GmbH

In this project VESCON has realized the programming and visualization of the control system for a welding cell in the door manufacturing section.

The project implied the consideration of several interfaces and subsystems and the integration into an existing control architecture.

Systems and technologies used:

WinCC, Step7, SEW, ABB-Robots, Fronius welding control systems, safety technology

Services provided by VESCON:


  • software engineering PLC including visualization
  • interface programming
  • risk assessment / Sistema analysis
  • commissioning
  • plant and cycle time optimization
  • production support
  • training and instruction

See further with VESCON: Headlight assembly line for the new "eyes" of the BMW 7 model.

Task:headlight assembly line
Department:Special machinery engineering | Automation
Business:automobile industry

Drivers and owners of the new BMW 7 model enjoy state-of-the art light technology, not least owing to the assembly lines designed by VESCON. ZIZALA Lighting systems has developed a LED headlight and a unique "searchlight" for BMW which is produced in Austria. Thanks to our long-term experience in the field of light technology VESCON has been able to contribute to the successful production and high quality of the new "eyes".

As in the automotive industry the headlights have become a major design feature and are increasingly based on LED technology, the assembly processes are getting more and more complex and demanding. The result is that ever higher demands are placed on the plant constructors not only regarding control technology and ESD protection, but also with respect to the use of material having direct contact with the product during the assembly process and the total logistics operations around the plant. This implies the necessity for tracing batches and individual parts during the assembly process.

With more than 100 different components, such as boards, heat sinks, light bars, reflectors, and design trims, being involved and the assembly processes becoming increasingly complex due to this large number of parts, the headlight assembly line constructed by VESCON is the largest one ever used at ZIZALA. 

The headlights are assembled and checked in line passing 15 partly or fully automated stations. The respective assembly processes like screwing, pressing or lasering run automatically. At the end of the assembly line the headlight is adjusted and the light pattern is tested automatically. After that the headlight is conveyed to the fully automated robot station where the adhesive bed is activated and the sealing and adhesive substance is applied by the robot. Then the pane is inserted and the completely assembled headlight is subject to a leak test. At the end, only 100 % tested headlights will leave the plant.

The newly developed "searchlights" that can be supplied on demand are also produced on a plant designed by VESCON. Thanks to an intelligent software and the on-board electronic system these headlights can identify obstacles at the roadside and illuminate them if they represent a potential source of danger. This assembly line as well has been produced at VESCON as a turnkey solution and then put into operation on the customer's premises.

Services provided by VESCON:


  • concept development
  • development and construction of a turnkey plant
  • training courses
  • production support
Christoph Legat
Department Head Sales & Distribution
Phone +43 3112 36006-750

More power with VESCON: Turbo assembly line at BoschMahle Turbosystems.

Task:turbo assembly line
Department:special machinery engineering | Automation
Business:automotive industry

For economic reasons the downsizing of motors has become a decisive issue in the design of new automobiles and engines. As a consequence, the development focuses on the charging of ever smaller engines assigning a significant role to the use of turbo chargers.

For the Austrian production plant of BoschMahle Turbo-systems VESCON has designed and realized several plant concepts. This project included among other things the development and construction of an automatic picking machine which pre-assembles the small and delicate components supposed to be installed in a high-speed turbo charger in an assembly tray. These trays are then used in the fully automated assembly line. The individual components are stored in specifically designed revolving magazines and separated. This allows an uninterrupted production, as the individual cartridges can be reloaded from outside. The separated parts are placed in the tray via several axis systems. In addition, the data of all individual parts are read in via data matrix codes during the assembling process which guarantees the consistent tracing of the components. 

In another plant developed by VESCON, where the pre-assembled trays are also employed, special chargers and turbo chargers for utility vehicles are produced in small quantities. As also for these chargers the same standards concerning quality and data tracking are demanded, we had to focus intensely on the measurement system capability and the process safety considering at the same time a higher degree of manual operations. In some sections manual operations alternate with fully automated processes. This coupling could be realized in a concept which had already been implemented several times before. Here, as well, all pressing, screwing and testing operations are recorded and the individual parts are conveyed to the plant while being batchwise monitored. The entire data are transferred to the internal PDA system and filed.

Thanks to easily replaceable and coded installation kits a rapid change to other types is possible which makes this concept highly flexible.

Services provided by VESCON:

  • concept development
  • development and construction of several turnkey plants
  • training courses
  • production support
  • maintenance and servicing
Stefan Ebenbauer
Division Head Mechanics
Phone +43 3112 36006-300

VESCON provides motion: Assembly line with EOL test bench for VW rear axles of the VW Caddy 4motion.

Task:assembly line with EOL test bench
Department:special machinery engineering | automation
Business:automobile industry

Within a period of 27 weeks - from order to delivery - VESCON has developed a turnkey assembly line for rear axles for the VW or MAGNA engineering centre in St. Valentin. The challenge was to guarantee a high flexibility allowing the personnel to take strong influence on the process when handling different production quantities on the one hand, and to ensure the same process safety and measuring system capability as with fully automated lines on the other hand.

The plant has been designed in such a way that a worker can either "walk along with" the axle through the production process, or - in case of a higher production volume - pass the workpiece carrier on to the next worker. Depending on the customers' call-offs one up to 6 workers can operate the plant.

This required the development of a PLC higher-level production data acquisition solution (PDA) including an interface to the internal SAP system. In the PDA system all process parameters, results and personnel data are recorded.

In the first plant section the raw, painted rear axle as well as bevel gears and crown wheel are measured via an integrated Zeiss measuring machine. Then follow the assembly of the gearbox and the backlash and friction measurements as well as the assembly of the half-axles and the wheel hubs with brake discs.   After this the Haldex clutch is fitted. Of course, torques and rotation angles in the screwing processes and pressing forces and ways in the pressing processes are recorded and controlled as well. The quality-relevant processes like measuring, pressing and screwing as well as the test run take place in a fully automated way. By indication via the PLC unit the worker is guided through the workflow and has to confirm the completion of the individual worksteps.

The finished rear axle is filled with two different oils on the EOL test bench before it has to undergo the test run (Haldex, gearbox, ABS sensor system).
During an iO run the axle is finally embossed and the corresponding assembly and test records are created. By this procedure it is guaranteed that the driven rear axles in the VW Caddy 4motion run smoothly and to the customer's satisfaction.

Services provided by VESCON:


  • concept development
  • development and construction of a turnkey plant
  • process data acquisition (PDA) with SAP interfaces
  • training courses
Stefan Ebenbauer
Division Head Mechanics
Phone +43 3112 36006-300
Martin Feichtgraber
Division Head Software Development
Phone +43 3112 36006-400