Virtual commissioning accelerates project execution

To ensure the efficient and reliable execution of a project of this scale, PIA Automation relied on Virtual Commissioning (VC) from the earliest concept phase. Programming logic, motion sequences and process workflows are digitally simulated and validated before any physical equipment is assembled. The resulting insights are then directly incorporated into further system optimization.

Compared with the traditional sequence of design, manufacturing, assembly and commissioning, this approach significantly accelerates engineering and ramp-up activities. “Virtual Commissioning reduces the number of review cycles and helps us minimize resource-intensive development efforts,” explains Markus Harlander, Project Manager at PIA Automation. “Particularly during ramp-up, time savings of up to 50 percent can be achieved because potential issues are identified and resolved in the virtual environment before they impact real production.”

Fully automated gear meshing and high-precision fastening

One of the key automation challenges within the project is the fully automated assembly of the transmission stage. In this process, three gears are precisely meshed before being inserted into the transmission housing. The production line can assemble multiple transmission variants in batch size one without requiring changeover operations. This flexibility is enabled by automatically adjustable grippers that adapt to the specific product variant being processed.

Another highly demanding process is the so-called “marriage” of the preassembled transmission and electric motor assemblies. Within a robotic cell, both components are brought together and secured using twelve synchronized fastening systems operating simultaneously. Continuous quality assurance is achieved through the monitoring and documentation of force-displacement curves, torque values and angular measurements.

Integration into customer-specific software standards

PIA Automation typically relies on its proprietary PIA Industrial App Suite to control and monitor production systems. For this project, however, the automation solution needed to be integrated into the BMW Group’s company-wide software standard. To ensure seamless integration with the automaker’s existing digital infrastructure, PIA specialists underwent extensive training on the customer-specific software environment.

Multiple PIA competence centers contribute to project execution

For nearly 20 years, PIA Automation has been developing systems for the fully automated assembly and quality inspection of components used in electromobility applications. The current E-Drive assembly project marks the first collaboration between PIA Austria and the BMW Group’s Steyr plant. At other BMW locations, PIA Automation and the BMW Group have already successfully completed several projects together.

The implementation of this large-scale project involves several centers of expertise across the PIA Group. While PIA Austria, as a specialist in powertrain applications, assumes overall project responsibility, PIA Croatia supplies complete robotic cells. These systems are assembled, precommissioned and factory acceptance tested in Zagreb before being transported to Austria for final installation.

“We are particularly pleased that our longstanding expertise in highly efficient automation, our extensive experience in electromobility and the positive results of previous joint projects were key factors in the BMW Group’s decision to partner with us on this exceptional manufacturing system,” says Franz Reiter, Business Segment Manager E-Drive & Powertrain at PIA Automation. “The project is progressing according to schedule, and we look forward to seeing the system enter regular production.”

Commissioning of the final production line sections is scheduled for 2027.