Pre-series vehicles run away from the familiar production lines and parallel to the processes that have been automated for years. Many new components, many new variants require different process steps, specialized workstations and flexible workers. Theoretical plans are translated into feasible processes and test steps, assembly methods and quality specifications are reviewed and redefined if necessary, and all of this was previously done with manual planning.

There are many special workstations, all of which are designed for specific activities. As a rule, vehicles must pass through these workstations in a sequence. At the same time as the vehicles, the corresponding picking trolleys must also be ready with the components specifically prepared for the vehicle.

The new Kathrein K-RTLS localization system has been in use at a German car manufacturer since 2020. This allows existing processes to be analysed, visualized and optimized.

All pre-series vehicles have been equipped with Kathrein UWB transponders since 2020. UWB (Ultra Wide Band) is not a new technology, but Kathrein has combined different technologies in one transponder for the first time. In addition to UWB RTLS, passive RAIN RFID UHF and NFC RFID transponder chips are also integrated, which are also logically connected to each other for the first time. The transponder can therefore be addressed via different technologies. The whole thing is rounded off with a 256-color LED for optical feedback to the user.

If a partially assembled body that is already equipped with a passive UHF label enters the pre-series, this ID is automatically "married" to the UWB transponder and the vehicle is then precisely localized on three levels of the pre-series building. In addition to the vehicles, the picking trolleys are also equipped with identical transponders.

Vehicles and parts trolleys automatically report their position in real time as soon as they are moved, and an intelligently integrated motion sensor in the transponder enables only position changes that are relevant to the process to be transmitted. All this important information comes together in the Kathrein CrossTalk IoT software platform.

The IoT software platform CrossTalk, which is used throughout the Group as standard, ensures productive operation with device management and is responsible for visualizing the process sequences. CrossTalk not only reports relevant process steps to the backend system, it also monitors process sequences and can issue alerts before time targets are exceeded or signal when free capacity is available. as