MARITIME SYSTEMS

The specifications for the installation of the electrotechnical equipment to be installed in vessels and yachts have become more demanding. In particular, interconnecting individual components within the whole system has become an ever-rising issue. Interfaces and their alignment usually have major influence on the functionality and cost.

In order to continue conquering such future challenges successfully, we enormously fortified our team in recent years. Meanwhile, we focus our efforts on the technical-engineering layout of the entire electrotechnical system on board. We assist our customers with designing basic and detailed plans, managing projects and installations, and commissioning maritime systems.

Further, in many subsegments we also offer specialized product solutions. These include variable scalable automation systems, which are able to process more than 10,000 measuring points, electric-power distributors and substations, infotainment systems, and other control and monitoring solutions.

Products

Projects

AllViu – A SOPHISTICATED MONITORING SOLUTION

AllViu is a monitoring and control system, invented by besecke in 2004. In the meantime, the system has progressed so far as to grasp the top spot among maritime automation applications. AllViu visualizes all on-board parameters that are expected to be under constant surveillance. Hence, all measuring data and status alarms get streamed inside an integrated system: e.g. engine revolutions, oil levels, room temperatures, fuel levels, status of doors, sliders and ventilation dampers, pump activities, exhaust gas temperatures, and much, much more.

AllViu's explicit display with an easily understandable user interface facilitates simultaneous control and management of all key functions – from energy supply, fire protection to monitoring the pH values inside the swimming pool. AllViu has been designed to record and visualize more than 10,000 measuring points.

The alarm and status signals are queried through a complex system of decentralized controls. By omitting a centralized server, AllViu offers the following advantages:

  • The onboard wiring can be substantially reduced.
  • In case of a single-control failure, all other systems will continue to function without interruption. An elaborate redundant server structure is superfluous.
  • The expense and effort associated with the installation are reduced. As a result, every single component can be inspected on whether it functions properly before it is integrated into the entire system.
  • AllViu can be extended by additional components and functions. Further, it can easily be integrated into the network with other besecke systems and add-ons (e.g. refer to beSECUR).

All such measures reduce the cost and secure the future sustainability of ships and yachts – regardless of their size and specifications.

beSECUR – EXHAUSTIVE SECURITY ON THE HIGH SEA

By offering the beSECUR security system, besecke introduced a brand new dimension in the maritime monitoring technology. This innovative software visualizes all security-relevant activities on board and sets off an alarm, whenever even a minor failure occurs.

As a result, beSECUR facilitates constant monitoring of up to 500 doors. The system manages all access authorizations, locks and unlocks doors automatically for specific individuals, groups or for pre-defined time periods. beSECUR also documents onboard movement, using a motion detection feature, which is part of the standard specifications. Additionally, maneuverable or fixed IP-cameras transmit crystal-clear HD video streams.

The control and monitoring of different security components can be adjusted on all authorized on-board operating stations. This increases the management efficiency and ability to act in cases of emergency.

Another significant advantage is that beSECUR and besecke's monitoring system AllViu have been built on the same technology. Consequently, both applications are completely autonomous and interact extremely well. This feature also allows for an installation option for a comprehensive on-board security network. Similar to AllViu, beSECUR comes in modules and can be extended by additional functions, depending on the security specifications.

View brochure 1

View brochure 2

beWATCH – VESSEL'S BRIDGE IN SAFE HANDS

beWATCH is a navigational monitoring alarm system – also known as the BNWAS (Bridge Navigation Watch Alarm System) – designed for the bridge. It meets all requirements and performance standards as required by the law. The system guarantees that the officer on duty stays alert and able to perform his duties.

For that purpose, the bridge is equipped with a reset button, which flashes at regular intervals which are adjustable. If the officer on duty does not respond by pressing the button early enough, the system will produce an acoustic alarm signal (alarm level 1). If no response is detected, the warning signal will automatically be forwarded inside the cabin and/or cabins of other navigational officers on duty (alarm level 2). If this signal is also ignored, the signal will alarm the rest of the crew (alarm level 3). A motion-detecting sensor, detecting all additional activities on the bridge, can be installed as an optional feature.

besecke's BNWAS system is based on a programmable WAGO controller – equipped with digital ports for switches and light to sound everywhere on board a reliable alarm. The beWATCH system can be switched on and off using the key-switch function. A web-based interface acts as an overriding control tool. The system can be monitored, controlled and settings adjusted on 7 different user interfaces. Most user interfaces are protected with a password to prevent unauthorized persons from access.

beWATCH has been designed as an ideal solution for retrofit installations and vessels of any size – as a stand-alone system or a system to be integrated into the besecke's AllViu monitoring system. The latter solution saves costs for additional hardware, cable systems, and crew training. The LOOK & FEEL features on the web-based user interfaces are identical, with the software facilitating immediate access to all signals and data.

beMOTION – LANDING SAFELY ON BOARD

beMOTION has been specially designed by beseckebesecke to monitor maritime helicopter landing areas. The system displays the roll and pitch angle and the heaving of the flight deck. The technology is compatible with the AllViu monitoring system.

besecke generally integrates beMOTION into AllViu by utilizing the hardware and cabling, which are already available on board. What's additionally needed for the controller is the hardware with a web-based user interface. It is not necessary for the crew to readjust: the LOOK & FEEL feature corresponds with the AllViu user interfaces and is available on all operating stations. The display presentation is in compliance with the requirements of the PYC-Code Annex 2, Chapter 5.1.

beMOTION can also be obtained as a stand-alone solution, independent of AllViu. The system can be upgraded anytime. The web-based interface can be displayed on a PC within the network in a browser.

SHIPTAINMENT – UNFORGETTABLE ENTERTAINMENT GUARANTEED

What passengers want on board is good entertainment and the feeling of security. For that purpose, besecke designed a state-of-the-art system that links infotainment with security and monitoring systems.

All relevant on-board systems are interconnected via an IP-network; e.g. passenger-relevant information, internal communication and light and air-conditioning controls via TV screens with the VOD (video-on-demand) and AOD (audio-on-demand) feature. Diverse alarms and fire alarm systems are included as part of the system.

The Operations Management Center (OMC) functions as a central monitoring and control center. All components are displayed and organized logically and can be controlled individually – on request by customer or dependent on pre-defined parameters such as time, position, or hotel or security status. The actual "shiptainment" version includes the additional mood-based sequence control system for all zones and is controlled by means of touch-sensitive input devices.

We have originally installed this innovative system in approximately 30 passenger liners and yachts...albeit, the number has been growing. It's not only the ideal interaction of different system components. "Shiptainment" can be easily connected to the present available board systems, which can be extended by additional applications.

Click here for more information on "Shiptainment" or give us a call. We'll be looking forward to providing further assistance.

Sample Project:

NEW YACHT CONSTRUCTION IN RENDSBURG

In 2013, besecke received its first contract, to build a new yacht, from Lürssen-Kröger shipyard in Rendsburg. The requested services to be rendered went far beyond just a mere supplier duty. besecke reviewed the individual specifications that were presented by the owner's representative and shipyard's professional technical department.

Assignment:

  • Customization of the AllViu monitoring system, which was developed by besecke, to the specifications outlined by the Kröger-Werft shipyard and the owner's representative.
  • Integration of the monitoring systems into the environment on the bridge – along with the centralized mood-color switching and dimming, as well as the BNWAS.
  • Close cooperation with the suppliers of the cable pathway and cable planning.
  • Recording, evaluation, documentation and clear visualization of all measuring points on the intuitive operating stations.
  • Delivery and layout of the energy supplying facilities, bridge, yardarm, engine-room consoles, UPS-systems, bridge racks, and the decentralized automation components.

besecke's Solution:

  • Development of customized technical solutions within the entire modular system built by besecke by implementing shore converters (2x300kVA), for instance.
  • Hardware assembly and software programming.
  • Offering a complete after-sale service, including the optional remote access to the on-board system. This enables besecke team to detect immediately potential functional failures and correct them regardless of the yacht's location, if necessary.

Customer Advantages:

  • A flexible sustainable integral system that can be extended by additional applications
  • A maximum security on the oceans

Sample Project:

INCREASING EFFICIENCY WITH THE BDE-CONTROL SYSTEM

Any products to be consumed on board – power, water, cold, heat, waste water, compressed air, etc. – must either be generated on board or must be taken along. This generates costs, which besecke notes with the aim of minimizing them – e.g. in the case of two mega-yachts built by Lürssen, or in the case of AIDAsol, that was launched by the Meyer-Werft shipyard.

Assignment:

  • Providing a monitoring system that makes reliable records and facilitates absolute transparency of operational on-board data.
  • Displaying performance reserves or bottlenecks in the distribution network well ahead of time.
  • Contractor: Shipyards Meyer-Werft and Lürssen

 besecke's Solution:

  • Developing the besecke BDE-control system. BDE-control is an innovative system that permanently displays – on mega-yachts, for instance – the energy consumption and process flows, is able to detect promptly unforeseen operational anomalies in the provisional networks and thus optimizes the vessel's operations to run efficiently.
  • Lürssen's yachts have, on board 120 sensor point stations that measure and report status and are absorbed by the system – from the power management to fire protection, from tender doors to the pH-value in the swimming pool.
  • • All processes can be traced back through the database systems, by having them exported as CSV files and transmitted via a remote connection.

Customer Advantages:

With the help of the BDE-control system, the economically efficient optimization potential can be detected more easily and utilized more quickly.

  • At the same time, the system will help to avoid stress situations well ahead of time. This reduces maintenance expense and increases operation times.

The software solution is suitable for all technical standard components and can anytime be extended by adding new applications.

Sample Project:

HIGH-SPEED MONITORING ON LUXURY YACHTS

The trend surrounding the mega-yachts is moving towards increasing a number of measuring points, with signals to be recorded, processed, and visualized automatically. The 180-meter long yacht that was launched by the Lürssen shipyard in Bremen in 2014 memorizes more than 10,000 measuring values for very different zones and processes – from the engine room, all the way to the bridge. Wago supplies raw signals while besecke converts them into approximately 100,000 significant messages, alarms or instructions.

Assignment:

  • Development of an automation concept for all zones to be monitored and controlled. These include, for instance, the vessel's engine, generators, door positions, fire extinguisher valves, fire detectors, NMEA data, security, filling levels, operating hours, alarm services, untreated wastewater, helicopter pad, windlass, power management (EPMS), HVAC, video monitoring (CCTV), maintenance system and entertainment
  • Challenge: to process quickly an unusual large amount of data and make results available anywhere anytime. Such action requires an extremely high computing capacity without increasing the number of controls.

besecke's Solution:

  • Implementation of 125 programmable and particularly efficient Wago Ethernet controllers that collect and bundle the information overload as decentralized controls
  • Layout of a pervasive Ethernet structure from the field to management level – on basis of an Ethernet-ring that combines all controllers
  • Deployment of the collected measurement data for processing and visualizing within the central Monitoring Control System (MCS) designed by besecke – via an OPC-server (designed by besecke), which processes data at a sixfold speed of the products available in the general market
  • Development of the controller software – for instance, for power distribution and security monitoring – and a standard program for acoustic alarms which is less prone to failure
  • Providing technical support over the entire operating life of the yacht

Customer Advantages:

  • There is no need for any sophisticated redundant server structure and cable paths.
  • The highest degree of security and system availability; since each controller works independently and failures have no impact on the integral system

The system's modularity allows for an easy and quick upgrade of individual modules – when changes are needed

Sample Project:

ABSORPTION REFRIGERATOR SYSTEM FOR AIDAmar

The presence of absorption refrigerator systems in hospitals and industrial plants reduces the cost of energy by utilizing usable heat for cooling purposes. The Meyer shipyard in Papenburg installed such a large system for the first time – on a cruiseliner AIDAmar – with the intention of testing it for two years. besecke supplied the software for this ambitious R&D project.

Assignment:

  • The absorption refrigerator system utilizes water as refrigerant and lets it evaporate at 3–5 degrees Celsius. The system drains the evaporated refrigerant and guides it back inside the closed water cycle. During this thermal process, the energy guzzling compressor to be used for cooling is no longer required.
  • The aim of the shipping company and the shipyard was to produce a Megawatt of the cooling medium for the refrigerated holds and air-conditioning – from two Megawatts of the heat loss that would originate from generators.
  • besecke's assignment was to design the entire software and to commission the on-board system.

besecke's Solution:

  • besecke's software regulates the entire system, compiles comprehensive alarm and event lists and sends the collective alarms to the overriding automation of the vessel. Always present: an automatic and regulated shutdown in the case of a failure.
  • Specialized controllers on board store more than 100 readings, alarms and status messages.
  • What's so special? The visualization software allows for all values to be displayed in the web-browser and provides for direct transfer of the performance documentation to the shipyard and shipping company.

Customer Advantages:

  • The following becomes obvious after the testing stage: both the system and software also function on the high sea and respond to a large demand for cooling.
  • besecke's pioneering work can therefore be applied to other application areas, thus, setting a significant milestone to energy savings by land and sea.

Sample Project:

INFOTAINMENT FOR RIVER CRUISE SHIPS

Electrotechnical systems for river cruise ships require highly specialized staff, in particular. The Den Breejen shipyard in Hardinxveld-Giessendam in the Netherlands has been trusting besecke's expertise for a very long time. Our experts build there on site quite some ships of that kind. We further cooperate closely with such shipping companies as Scenic and Arosa and project and supply them with plans for retrofit solutions. Our services encompass the whole range of electrotechnical board systems, which we select, adapt, and link in the network according to our customer's specifications. A highlight product is the Shiptainment – a system specifically designed for river cruise ships, a product with which Den Breejen has set the new standard.

Assignment:

  • Development of the state-of-the-art system for the passenger on-board infotainment and security and remote monitoring systems (the present version is controlled using touch-sensitive input devices and based on sequential control of the scenes in all zones)

besecke's Solution:

  • Projection of the entire plans for the electronic systems on board via an IP-network, including the TV, along with the video-on-demand and audio-on-demand solutions, passenger information, internal communication, lights and air-conditioning control, and with respect to the implication of alarm and fire alarm systems within the visualization
  • Integration of an Operation Management Center (OMC) as the central station to monitor and control all IP-based systems
  • Alignment of interfaces with all other systems on board
  • Detailed construction, delivery, and installation of all system components, including the corresponding cabling and software
  • Providing training for the crew, maintenance and service for all supplied systems
  • Admission of other board systems into the IP-network – e.g. the automation

Customer Advantages:

  • An ideal interchangeable interaction of the systems
  • Uniform visualization and individual control of all system components, on request by customer, based on various parameters (time, position, hotel and security status, etc.)
  • A smooth connection to the available on-board systems and extension of the IP-network by adding other applications

FOOD INDUSTRY

As an automation company from the "brand-name" capital of Bremen, we feel quite comfortable with the food and beverage industry as well. Be it beer, chocolate, cereals, coffee, or convenience foods – besecke weighs, doses, mixes, portions, and inspects using not only batch and lot-based systems but other complementary solutions as well, ranging from the SPS-controls with electromotors, or special switches and sensors, to providing solutions for visualizing entire processes.

At the same time, SAP interfaces and MES are integrated automatically. All data pertaining to running production is recorded precisely and made available to management immediately. This allows for the best-attainable transparency and secure foundation when making business-related decisions.

Sample Project:

FREEZE-DRYING FACILITY FOR KRAFT FOODS

Kraft Foods produces freshly roasted instant coffee in Gorelewo, a city in the vicinity of St. Petersburg. Here, the coffee beans get roasted, grounded, extracted, frozen, dried, and packaged in less than 24 hours. In 2009, on site in Russia, besecke was hired to get one of the largest and the latest freeze-drying facilities in the world up and running.

Assignment:

  • Development and realization of the facility plans in cooperation with the Kraft Foods' staff
  • Implementation of the freeze-drying facilities as part of the near-complete automated production processes of the factory
  • Ensuring a permanent temperature of –50°C inside the vacuum dryer and adjacent grinding and sifting chamber is maintained, while the extreme temperatures are prevented from developing the thermal bridges between the building's walls and ceilings
  • Project participants: SIA Besecke from Riga and besecke assembly teams from other parts of Europe

 besecke's Solution:

  • Development and projection of nearly the entire electrical engineering and control electronics
  • Construction under the application of the extreme freeze-resistant vacuum dryer Konrad, being the center of the freeze-drying facility
  • Construction of dozens of electric cabinets in Bremen and their transport to Gorelewo, including installation
  • Assembly of all components and commissioning of the entire facility on site
  • Complete cabling, partly using meter-wide cable paths to sustain the working temperature and insulate the heat of the building

Customer Advantages:

  • An extensively automated location that meets the utmost quality requirements while
    • it continuously maintains its annual production at 10,000 tons of instant coffee without interruptions
  • Direct access to the Russian market – the second largest market for instant coffee in the world

Sample Project:

PRODUCTION LINE FOR FROSTA’S DEEP-FROZEN DISHES

Frosta AG is well known for its diversity of deep-frozen dishes. The installation of the new production line, P17, in Bremerhaven proved to be a great challenge and took two years. besecke was entrusted with the project management with regard to managing and monitoring the complex facility – particularly, since some on the team have already installed successfully the previous project, P16.

Assignment:

  • Installation of the P17 production line in the largest Frosta factory in the fishery port in Bremerhaven. Its operation ranges from having deep-frozen ingredients delivered directly from the raw materials warehouse, mixing and preparing recipes inside the tumble drier, to packaging and stacking of finished dishes onto palettes. The final station of the P17 is the fully automatic deep-freeze high-level storage, where the palettes are stalled for shipping.
  • Special challenges the management control of such complex facility has to conquer:
    • The deep-freeze chain process may never be interrupted.
    • The pre-defined mixture ratio of ingredients in a recipe must be dosed exactly for each serving.
    • Each serving must have the same weight.

besecke's Solution:

  • Planning and construction of a process-control technology, which is based on the following two components:
    • a computing system that manages the production, and
    • an operating and monitoring computer that compiles data to visualize, monitor and manage all processes.
  • Programming interfaces with the overriding databases and computing systems. These feed the system with all important information, such as the production rules, recipes, etc.
  • Developing visualizations on touchscreen monitors. In case of a failure, this feature enables Frosta's employees to intervene with the production process at any time and on any station.
  • Wiring and assembling electric cabinets for Frosta and other companies participating in the P17 project
  • Assembling and commissioning the facility on Frosta's factory site

Customer Advantages:

  • An ideal functional interaction of all links in the factory and with external suppliers

Sample Project:

AN EXPERIENCE IN INDIA WITH COFFEE ROASTERS FROM PROBAT

Sri City, a city in Southeastern India, has been emerging as an attractive business location for companies from all over the world. In 2012, the subsidiary of an Italian coffee-multi launched here its own roastery. PROBAT and besecke were part of that international project; nevertheless, the project was completed under incredibly challenging conditions – between the mega-metropolis Chennai and the tent-slums by the Bay of Bengal, under the scorching sun with 35° C in the shade and tropical humidity.

Assignment:

  • Installation of an ultramodern coffee roastery, which is able to refine six tons of coffee per hour
  • Contractor and project partner for the plant construction and engineering: PROBAT – a worldwide operating roastery specialist from Emmerich
  • A special challenge: in spite of the persistently prevailing hard-working circumstances on site, there was no room for delays. This was not because of the fixed completion deadline but mainly due to the strictly limited residence permit in India. No besecke employee was allowed to stay for longer than 180 days.

besecke's Solution:

  • Construction site management, together with PROBAT – including the search for and acquisition of machines and materials locally
  • Assembly of the roaster, mill and silos, some of which were 15 meters tall
  • Assembly of the air-compressor system
  • Projection, realization and commissioning of the entire electrical technology and automation

Customer Advantages:

  • A swift and reliable project handling based on a trusting relationship with PROBAT, which has been maintained for decades, plus the global expertise with regard to the construction of coffee-roasting facilities which evolved over time as a result

Sample Project:

BARCODE LABELING STATION AT MARKUS KAFFEE

The modern high-racking storage facility at Markus Kaffee was co-developed by besecke (refer to here) and offers space for 10,000 europalettes – filled up all the way to the top with ground coffee, coffee beans, coffee pads or even a variety of teas. But who packs which palette and where are they supposed to go? This information is provided on the EAN-128 labels. They track each palette exactly, from the production, through the warehouse, to the supermarket. The question of allocating the right barcode to the corresponding palette was solved by besecke's installing a special labeling station.

Assignment:

  • Installation of six barcode-labeling stations that would automatically label each finished palette or providing for labeling by hand with an EAN-128 label.
  • Administration by each station of up to nine production lines – to process the labeling order anytime anywhere

besecke's Solution:

  • Implementation of a central database with an interface to the overriding ERP-system. The new or finished labeling orders are forwarded/reported via interface back to the labeling station
  • Equipping each station with a Siemens S7 SPS controller barcode printer, industrial panel PC-operating station, and a scanner unit
  • Programming the labeling system with the modular Wonderware system platform software

Customer Advantages:

  • Highly efficient implementation of the labeling stations with the modular software system for all required interfaces
  • Nearly unlimited extension options as to the software functions
  • Realization of future extensions within a standardized software architecture, which is more secure as to the planning and the cost, as opposed to in-house solutions
  • Optional adjustment of licensing models, based on individual demands and requirements – either by providing a specific number of client access logins, due to the changing access dynamics or by defining a fixed number for specific workstations

AUTOMOTIVE

Contemporary new cars are as individual as their owners. The production usually begins only after it's clear what paint, seat covers, or what rim size customers asked for. This requires a finishing technology that offers both features at the same time: extreme flexibility and high availability.

In cooperation with mechanical engineers, besecke has developed intelligent automation systems for the dynamic automobile production.

The SCADA-system reads the actual values, measured in the production (e.g. painting color, seat covers), while simultaneously forwarding the target values for the next automobile to the controllers. A continuous recording of data contributes to downtimes reductions. And if necessary, using a particularly user-friendly interface the staff operating the machinery is able to intervene in the process without actually interrupting it.

Sample Project:

VOLKSWAGEN IN EMDEN

The besecke site in Emden is located directly next to the University of Applied Sciences, in the proximity of the Volkswagen factory. Here, theory and practice intertwine, yielding a specialized expertise in the construction of VW Passat and CC Coupé. Whenever VW commits to more sophisticated technical changes on a vehicle, besecke's there to provide support by supplying know-how and experience.

Assignments:

  • Development of an Automated Guided Vehicle (AGV) for the Factory Logistics The vehicles moving on a magnetic rail are fed information – as to what task they are supposed to execute where – with the information originating from a chief PC and the so-called RFID-tags. The RFID-tags are a kind of a wireless label, which can be read wirelessly when a reading device passes by – even if several yards (meters) away.
  • Development of a Facility for Ventilation and Aerification of Paint-Finishing Lines For this purpose, electric powertrains with a performance output of up to 250 kW were implemented as part of the production process – halfway through the production hall up to 28 meters.

besecke's Service:

  • Construction and programming, in close agreement with the plant management
  • Assembly and commissioning in the factory

Customer Advantages:

  • A quick realization of new production specifications by making a complete besecke team available – consisting of programmers, electrical engineers, electricians and a mechanic.
  • The top-quality assurance by obtaining assistance from an expert team, with a long-standing Volkswagen experience, that is thoroughly familiar with details of the production facilities.

Sample Project:

CENTRAL CONTROL TECHNOLOGY FOR VOLKSWAGEN IN WOLFSBURG

Volkswagen AG is one of the premium automobile manufacturers in the world. In order to deliver millions of new automobiles year after year, it is necessary to have a high degree of automation. The system platform of the Wonderware company opens up a great number of new alternatives that make it easier to record operational data and control the production. besecke has exploited that potential and been optimizing the production of VW Golf and Tiguan since 2008 – using a routing application for the assembly line 1.

Assignment:

Development of a control technology solution based on the Wonderware application server – with the aim of

  • documenting and visualizing the entire assembly line 1,
  • aggregating all visualizations that already exist in one application,
  • archiving and analyzing all failure alerts and alert data through database support,
  • integrating special search functions for users,
  • enabling a vehicle tracing,
  • displaying data concentrator information, and
  • extending the production data information system (ProDis) while setting it up for the future.

besecke's Solution:

  • Visualization of the whole system via decentralized view clients.
  • Re-engineering of the SPS interfaces to the Siemens' SPSs, which are in place according to the VW standard.
  • Integration of the SPSs into the application-server-solution, creation of device-integrated-objects (DI-objects) for the galaxy, and the commissioning
  • Extension of the intranet-based information portal "ProDis" to facilitate access via web-browser to the actual and historical facility information.

Customer Advantages:

  • Reusability, thanks to the development and deployment of logical and graphical templates. If, for instance, graphics must be altered at a later point, the templates can be used as often as necessary.
  • Conceptual design as a multi-user system: multiple users can work within the same data galaxy.
  • Optimization of performance, thanks to a divided system build-up that can be extended without limits: if, for instance, problems occur at some place, individual platforms can be unloaded while others make the objects available again.
  • Individual menu navigation on View-Clients: the strict segregation of the logic and graphics allows for adjusting each View-Client to users' needs – provided these are part of the administration group.
  • Immediate and uninterrupted availability of all information: the VW maintenance staff is spared long communication paths through different production halls and is given the opportunity to check the overall status by directly monitoring the assembly line 1.

SPECIALIZED INDUSTRY

The added value with regard to the global flow of commodities mainly depends on logistics. It's not to only optimize it but to re-think it again and again. Many large industrial and trading companies take advantage of besecke's know-how.

Acting as a supplier and prime contractor, besecke offers a full range of logistical innovative solutions from single source – be it the highly specialized automated guided vehicle technology for transportation vehicles or complete high-racking storage systems.

Sample Project:

HIGH-RACKING STORAGE WAREHOUSE AT MARKUS KAFFEE

Markus Kaffee, Weyhe (in the proximity of Bremen) and Westfalia Systemtechnik GmbH have both been besecke's customers for many years. We used this confidential relationship by developing together a high-racking storage system, we customized exactly to the needs of the Markus Kaffee company. In the process, all development stages were coordinated so that the facility would "earn its own money" as soon as possible.

Assignment:

  • Development and construction of a fully automatic high-racking storage system warehouse, which would save storing space and enable quick consignment of more than 10,000 palettes full of goods
  • External dimensions: 45 m (length) x 35 m (width) x 42 m (height). Number of racks: 16
  • Supplying a system that would store and pick palettes with the help of automated rail-guided vehicles that would serve the whole warehouse
  • Project partner for the mechanics: Westfalia Systemtechnik GmbH

besecke's Solution:

  • Drafting plans, together with the end customer and partner company
  • Electrical engineering of 2 automated guided vehicles, along with approximately 100 meters of conveyor technology
  • Programming the automated guided vehicles, conveyor technologies, and security control
  • Assembly of the electric cabinets
  • Preliminary commissioning in a testing facility
  • Cabling and commissioning of the system on site
  • Providing instructions and training to Markus Kaffee's operating staff

Customer Advantages:

  • A highly customized solution, which also keeps in check all economic aspects, in addition to the technical details.
  • Time and cost savings for the customer through the preliminary commissioning of the vehicles in the testing facility. The work on site is reduced, the system gets deployed earlier.

Sample Project:

PRESENT-DAY MANUFACTURING AT KARL OTTO KNAUF

How do huge tree trunks turn into tiny ice-cream sticks? No one knows it better than Karl Otto Knauf – a medium-sized enterprise from Stockelsdorf, Schleswig-Holstein, Germany. The company has been making ice-cream sticks of beeches for many decades. besecke retrofitted the production facility to fit it the latest technology.

Assignment:

  • Modernization of the on-site facility that has been used for measuring, analyzing, sawing, and reporting
  • Special challenges:
    • due to the age of the facility it was not possible to refer to the documentation or program codes
    • the entire renovations were to be realized during the production break, within merely three weeks.

besecke's Solution:

  • Building a completely new control technology on the basis of the operating cycles that have been recently known
  • Programming and building visualization – also, with the help of Knauf employees and their experience they gained over the past decades
  • Integrating the S7 control concept because no spare parts were partly available for the existing technology until that point
  • Deploying the latest light grid and ultrasonic displacement sensors made by Turck to saw the supplied tree trunks to a production-conform length
  • Completely disassembling the facility's previous electrical systems, installing new electric cabinets, control panels, and field wiring
  • Performing test-runs and commissioning the facility and providing instructions to the Knauf employees with respect to the "new" production

Customer Advantages:

  • High cost savings and sustainability due to the preservation of the previous facility – while simultaneously optimizing the work processes

Sample Project:

CONVEYOR TECHNOLOGY IN THE RFT PORT OF LADING IN RIGA

RFT is a huge transshipment point for fertilizers in the port of Riga, the capital of Latvia. Here, the trains – which arrive daily from Russia – unload their cargo for temporary silo storage where it sits until its next reshipment to around the world. Since January 2014, 2 million tons of fertilizers have passed through the port terminal – with 1,200 tons per hour being unloaded and 1,900 loaded onto ships. Therefore, RFT counts as the most efficient logistics center for fertilizers across Europe. SIA Besecke, Riga and besecke, Bremen have jointly contributed to this reputation.

Assignment:

  • Development of the control system program for unloading of train cargo at the train unloading station, a differential loading of eight dome silos, and unloading of silos at two ship loading stations.
  • Development of a uniform visualizing and operating system that will integrate all processes that are usually processed at the terminal – even those that are not controlled by besecke technology (e.g. the lighting or the dedusting plant).

besecke's Solution:

  • Programming and partial construction of the controlling technology which removes cargo quickly and safely from the train, moves it through silos and onto the ships – in their respective quality and quantity
  • Installation of the visualization technology on basis of a redundant server system made by Siemens, with an integrated database computer
  • Construction of electric cabinets, made of the sea-air resistant plastic
  • Installation of the electric technology on site at the terminal – including assembly, wiring, and commissioning

Customer Advantages:

  • High flexibility and efficiency, based on the integration of the system-alien conveyor channels within the visualization
  • Direct unlimited access to besecke's programming and visualization know-how in Riga
  • An ideal information flow, thanks to native speakers working for SIA Besecke

Sample Project:

PACKAGING ROBOT FOR RPC, KUTENHOLZ

The international RPC Group is one of the top manufacturers of plastic packaging. In Kutenholz, Lower Saxony, PET blow-moulding machines keep spitting out bottles for shampoos and other cosmetic products. The bottles are packed in boxes directly on the conveyor belt and shipped to brand owners, to be filled and labeled with the corresponding etiquette at a later point. besecke has automated numerous RPC packing cells with highly flexible Kuka-robots.

Assignment:

  • Modernizing and making the robot-controlled packing cells and conveying facility more flexible
  • Planning an overriding control concept that would simplify the operation and that could be applied to any type of packaging

besecke's Solution:

  • Exchanging the obsolete packing robot for the KR16 robot made by Kuka. Unlike the traditional solutions, the new robots are able to grip different bottle forms, change their gripping direction, and direct the item even around the corner.
  • Developing an especially user-friendly visualization and control concept. A multi-panel enables users to alter the parameters as needed (e.g. the bottle size), while it automatically adjusts the packaging pattern.
  • Handling the entire project – including the layouts for sensor technology and pneumatics, machine components, construction, commissioning and final training of staff

Customer Advantages:

  • The highest degree of flexibility as to packing very different bottles safely without interruptions and placing them inside boxes to be transported onto the palettes.
  • Minimal planning efforts, by deploying direction-flexible Kuka robots, as opposed to the linear portal robots that are only able to convey outer packaging straight forward.

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Sample Project:

EXTRUDER CONTROL FOR THE METEOR RUBBER FACTORY

What laymen tend to call a "rubber seal" is, in terms of technology, a very challenging elastomer – a form-stable, yet highly elastic plastic, which is made using the so-called extruder. Finished seals for windows, doors, tires, or machines are oozed out of the machine as if out of a meat grinder. Meteor operates such production lines in Germany, China and in the US, three of which are located in Bockenem am Harz – along with the besecke know-how.

Assignment:

  • Engineering the controller technology for an extruder – in cooperation with the B&R company that supplied the controller components
  • A special challenge: where seals fill out a 90-degree angle around the door and window frame, the outside rim needs more material than the inner one. This calls for a precise control of the material flow – with the flow speed at 20 meters per minute at fluctuating temperatures

besecke's Solution:

  • Development of a software which measures and controls, exactly to the millimeter, the flow rate of the material at the right spots
  • Installation of a visualization system that facilitates – for the Meteor's employee operating the machine – hourly monitoring of flow rate values while adjusting them as necessary.

Customer Advantages:

  • This besecke system is another step in making production more flexible. It realizes Meteor's future vision – to run around 2,000 different recipes on its production line, with materials being exchanged using a password-protected data stick.