GERMAN AGRICULTURAL MACHINERY: Class Axion 960 - Birth of a High-Tech Tractor | WELT Docu

characters as far as the eye can see but consumes up to 20 percent less fuel Assembling a

tractor

is very similar to assembling a car, only on a much larger scale. I was impressed when I started here. I used to work in the automotive industry, where everything is much smaller. Modern robots operate here, for example in This 12 meter

high

and 24 meter long rack warehouse is fully automated. The free robots prepare around 2,000 trays per hour in facilities with 100,000 square meters of surface area. Assembly teams build

tractor

s non-stop every day. About 60 tractors travel the 500 meters long. On the main production line we can work much faster here and build more synchronized tractors.

Each unit goes through the test bench, including acceleration, braking or load testing at the factory, on the road and in the field. Every component of the tractor is inspected if we are moving and I can. let the steering wheel and the system be autonomous in 2021

agricultural

journalists awarded the Axion 960 CMOS with the international sustainable tractor of the year award the tractor has extraordinary energy efficiency the German

agricultural

machinery

manufacturer operates two factories in East-Westphalia the factory The main factory in Hazavinka mainly manufactures combine harvesters and forage harvesters, while the factory in Padabon produces important components for some of the agricultural

machinery

manufacturers of the tractor model series, for example, the tire pressure monitoring system.

It can increase the pressure in the tires of all four wheels of the tractor from 0.8 to 2 bar in just two and a half minutes. The adjustable tire pressure protects the ground and improves traction. This tire pressure monitoring system also It is installed in the Axion 960 CMOS that experts consider especially energy efficient. The engine of this tractor delivers up to 445 horsepower and consumes up to 20 percent less diesel fuel. It weighs more than 13 tons. It measures 5.74 meters long and 3.42 meters.

high

and a wheelbase of 3.15 meters The actors are in operation in 80 countries thanks to the tractors of the German agricultural machinery manufacturer are assembled in Le Mans France since class acquired the Renault factory in 2003 it has invested more than 80 million of euros to modernize and expand it today it is one of the most modern factories in the world high-

tech

components from Germany arrive on site some of them are necessary for the Axion model series tractors the engines come from various suppliers and are combine here with transmissions and axles from Germany to form Drive trains the base unit of the tractor the drive train includes the engine transmission and the front and rear axles the Le Mans factory assembles five tractor models Standard in various equipment configurations also includes the Axion 960 CMOS in the wheeled version and as a half-track thanks to everything works automatically here one after another exactly the right components for the specified tractor model always arrive on the production line together the assembly of the drive train requires several hundred of threaded fasteners a load of three and a half metric tons suspended in the air thanks to every nine minutes the mechanics assemble a new drivetrain requires precise work and extremely high concentration.

I make sure all screw connections are tight otherwise parts could come loose and that would be a big problem the staff all the work steps required which means they always know what to do next and that prevents mistakes thanks in this work step the two final drive elements with the brake discs are mounted on the rear axle Of the three and a half meter long drive train, the mechanics use 10 bolts of grade 10.9 stainless steel. The SE bolts here are especially strong now that the front axle is mounted to the tractor drivetrain. The soul of the Axion 960 CMOS weighs over 1.5 metric tons, meaning it can handle both heavy front-mounted implements and twin wheels.

This is followed by the rest of the hardware, such as cable duct fasteners. Assembling a tractor is a lot like assembling a car, except here everything is on a much larger scale and requires a lot of force. to handle these huge pieces. I was very impressed when I started working here. I used to work in the automotive industry where everything is much smaller. It takes one to two hours to assemble a transmission and then the chassis consisting of the motor transmission and axles is ready to go. The next step of the job is about to get wet, so an employee covers the sensitive electronic components, pays special attention to make sure everything is perfectly assembled, and only then proceeds to the paint shop.

The Le Mans tractor factory is home to one of the most modern paint shops in the world now that the chassis has been fully assembled with the transmission and axles, it is coated with primer and paint. The process is carried out in multiple stages. Cleaning, degreasing, drying and coating. Most of these work steps are performed by robots. Thorough cleaning is absolutely necessary for the chassis to be completely free of contamination, otherwise the paint will not adhere. All salts were previously removed from the water, which would also impair the adhesion of the coating. The chassis is dried in special cabins at a temperature of 95 degrees Celsius only after drying.

The last drop of water disappears. Can you continue to the next step? Employees meticulously mask all sensitive parts and openings. This is what we use to protect sensitive areas during the coating operation. These barcodes ensure part traceability and also provide protection. We cover the turbocharger with this tape, otherwise it could become blocked with coating residue, which would be quite annoying. We used these yellow plastic plugs to protect several threads where the screws will be inserted later and it's the same story here if paint gets into these holes, eventually someone will. We have to take a lot of time to clean them and that's how we cover the moving parts of the engine here too.

We have to do a very good job, otherwise we might have problems in production later. The assembly will be primed and coated depending on the requirements. The painting robots spray between two and four liters of paint to obtain a layer one millimeter thick. In the process, depending on the tractor model, they can activate 80 different coding programs, the

tech

nicians The paint shop then inspects all surfaces that the robots have sprayed and reworks them anywhere. Just six minutes later the coating operation is completed and immediately dried at 80 degrees Celsius. This step optimizes the adhesion of the primer and coating to the components.

Now the protective mask is removed and the finished painted chassis is automatically returned to the ground floor, but before the tractor-based unit moves onto the main production line, employees still have to assemble the implement linkages at the front. and rear of the set. Subsequently, farmers can attach and hang an extremely wide range of implements, such as mowers, disc harrows and plows. The Axion 960 is considered extraordinarily efficient thanks to the CMOS optimization system. Helps the driver adapt the tractor and soil cultivation implements to the operating conditions. Reduces fuel consumption by up to 20 percent. Adjustable tire pressure protects the ground and improves traction.

Tracked undercarriage reduces ground pressure by an additional 50 percent at the factory. Driverless transport systems or DTS for short complete tractors are now assembled on the chassis with transmission and axles. Under computer control, the driverless transport systems extend to the exact length required for the respective tractor model from this point on the chassis, piggyback them along the main production line until the fully assembled tractors are finally receive their own wheels. Transport up to 20 tons thanks to an internal navigation system, each DTS always knows exactly where to go. the main production line tractors are now assembled in 36 work steps the main production line is the heart of the tractor factory in Limón here a total of 100 mechanics install several hundred components simultaneously hydraulic lines brake hoses the fuel supply cooling lines and ducts for electronic cables thanks to 1,900 Nm of torque this tractor is a real workhorse its tire pressure control system automatically adjusts the air pressure of the tires to protect the subsoil and guarantee the Fuel Its fuel tank has a capacity of 640 liters It can reach speeds of just over 50 kilometers per hour It is also controlled by satellite and costs up to 366,000 euros depending on the configuration of the equipment The employees connect systems of tubes and hoses through which flow hydraulic oils for steering brakes and implement control, then several hundred meters of tubes, cables and hoses are installed on each tractor, whether for the steering, transmission, fuel injection or system hydraulic, all functional areas of today's tractor are controlled electronically.

The connecting parts this mechanic is installing, for example, will give the driver in the cab precise and responsive control over the tractor implements. Installed here will allow controllers, components and implements to exchange data at lightning speed with the control panel in the driver's cabin. The Le Mans tractor factory has a huge warehouse for large and small parts. Every day, about 80 trucks deliver all the necessary components for the tractor. Just-in-time assembly operation, depending on the models that have just been ordered and are being built overseas, keeps track of everything at all times. Replenishment orders are automatically placed for any missing parts, ensuring production runs smoothly with no waiting periods.

Parts arrive at the warehouse daily from other factories and suppliers throughout Europe and many others leave them on their way to the production plant. The key to it all is this hyrax automated storage facility with hundreds of thousands of small hardware components and is made up of six rack sections, each of which is 12 meters high and 24 meters long, in total there are twenty thousand storage places here. The fully automated high-bay warehouse always supplies exactly the right parts to the production line and also has another advantage: the available space: we need less space and can use it optimally. of the height of the building and also requires less staff.

Three robot systems prepare up to 38,000 trays daily and supply them to a central distribution point in the factory from here, where they are delivered to the exact production location where they are needed, right at the moment when the entire database The factory ensures that drivers always know which workplace to take parts to, many small pieces of hardware end up at the Orleans Metro workplace, then distributes them to their colleagues on screens on the main production line and gives them indicate which screws and washers. He has to distribute the quantities in which he fills hundreds of plastic cups every day. no tractor would be finished without it.

It's much more practical because you can't make a mistake. You'll never have to worry about several thousand pieces missing. per shift five days a week to prevent the work from becoming too monotonous employees change stations every few days among other things screws and washers are necessary to assemble and secure the tractor exhaust system an essential part of the system exhaust the highly complex exhaust gases after The treatment system consists of several components along with the adblue tank which will be added later. Its main elements include the particulate filter and the catalytic converter. Eventually, the adblue urea solution will be injected into the hot exhaust gases and the nitrogen oxides generated during combustion will become Adding nitrogen and water, adding blue and using a particular filter to filter out the soot reduces the environmental impact of the engines. modern diesels.

These hoses are secured with metal clamps to ensure that they do not come loose under pressure during operation. Then the windshield wiper fluid tank is installed. Mounted on tractors along with windshield wipers, it will give the driver a clear view of the field even in very dusty conditions. After just one hour on the main production line, the first part of the exhaust system and other additional parts are alreadyinstalled. Extraneous connections are tightened in the next work step Mechanics connect all wiring harnesses with their waterproof connectors Several hundred meters of cables and hoses are installed on each tractor Color coding helps mechanics install cables and hoses each color symbolizes a particular component or a special connection and when the job is finished the computers also check each connection, this minimizes errors, driverless transportation systems can be raised to exactly the correct working height, this makes installation easier, It's easier on the back, reduces stress and minimizes the risk of error on the part of mechanics.

The huge radiator assembly at the front of the tractor's engine lifters helps move the parts, some of which weigh several hundred kilograms, precisely to their intended location. The only thing left for the installation crews now is to tighten the bolts and connect the lines after about two hours. Installation of the complex cooling and exhaust systems is complete. Most of the work needed to start the tractor has already been done. Although it doesn't look much like a tractor, about 17 million hectares are used for agriculture and forestry in Germany alone. Representing approximately half of the country's total area, Bavaria ranks first in size, followed by Lower Saxony and Mecklenburg.

In Germany there are around 270,000 agricultural holdings, employing a total of around 1 million people. The workplace of a modern tractor almost looks like the cockpit of an airplane. Fully air-conditioned and, on request, practically autonomous at the LeMans France tractor factory, the driver's cab will now be installed on the chassis with drive and axles the cabs are delivered to the main production line fully assembled appearance we will soon get married With the rest of the tractor production celebrates about 60 marriages per day here each cabin is made of steel glass and more than a thousand individual parts such as the instrument panel, steering wheel, seat, roof and fenders, in This work step safety plays an important role, these cabins weigh between 500 and 1.2 tons when joined with the chassis, this enormous weight sometimes swings back and forth, which is why team leader Batiste Jasson makes sure that the employees on your team take special precautions, we build many different versions here, so my colleagues have to pay attention, for example, to make sure that this little red ring is placed correctly, otherwise the liquid could leak later, they also have to pay attention for themselves. safety when getting out of the cabin you must be very careful not to trip or pinch your arm after that it is about connecting everything correctly we use torque wrenches to do this we do not need anything else during installation the key is to insert the bolts of more than 15 centimeters long directly into the threaded holes, twisting even just one of the 12 bolts will prevent the kit from attaching the cab to the chassis securely.

In just seven minutes, the mechanics now fix the 12 cabin bolts. Connect 10 hydraulic lines and connect seven connectors for on-board electronics. This work step is important because all connectors, hydraulic lines and electronic data cables converge in the driver's cabin and will later allow the driver to maintain full control over the multiton. tractor in the foreign field the manufacturing process comprising 36 steps in total continues now it is time for the tanks, depending on the model, to contain between 150 and 850 liters of diesel fuel, the Axion 960 CMOS consumes around 45 liters per hour To run for the same amount of time, comparable tractors need up to 5 liters more for some tractor models.

The empty diesel tank can weigh almost 130 kilograms too much for an employee to lift, so hydraulic equipment is used on the production line. main is more than 460 meters long, almost half the time The factory's 800 employees work here, ensuring that more than 10,000 tractors come off the line each year at the next station the tractor is filled with all the fluids it needs together with diesel fuel the basic fluids include adblue engine and transmission oil engine coolant and air conditioning coolant as well as hydraulic oils brake fluid and windshield washer fluid it only takes a few minutes to fill any tractor with all its fluids and only then can it be started the engine for the first time The engine does not yet have a casing so This shield protects employees in case any part comes loose during the first run-in.

Now, for the Moment of Truth, the editing team's work has paid off. Another tractor will soon be ready to do its work in the field, but first it must be tested. series of mechanical and digital checks to verify that all systems are running smoothly engineers are satisfied everything works perfectly now that the engine has been successfully started and all systems have passed their tests employees install additional components such as the trailer coupling to the side The engine of each tractor receives its hood with the appropriate model designation model size the hood can weigh more than 50 kilograms this is also the case with the hood of the Axion 960 CMOS that is why a machine does the heavy work here adorned like this one after another at regular intervals intervals measured in just minutes up to 60 times a day the hood and its mounting hardware are attached to the chassis with several bolts now all that is missing are the fenders for the wheels and the wheels themselves, then the assembly of the tractor will be complete at the factory At Lamont it takes between 28 and 50 hours to completely assemble a tractor and have it ready for delivery.

Since 2003, the German agricultural machinery manufacturer has invested more than €80 million in the modernization and digitalization of its tractor factory in Le Mans, the modernization of which allows it to be built. Increasingly complex and individually configured tractors abroad at the last station of the main assembly line the tractor receives its wheels on the Axion 960 the standard rear wheels have a diameter of 2.15 meters the front wheels have a diameter of up to 1.7 meters mobile robots take wheels from the warehouse and deliver them to each tractor automatically Wheels perfectly positioned on the suspension A laser system is used that shows the mechanic exactly where the wheel belongs so that nothing gets twisted when tightening the fasteners once joystick Assembly technician guides the wheels to the tractor Laser markings help position them precisely on the axles.

The game tells me exactly what to do here, for example I have to tighten two bolts on the wheel here and here I use the joystick to set the position and tighten or loosen again, the system also shows me. When everything is perfectly in place, there are hundreds of different tire combinations depending on the model and customer preferences, along with the rims, each of the tractor wheels weighs between 300 and 1000 kilograms thanks to the hydraulic lifts, the equipment You don't have to lift the wheels on their own, instead you just have to attach them to the tractor with Precision Fit precision.

At any given time, a special pneumatic torque wrench always tightens exactly two of the eight bolts that secure the wheels to the suspension now the tractor moves on its own wheels for the first time, we move on to the final quality control, this is a great progress for control purposes. We used to use photos to compare different wheels. Today, the entire process runs almost automatically, so we can work much faster and more effectively and build multiple tractors in sync. The last work step in the tractor factory is also one of the most important. Each finished machine undergoes a multi-stage quality control inspection before leaving the plant.

On this test bench, inspectors verify that the tractor accelerates quickly and smoothly and reaches maximum speed. up to 50 kilometers per hour this tractor does exactly what it is supposed to do and can continue until the next test this test bench measures braking performance it is important that the tractor stops in compliance with standard regulations and decelerates smoothly when going downhill Brake pressure is applied. The front and rear of the tractor are also secured with steel chains to ensure that it cannot come loose from the test stand. The test bench automatically scans each tractor to determine the model length and tire diameter and then uses that data to make the correct route. test sequence for each machine well after about 20 minutes all driving conditions simulation tests are complete Benjamin bullion registers this tractor in the system as error free everything has to be adjusted with the specifications of the tractor and the tractor is much more complicated than the car, so it means that all the parameters in the system are linked with all the options of the factors of the front wheel side of the rear wheel side weight of the tractor options sorry, yes, it really is specific between the comma of each chapter that comes here on the braking suspension after a brief test drive through the factory, an engineer verifies that the lifting forces meet the required specifications and whether the linkage can support tons of load under these extreme test conditions.

More than four tons. Press the front linkage and it handles them without any problem. The test simulates extreme forces. It is rarely found in the field, as a result, the tractor is always prepared, no matter what, it also passes this test. Here the electronics and hardware are checked. The engineer checks that all the light pedal switches and levers work perfectly, but that's not all in the final test. The engineer confirms the results of the previous inspector. Anything worth doing is worth doing twice. The final test sequence covers a list of 100 checks on and off the tractor.

The engineer also performs extremely careful examination of any reworked parts due to nonconformity during previous inspections that the tractor cannot. be delivered to the customer until everything is 100 percent right here also at the factory several hundred finished tractors await their new owners 75 percent of the tractors built here in Le Mans are exported to the USA and throughout Europe and even to China, Africa and Australia. Providing healthy and sustainable food to as many people as possible is a global challenge. Food production and forestry are responsible for up to 12 percent of all greenhouse gas emissions in the EU.

Modern and affordable agricultural machinery helps reduce greenhouse gas emissions and protect the environment. The challenges continue to develop and build even more efficient tractors. The agricultural machinery manufacturer operates a test and development center near Limón, six miles west of Le Mans. Engineers perform stress tests to obtain important findings regarding all installed parts. The entire life of a tractor with almost 30 tonnes pushing against the machine at each contact point, the system recreates the extremely wide range of road and field conditions experienced by the average tractor during its more than 10,000 hours of operation. Based on the results of these tests, engineers determine which parts wear out prematurely or come loose and we can redesign them accordingly Fabian Lombrezi is product evaluation manager and responsible for making tractors increasingly stronger, more effective and more efficient.

The goal of this testbed is to see very, very quickly things that we would see in a long time in real conditions. life, so we want to see how things happen, this is really the end because every bug they discover here can still be fixed before it actually happens during operation in the field. The errors are instructive for engineers, allowing them to continually optimize tractors. We have to make it stronger by changing the concept, the concept of how things are put together, changing the suspension, the stiffness, you have multiple ways to improve things, but of course we think about the test feedback, but we have to explain this to R&D and engineering, and then they can change and improve the design.

This is not the only development department of the tractor manufacturer. There are similar facilities in Germany and elsewhere specializing in energy efficiency, tire pressure monitoring system or tracked undercarriage systems. For example, here in France, the main objective is to improve the strength and endurance of the tractor. To this end, the site has its own tractor test track and its own proving ground. Today, engineers are testing the most popular model along with the tractorbigger and more powerful. of the Axion model series with 445 horsepower and tracked undercarriage, Robert Perlamoa is verifying that the GPS-assisted autopilot works perfectly. Yes, the GPS can control, so for example I just press this button and now we are moving and I can let the steering wheel and the system is autonomous and now I just have to manage the speed.

I can speed up or slow down and I can walk like this easily. The professional driver even turns the tractor in the field and always maintains the optimal path for working the field today, engineers are also By verifying that the GPS systems of the two tractors work together with the same precision, they intentionally drive in a single row to check whether the transmitted traces are retracted exactly and whether the automatic turns are executed with the same precision. In other tests, engineers also determine how good the tire pressure is. control systems work systems automatically adapt to specific terrain conditions reducing fuel consumption and minimizing stress on the soil findings are continually applied to the development of new models the goal is to develop more effective, more energy-efficient agricultural machinery and more sustainable tillage and harvesting of agricultural land are time-consuming and costly tasks.

A single combine usually costs more than 300,000 euros. That is why today many farmers no longer own large modern agricultural machines, but rent them together with the driver to so-called contractors. the right machinery for the fields and take care of all soil preparation, planting, field maintenance and harvesting operations, for example, the contractor AGA service Saxon, which specializes in the planting and harvesting of grains and corn, today these men and his machinery are harvesting a farmer's corn fields in Heinzbach, near Dresden, Germany, together with the support of the dealer responsible for this part of Saxony, the contractors offer their full range of services, from tillage to sewing, crop protection and fertilization until harvest.

To this end, they offer an extremely wide range of tractors, combines and forage harvesters. and trailers to rent along with drivers, when the farmer cannot operate his own machines profitably this is often a cheaper alternative. Maximilian Von Scherenberg is one of the best-known agricultural service providers in Saxony almost every day and with true conviction he likes to drive tractors and other machinery. Since the day I was born, it was clear to me what career I would follow. I grew up in farming and have always been fascinated by machines and technology and he is also concerned about rising fuel prices, no wonder with 20 machines continuously burning diesel. running all season long, that's why every fuel leader you save is important to the contractor to avoid having to continue increasing their rental prices.

Sustainability is always an issue, of course, we could compare it to the supplies we need in this case. basically diesel fuel and we can say that the consumption itself is already lower now than with the previous model, but also compared to comparable brands we use five to ten percent less diesel, which does not seem like much at first, But with many tractors, this means savings of tens of thousands of euros over the course of a year and CO2 emissions are also reduced, an important step on the way to achieving the EU goal of being climate neutral by 2050. who works for the local distributor grew up on a farm and has learned to operate farm machinery since he was a child.

He is very comfortable, of course, I would even call it luxurious inside a modern tractor, in comparison, the older ones are more difficult to maintain. Some things always leak somewhere. There is no air conditioning and the cabin never. It has a very nice suspension so the new tracks are much better and they are more fun and you can also do more things and then you don't fall into bed at night. It's really fun. The technical advancement of tractors conserves not only the environment but also the patience and time of the farmer because the intensity of his work continuously increases to meet the growing demand for agricultural products basically agriculture is my passion it is already difficult to make a living with agriculture but it is a lot of fun and in the end agriculture is what feeds people nothing else does and many people forget that harvest time runs every day from early in the morning until late at night, we make sure that we all have fresh, local and healthy food on our plates whenever we want, wherever technology works. helps people produce faster, more efficiently and more sustainably.

Modern and efficient tractors contribute significantly to more environmentally friendly agriculture. Their high-tech engines and process optimization make these Le Mans tractors among the most efficient in the world. Industry experts also consider the factory that builds them. one of the most modern of its kind in the world in a facility with a surface area of ​​one hundred thousand square meters 800 employees build more than ten thousand tractors a year thousands of large and small parts countless screws and washers and a total assembly In a time of only 28 to 50 hours, then another new tractor comes out from the French tractor.

Factory-controlled robots and laser technology ensure wheels weighing up to a ton or more and measuring up to 2 meters in diameter are properly mounted on tractors 14 tons, nearly 6 meters long and up to 445 horsepower, the Most powerful tractor produced here is a true Titan. More than 10,000 tractors leave the Limón factory year after year and operate in some 80 countries around the world.