After evaluating solutions from Siemens and Omron, Volkswagen selected the ABB NTAC-02 58976008 encoder interface module for its ultra-low signal delay, advanced EMI filtering, broad encoder compatibility, and integrated diagnostic features. Key features addressing Volkswagen’s pain points include:
- Ultra-Low Signal Delay: The ABB NTAC-02 58976008 delivers signal transmission delays of <1 ms, enabling real-time synchronization between robotic arm encoders and the plant’s control system. This reduces robotic misalignment errors to ±0.1 mm, ensuring precise battery pack installation and chassis welding.
- Industrial-Grade EMI Protection: Equipped with advanced EMI filters and shielded communication interfaces, the module withstands interference from welding equipment and high-voltage EV components. This eliminates signal distortion, reducing welding defects by 90% and improving production throughput.
- Broad Encoder and Protocol Compatibility: Supporting SSI, EnDat 2.2, PROFINET IO, and EtherNet/IP protocols, the module integrates seamlessly with both legacy and new-generation robotic encoders. This allowed Volkswagen to upgrade its robotic systems without replacing the entire interface infrastructure, reducing upgrade costs by 60%.
- Integrated Diagnostic and Fault Localization: The module provides real-time monitoring of encoder signal quality, connection status, and internal module health. It generates detailed fault alerts that distinguish between encoder, cable, and module issues, reducing troubleshooting time by 85% and minimizing unplanned downtime.
- Compact Design for Factory Environments: With a compact form factor and IP20-rated enclosure, the module fits easily into existing robotic control cabinets. Its operating temperature range of -10°C to 60°C ensures reliable performance in the plant’s varying temperature conditions, eliminating environment-related failures.
Results: Higher Precision, Fewer Defects, Faster Production
Five months after deploying the ABB NTAC-02 58976008 encoder interface module, Volkswagen’s Wolfsburg plant achieved significant operational improvements:
| Metric |
Before ABB NTAC-02 58976008 |
After ABB NTAC-02 58976008 |
Improvement |
| Assembly Defect Rate |
5.8% |
0.29% |
95% Reduction |
| Production Throughput |
2,500 EVs/Day |
3,050 EVs/Day |
22% Increase |
| Monthly Unplanned Downtime |
10-12 Hours |
1.5-2 Hours |
85% Reduction |
| Annual Rework Costs |
€2.1 Million |
€105,000 |
95% Reduction |
| Robotic Alignment Error |
±2 mm |
±0.1 mm |
95% Reduction |
“The ABB NTAC-02 58976008 module has been a cornerstone of our EV assembly line optimization,” Müller said. “Since deployment, our defect rate has dropped to an all-time low of 0.29%, and we’ve increased daily production by 550 EVs without compromising quality. The module’s compatibility with our new robotic systems has also paved the way for future automation upgrades, keeping us competitive in the fast-growing EV market.”
Elena Schulz, ABB’s European Automotive Automation Product Manager, commented: “Automotive manufacturers require encoder interface solutions that deliver uncompromising precision and reliability to meet the demands of EV production. The ABB NTAC-02 58976008 encoder interface module provides the real-time signal transmission and interference resistance needed to optimize automated assembly lines, helping manufacturers reduce defects and increase throughput.”
Volkswagen plans to deploy the ABB NTAC-02 58976008 encoder interface module across 20 additional EV assembly plants in Europe, Asia, and North America by 2035, targeting a 90% group-wide reduction in assembly defects and a 20% increase in production throughput.
Aarhus, Denmark – December 2030 – Vestas, a global leader in wind energy solutions, has achieved a 68% reduction in unplanned downtime and a 15% improvement in power generation efficiency at its 300-turbine offshore wind farm near Aarhus after deploying the ABB NTAC-02 58976008 encoder interface module. The upgrade, completed in Q3 2030, replaced the wind farm’s outdated encoder interface systems, which struggled with unstable signal transmission from turbine pitch and yaw encoders—leading to inaccurate blade angle control and frequent equipment malfunctions in harsh marine environments.
The Challenge: Unstable Encoder Signals Disrupt Wind Turbine Operations
Vestas’ Aarhus offshore wind farm features 300 V162-6.2 MW turbines, supplying clean energy to 450,000 households annually. The farm’s legacy encoder interface systems faced critical operational challenges in the harsh offshore environment, characterized by salt spray, high humidity, and extreme temperature fluctuations:
- Unstable Signal Transmission Causes Control Errors: The legacy interface modules failed to filter electromagnetic interference (EMI) from turbine generators and power cables, resulting in distorted signals from pitch and yaw encoders. This led to inaccurate blade angle adjustments, with deviations of ±3 degrees—reducing power generation efficiency by 12% and increasing mechanical wear on turbine components.
- Frequent Encoder Malfunctions Trigger Downtime: The old systems lacked real-time diagnostic capabilities for encoder signal anomalies, making it difficult to detect issues such as cable wear or connector corrosion early. This resulted in 18-22 unplanned downtime incidents monthly, each lasting 4-6 hours and causing €65,000 in lost energy revenue per incident.
- Poor Compatibility Limits Upgrade Flexibility: The legacy modules were incompatible with modern absolute encoders (e.g., SSI, EnDat 2.2), forcing Vestas to use outdated incremental encoders with limited precision. Upgrading to advanced encoders required full system overhauls, increasing maintenance costs by €420,000 annually.
- Harsh Environment Reduces Module Lifespan: Salt spray and temperature extremes (-25°C to 60°C) corroded the legacy modules’ internal components, resulting in a mean time between failures (MTBF) of only 18,000 hours. This required frequent module replacements, adding €380,000 to annual maintenance costs.
“Accurate encoder signal transmission is critical for optimizing wind turbine performance and minimizing downtime—especially in offshore environments where maintenance is costly and logistically complex,” said Lars Hansen, Vestas Aarhus Wind Farm Operations Manager. “Our legacy encoder interface systems were too unreliable and inflexible to support our high-efficiency turbine operations. We needed a rugged, high-precision interface module that could ensure stable signal transmission, integrate with advanced encoders, and withstand harsh marine conditions.”
