BHB Waschanlagen Vertriebs GmbH developed a new tram washing system that is very resource-efficient for Zurich’s public transportation operator with assistance from Mitsubishi Electric and the engineering firm ATINA. It was implemented with much lower costs and time because of digital twins and low-code programming.
The Oerlikon district of Zurich has a modern tram cleaning system that is unique in a number of aspects. Four individually mobile washing cars are employed in place of the customary two, and Mitsubishi Electric’s automation technology allows for exceptionally thorough cleaning outcomes with quick washing durations and great energy economy.
This challenging project also marks a turning point in the digital transformation of BHB Waschanlagen Vertriebs GmbHÂ that completed it and is a customer of Mitsubishi Electric.
It was the first time low-code programming was combined with an innovative digital twin approach. As a result, commissioning times were dramatically shortened and the complicated system could be planned with much less effort.
ATINAÂ and experienced software specialist from Mitsubishi Electric’s partner network, provided help to the 20-person machine manufacturing team.
Low-code programming and digital twins
Increasing customer demands for flexible, networked, and resource-efficient systems—especially amid skilled labor shortages—require new digital concepts, says BHB managing director Tobias Straub. “Through Mitsubishi Electric and its Automation Network, we came into contact with the engineering firm ATINA, which has provided us with significant support in our digitalization efforts,” Straub reports. “This enabled us to use a digital twin and the new low-code programming for the first time in the Zurich project.”
As a pure scripting language, ATINA’s low-code programming eliminates the need for hard-coded, line-by-line programming. Washing programs can be easily parameterized using Excel spreadsheets, even without in-depth programming knowledge.
This saves time, reduces sources of error, and facilitates subsequent revisions. With only 200 lines of text instead of 4,000, the programs are clearer and easier for service personnel to understand. The programs created in Excel can be transferred directly to the Mitsubishi control system via a simple CSV export.
In addition to the script language, BHB used a digital twin for the first time for the Zurich project. All mechanical and electrical components of the washing system are stored there as fully functional 3D models and can be controlled by a real Mitsubishi PLC.
Since the programs can be tested very accurately at the desk, commissioning on site is greatly accelerated and virtually error-free — an enormous economic advantage for everyone involved, especially in more complex projects.
Innovation meets automation
However, digital twins and low-code programming alone would not have been enough to meet high customer requirements. That is why the software innovations are based on Mitsubishi Electric’s reliable hardware. At the heart of the control system is the compact MELSEC FX5U-64MR/DS PLC. “Our hardware is exceptionally robust and backward compatible across generations,” explains Michael Brandecker, a sales engineer at Mitsubishi Electric. “This enables machine builders, such as BHB, to offer their customers products whose components can be replaced after many years without costly reprogramming.”
Additionally, Mitsubishi Electric drives ensure efficiency during operation. The FR-E800 series of frequency inverters enables flexible motor control, reducing energy and water consumption and contributing to economical and resource-efficient operation of the plant.
Future-proof machine building requires digital transformation and the right partnerships
The BHB project serves as a role model, particularly for medium-sized German machine builders. Thanks to close cooperation between partners who work seamlessly together, the company successfully drove forward its digital transformation at the right time.
BHB contributes its many years of experience in plant engineering, ATINA provides software expertise, and Mitsubishi Electric supplies robust automation components.
The result is a tram washing system that meets the growing demand for sustainability, quality, and efficiency while showing how medium-sized machine builders can remain competitive and attractive to skilled workers by using digital technologies.
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