Rail Guided Vehicle (RGV) Engine Decking System

Fori India recently designed, built and integrated a Rail Guided Vehicle (RGV) style engine decking system to an automotive manufacturer near Pune, Maharashtra.

Features:

  • Jobs Per Hour: 25 jobs
  • Features: Engine dress conveyor and pallets, overhead hoist and rail system for loading engine on pallet
  • Results: Increased production rate, improved decking process

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The system was supplied for accommodating the customer’s new vehicle model. The system was integrated into an existing assembly shop and was designed for 25 jobs per hour. The decking system supplied runs cross-car to the underbody conveyor line. The decking for the engine assembly is completed in a static position.

The RGV movement was completed with a friction drive wheel. A hydraulic scissor lift was provided for vertical movement of the pallet and engine. The control architecture for the system was Allen Bradley PLC based.

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The decking system also included the engine dress up conveyor and pallets, as well as a buffer conveyor with overhead hoist and rail system for loading the product on the pallet.

For more information about Fori Automation’s automotive capabilities, please visit our website.

Automotive Assembly–Automated Guided Vehicles (AGVs) for Front End Assembly

Fori Germany recently supplied a custom designed AGV for an automotive manufacturer for their front end assembly project in Munich.

Features:

  • Guidance Technology: Optical
  • Capacity: 1,100 lbs./500 kg.
  • Safety: Safety scanners, e-stops
  • Controls: Siemens safety PLC, vehicle management system (VMS)
  • Keys to Success: Custom designed chassis, lithium ion battery, optical guidance
  • Results: Reduced infrastructure, increased flexibility

Fori Germany supplied 31 AGVs for a front end assembly line. The AGVS are used to transport the workpiece carriers that are mounted on the carrier plate of the AGV.

The total capacity required for each AGV was 1,100 pounds in order to support the pallet and associated product. The carrier plate used for locating the product was mounted onto a trunnion to provide better ergonomics and accessibility for the operator completing the assembly.

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Each vehicle consisted of two fixed drive wheels, an integrated trunnion, and a 24 volt lithium ion battery to power the vehicle. The system was based on an open controls architecture, utilizing a Siemens PLC for the vehicle control.

Each vehicle utilizes a camera based guidance system that follows colored tape or paint. The optical guidance system provides a flexible, reliable and cost effective solution for guiding the vehicles throughout the assembly plant.

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The system was supplied with a Siemens based Vehicle Management System (VMS) to schedule and coordinate vehicle moves, communicate with the plant and for monitoring of the vehicles.

For more information about Fori Automations’ AGVs, please visit our website.

Automotive End of Line–Wheel Alignment, Headlamp Aiming, Roll & Brake Testing

Fori China recently designed, built and integrated an end of line system for an automotive manufacturer.

Features:

  • Jobs Per Hour: 15 jobs
  • Testing Completed: Wheel alignment, headlamp aiming, roll and brake
  • Results: Increased production rate, reduced labor, improved quality

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The end of line system was included: non-contact wheel alignment, automatic headlamp aiming, and roll and brake testing.

The Wheel Alignment machine is designed for automatic measuring and manual adjustment of the vehicle parameters.  The system was designed to measure Toe & Camber with a wide range of wheel bases, tread width, and tire sizes.

An integrated headlamp aimer measures the vehicle headlight intensity and position automatically and guides the operator to adjust the lamp position semi-automated. The “Fori Vision” aiming unit utilizes a camera based system to measure the intensity and position of the headlight.

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Roll and brake testing is also completed on the end of line system, which includes testing for acceleration, cruise control, transmission, rear gear, dynamic braking and engine.

For more information about Fori Automation’s end of line systems, please visit our website.

 

Automotive Assembly–Caster Camber Pre-Set Fixture

Fori supplied a cost effective solution for setting the front suspension caster and camber alignment prior to the end of line equipment.  

 

Features:

  • Safety: Safety scanners, system interlocks
  • Controls: Allen Bradley
  • Keys to Success: Highly accurate and repeatable, fully automatic with manual override functionality.
  • Results: Increased production rate, reduced personnel injuries

The Caster Camber fixtures (primary and back up) were built to fit within the existing assembly plant. The system proved to be a challenge in the already congested twin strand pedestal conveyor. The fixture itself hangs from an overhead rail system and is capable of locating and tracking with the vehicle frame as it passes beneath.

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The fixture lowers itself onto the vehicle frame, and then pins and clamps to the frame which establishes the control datum points to locate to. The machine’s two pivot arms swing in and clamp the upper and lower control arm ball joints. DC Nutrunners loosen the lower control arm fasteners. Servo motors position the X and Y location of the lower control arm. DC nutrunners secure the lower control arm into the correct location. The fixture then un-clamps and lifts off of the frame. At that point the fixture drives itself back to it’s home position ready to accept the next unit.

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The system consists of a fully integrated Safety PLC. The PLC has the ability to track and store faults, monitor and record positional and setting information as well as monitor all safety devices.

For more information about Fori Automation’s automotive assembly capabilities, please visit our website.

 

Automotive Welding System–Front Sub Frame MIG Welding/Projection Welding Systems

Fori Mexico provided a robotic MIG and projection welding system for a sub frame line for an automotive manufacturer.

Features:

  • Assembly Cycle Time: 54 seconds
  • Keys to Success: Integrated robots and custom designed turn tables, custom precision welding
  • Results: Decreased cycle time, increased quality

 

The front sub-frame line has a total capacity of 292,000 units with a cycle time of 54 seconds. The assembly consists of MIG welding, projection welding and clinch studs.  Fori processed this with dial tables mounted to the customer’s base system for ease of installation.

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The assembly line consists of 22 MIG welding robots and ten material handling robots.  MIG welding is the main process completed, but the line also has Vitronic cameras to scan welds for quality control, post welding pierce stations, and machining centers for key attachment points and a map vision system to verify dimensional accuracy.

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Fori USA was responsible for project management and engineering for the program.  Fori Mexico was responsible for building the line, debug and run off on their floor. The robotic welding system proved to be a successful collaboration between Fori USA and Fori Mexico. The ability to support the setup, buyoff and installation near the customer plant was of great value to the end user.

For more information about Fori Automation’s welding systems, please visit our website.

 

End of Line Testing–Advanced Driving Assistance Systems (ADAS)

Fori Korea supplied an Advanced Driving Assistance System (ADAS) to accommodate several vehicle platforms and test a variety of safety features.

Features:

  • Safety Testing: Lane departure warning, automatic headlights, over speed prevention, traffic signal recognition, distance warning
  • Results: Decreased infrastructure, increased production rate, accommodation of future vehicle models

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ADAS test benches certify the operation of the vehicle cameras related to Lane Departure Warning (LDW), Automatic Head Lights (AHL), Over Speed Prevention (OSP), Traffic Signal Recognition (TSR) and Distance Warning (DW).

The ADAS system also validates functionality of the vehicles radar system which detects the moving elements in front of the vehicle from a significant speed and the operation of the vehicle. Examples include Adaptive Cruise Control (ACC), Advanced Emergency Braking System (AEBS) and Forward Collision Warning (FCW).

Another test completed by the ADAS is the AVM (Around View Monitor). This process is completed with four cameras (front, rear, two for side mirrors) and then displays the image captured by the cameras to the operator in their cones of vision (e.g., help for the blind spots, help for the car parking).

The ADAS system has reduced the infrastructure required for the various sensor testing that is completed on production vehicles. The system allows multiple tests to be completed in one station.

For more information about Fori Automation’s end of line testing products, please visit our website.

 

Chassis Sub Assembly System–Assembly Line & Engine Decking System

Fori India designed, built, and integrated a chassis marriage Rail Guided Vehicle (RGV) system for front and rear assemblies.

Features:

  • Electro-Hydraulic Scissor Lifts
  • Friction drive wheel
  • Wheel base adjustment
  • Results: Increased production rate

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The Rail Guided Vehicle system supplied was comprised of a Fori standard friction wheel drive for the required forward and reverse movement. The vehicle included two separate electro-hydraulic scissor lifts that are used for decking the front module and rear axle assembly. The system also included wheel base adjustment that was required to accommodate multiple models for the rear axle assembly.

The RGV was designed to be user friendly and simple to use. An example of this methodology is the within the control System which was designed to be very simple for the end user, utilizing a relay based logic.

For more information about rail guided vehicles, please visit our website.

 

Automotive Assembly–Workpiece Carriers for Front End Assembly

Fori Germany supplied a custom designed work piece carrier for an automotive manufacturer for their front end assembly project.

Features:

  • Keys to Success: Custom designed work piece carrier, trunnion for part access
  • Results: Reduced infrastructure, increased flexibility
  • Solutions: Module assembly system, work piece carrier with integrated trunnion.

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Fori Germany supplied 21 work piece carriers for a front end assembly line. The work piece carriers were integrated with an existing automated guided vehicle (AGV) system, and are mounted directly to the AGVs.

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The purpose of the work piece carriers is to provide a repeatable solution for locating the parts to the pallet for assembly. The work piece carrier also provides a process to the operator for adjusting the part location and orientation. Adjustment is completed through a powered trunnion.

The carrier trunnion has an integrated motor in order to tilt (the system has four automatic tilt angles) the fixture both automatically and manually. The carrier utilizes the power available on the AGV and communicates with the it to provide confirmation of the correct position. Upon completion of the front end module, the carrier returns to the home position and the module is unloaded via a lift assist.

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The system supplied provided a simple technique for locating the front end module for the operator. The design considerations were based on a high level of reliability and minimal maintenance.

To learn more about Fori Automation’s AGVs and assembly capabilities, please visit our website.

Automotive End of Line–Wheel Alignment, Headlamp Aiming, Roll and Brake Testing

Fori China designed, built and integrated an end of line system for an automotive manufacturer.

Features:

  • Jobs Per Hour: 30 jobs per hour
  • Testing Completed: Wheel alignment, headlamp aiming, roll and brake
  • Results: Increased production rate, reduced labor, improved quality

The end of line testing system was integrated for a two vehicle inspection line. Testing completed included: non-contact wheel alignment, automatic headlamp aiming, roll and brake testing, and various other sensors.

The wheel alignment machine is designed for automatic measuring and manual adjustment of the vehicle parameters.  The system was designed to measure toe and camber for a wide range of wheel bases, tread width, and tire sizes.

An integrated headlamp aiming system measures the vehicle headlight intensity and position automatically which guides the operator to adjust the lamp position with semi-automation. The “Fori Vision” aiming unit utilizes a camera based system to measure the intensity and position of the headlight.

Roll and brake testing is also included in the end of line system which consists of testing for acceleration, cruise control, transmission, rear gear, dynamic braking, and engine.

For more information about Fori Automation’s end of line systems, please visit our website.

 

Fori Automation named a Top 5 System Integrator Giant for 2020

Fori Automation has been selected as a Top 5 System Integrator Giant for 2020. The selection of System Integrator Giants is based on each respective companies revenue that is attributed to system integration. For more information on System Integrator Giants, please visit the Control Engineering webpage.

2020 Integrator Giants

The System Integrator Giants announcement can be found here.

Fori Automation privately held and U.S. owned and operated since 1984, specializes in the custom design, build and integration of automated material handling, assembly, testing and welding systems for the automotive and non-automotive industries.

Our equipment and systems include:

Products

Fori has supplied equipment across the globe for a variety of Automotive & Non-Automotive OEMs and Tier 1’s. Customer verticals served include the Aerospace, Automotive, Defense, Nuclear, Recreational Vehicle and Construction industries. With over 30 years of experience and seven locations across four continents, Fori is positioned to support its customers around the globe.

For more information on Fori Automation, please visit our website.