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.