Automotive Chassis Marriage System

Fori China designed, built and integrated a chassis marriage system for a automotive manufacturer located in Slovenia.


  • Jobs Per Hour: 45 jobs
  • Results: Increased production rate, reduced labor, decreased injury concerns


The marriage line is a sub-set of the trim and chassis final assembly system that delivers the completed front and rear modules to the marriage line after being assembled. The overall project is based on the green field sit to provide the delivery conveyance of the completed sub-assembly from the tunnels to the marriage line automatically where the complete chassis assembly will be automatically married and secured to the car chassis.

The body carrier and frame are powered into the stations via asynchronous conveyors. The spindles index and begin securing the front module, differential cradle, and rear module. All 14 fasteners must be torqued at the same time. There will be three wheel base variations that have a common front module and center cradle positions.



An inspection station was supplied with the system. The station will provide positive verification that the details match the corresponding configuration of the vehicle sequencing through the assembly process. The vision inspection is completed at a stop station.

The marriage station includes an electro-mechanical hook style body clamping device for models that require holding the body during the marriage process. An external actuator in the station is used to clamp the body to the pallet. Once married the overhead carrier drive is disengaged allowing the pallet conveyor to the move pallet/carrier assembly down the line. Future non-related products may be introduced by either pallet redesign or through additional pallets and a future pallet storage system.

For more information about Fori Automation’s body and chassis marriage systems, please visit our website.


Automated Suspension Assembly System for Front Vertical

The Fori module assembly system sequences and processes multiple product variants utilizing Fori’s Rail Guided Cart (RGC) assembly solution.


  • Assembly Cycle Time: 32 jobs per hour
  • Keys to Success: Automatic camber set, automated front coil over shock assembly, automatic lateral runout, flexible product transport from dunnage to line
  • Results: System capable of sequencing multiple variants, increased quality

Fori’s integration of manufacturing execution systems with the RGC system allows the value added assembler the means to create multiple variants of brake systems. The sequenced brake systems are then assembled as requested by the original equipment manufacturer (OEM) and ready for installation into the vehicle.


The single loop style conveyor system consists of 13 RGCs to transport front brake corner and strut components (front vertical assembly) from incoming material dunnage through the various assembly processes including:

  • Automatic hub bearing and rotor lateral runout test and assembly
  • Knuckle and splash shield assembly
  • Caliper installation and assembly
  • Vision system inspection and verification of caliper selection and installation
  • Vision verification of brake pad presence
  • Automatic front coil over shock assembly
  • Automatic setting of camber angle and marriage of front coil over shock to brake corner

Utilizing experienced resources, Fori developed a viable process, engineered the system, manufactured the equipment and integrated the assembly line at the end user. The module assembly system has resulted in positive results for the customer and OEM.


For more information about Fori’s modular assembly systems, please visit our website.


Automotive Stamping System–Hot Stamping Line

Fori Mexico was involved in the relocation of an existing hot stamping line during production from Detroit, MI to Ramos, Mexico.


Timing for this project was critical, because it was going to take place during production.  The customer was required to build a bank of stampings for production while the equipment was being relocated.


The existing hot stamping line in Detroit was a singular process.  The customer requested that a new process in Mexico be a parallel process to improve the output of the system.  Fori was responsible for engineering the new process.  Fori developed the new system layout and completed all the robotic simulations with offline programming to verify the performance of the new parallel process system.  The customer requested that Fori use as much existing capital as possible to help control costs, therefore anything that was not available for reuse had to be built by Fori, including the controls of the new system.




Once the engineering was completed and signed off, Fori Mexico managed the installation, integration, and run off of the new parallel process.  Fori USA was responsible for project management, engineering, and quotation.

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


Rail Guided Vehicles (RGV) for Automotive Chassis Decking Line

Fori Korea recently supplied 14 chassis marriage Rail Guided Vehicles (RGVs) for an automotive manufacturer.


  • Capacity: 4,000 lbs./1,818 kg.
  • Safety: Safety bumpers
  • Controls: Rockwell Open Architecture
  • Keys to Success: Custom designed chassis, accurate and repeatable
  • Results: Increased flexibility, decreased infrastructure


Fori Korea was contracted to replace an existing Chassis Marriage system. The system consisted of 14 Chassis Marriage carts, two chain lifts, and associated tooling plates to accommodate the three different vehicles assembled within the process. The system was built to meet a production capacity of 60 jobs per hour.

The Chassis Marriage cart was unique due to the ability to move the wheel base for the front and rear pallet separately in order to accommodate the vehicle variations. Doing so allowed the Chassis Marriage system to meet the various engine decking points within the limited hanger pitch.


The chassis marriage RGV system consisted of a single traffic control panel for the 14 vehicles. The main control panel ensured proper vehicle pitch and synchronization through the chassis marriage process.


In order to ensure a smooth installation and buyoff at the customer facility, the entire chassis marriage was setup, debugged and bought off on Fori Korea’s floor.

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

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.


  • 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


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.


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.


  • 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.


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.


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.


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


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.


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.  



  • 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.


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.


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.


  • 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.


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.


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.


  • 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


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.