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.

Aerospace Assembly–Automated Guided Vehicles (AGVs) for Wing Assembly

Fori provided six high capacity Aerospace AGVs for the automated transport of tooling for stringer assembly, supporting the wing assembly.

Features:

  • Guidance Technology: Magnetic bar, inertial with pencil magnets, natural feature, laser contour
  • Capacity: 40,000 lbs./54,545 kg.
  • Safety: Safety scanners and bumpers, Siemens safety PLC, system interlocks
  • Controls: Siemens open architecture, vehicle management system
  • Results: Improved flexibility, decreased crane usage
  • Solutions: Vehicle synchronization, auto-leveling, vehicle management system

The six high capacity AGVs, capable of auto-leveling and synchronized transport of tooling up to 40,000 pounds have been designed to accommodate projected wing production. The AGV system is required to be synchronized during the lift of the tooling and product, as well as synchronization of the three AGVs during transport. The system includes an auto-leveling feature that dynamically levels the tooling during travel to ensure a level plane is maintained during transport between stations. The Fori AGVs will be the primary method of transporting the tooling and product through the assembly process.  Traditional assembly systems rely heavily on overhead crane utilization, whereas the AGV based solution eliminates the reliance on cranes.

Boeing - CWC - Stringer AGV - 4

The AGVs were developed to support the customer’s lean automated manufacturing methodology. The goal of the project was to automate the entire material handling process for the assembly of the stringers (specifically the load and unload of the autoclaves used for curing the composite wing stringers). The loading of the autoclave is completed utilizing a natural feature guidance system. Then the AGV uses the walls of the loaded autoclave for the guidance in and out, while still maintaining +/- 5mm accuracy.

The design intent was to build a vehicle that was modular and interchangeable. The AGV system is required to transport many tools of different lengths and weights. The AGV system needs to be able to accommodate synchronization of up to three AGVs during the lift and transport from assembly stations.

Boeing - CWC - Stringer AGV - 1

Each of the AGVs is outfitted with two servo based lifters and a laser alignment system which provides measurement feedback to the onboard PLC for the dynamic leveling of the tooling during transport. The system must maintain levelness within +/- 1/8” from each end of the tool.

A Fori Vehicle Management System (VMS) has been provided to monitor system I/O, communication between the AGVs, tooling and automated assembly stations. Scheduling of moves also occurs at the Fori VMS.

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

 

Automotive Assembly–Automated Guided Vehicles (AGVs) for Chassis Marriage

Fori recently designed and built a chassis marriage AGV utilizing induction power and magnetic guidance. 

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Features:

  • Guidance Technology: Magnetic bar
  • Capacity: 6,000 lbs./2,727 kg.
  • Safety: Safety scanners, safety bumpers, Rockwell safety PLC
  • Controls: Rockwell open architecture, vehicle management system (VMS)
  • Keys to Success: Vehicle synchronization, custom designed chassis, high capacity lifts
  • Results: Improved flexibility, decreased infrastructure, elimination of batteries and chargers

Chassis marriage has traditionally been completed with a Rail Guided Vehicle (RGV) and in floor track. The system has been a longstanding robust and reliable solution; however some customers require additional flexibility to support their process.

The chassis marriage AGV looks to improve on the RGV technique by utilizing induction power. Using induction provides a limitless power source and magnetic guidance which is a proven guidance technique for AGVs providing a high level of reliability and accuracy.

One of the main design considerations for the chassis marriage AGV development was flexibility and infrastructure reduction. Utilization of an in floor induction wire and magnetic bar will decrease the cost and time associated with the installation of Chassis Marriage systems. The ease of layout changes supports the added flexibility requested by the end users of these systems.

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In floor induction wire.

A Vehicle Management System (VMS) is supplied with the vehicles to manage communication with the overhead conveyor, synchronization of vehicles and system diagnostics required by the end user. This inductive chassis marriage AGV can be designed to use the proven and reliable patented Fori electric chain lift or other suitable lift devices.

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For more information about Fori’s AGVs or Chassis Marriage systems, please visit our website.

 

Tuggers – Automated Guided Vehicles (AGVs) for Product Delivery

Fori has further improved on its standard Tugger AGV design by doubling the overall towing capacity.

Features:

  • Guidance Technology: Inertial with pencil magnets, bi-directional, capable of 0 degree turn
  • Capacity: 35,000 lbs./15,909 kg.
  • Safety: Scanners and bumpers
  • Controls: Siemens Open Architecture
  • Keys to Success: Highly accurate and repeatable
  • Results: Increased production rate, reduced personnel injuries, decreased infrastructure

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Fori was enlisted to supply a derivative of the standard Tugger AGV product line that is capable of nearly double the capacity of the original design. The driver of this increase was the goal of being able to transport three carts carrying axle assemblies for a large automotive OEM.

Due to the capacity, more product was transferred during each move which further increased the return on investment while decreasing the total number of required vehicles. The Tugger AGVs were commissioned to replace non-value added material handling tasks within the assembly process. The most important process consideration was safety and reliable delivery of product.

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Integration of a Fori Vehicle Management System (VMS) introduced further improvements to safety and reliability. Vehicle scheduling of moves, tracking and traffic control is coordinated through the Fori VMS. The Fori Tugger is a proven and robust product that can be applied to a variety of material handling applications.

For more information about Fori’s Tuggers and other material handling systems, please visit our website.

 

Automated Guided Vehicle for Automotive Chassis Decking Line

Fori recently provided a precision battery powered automotive Chassis Marriage AGV for an electric car manufacturer.

Features:

  • Guidance Technology: Magnetic tape or bar
  • Capacity: 4,000 lbs./1,818 kg.
  • Safety: Scanners, bumpers, system interlocks
  • Controls: Allen Bradley Open Architecture
  • Keys to Success: Custom designed chassis, accurate and repeatable
  • Results: Increased flexibility, decreased infrastructure

Fori has traditionally supplied Rail Guided Vehicles (RGVs) for automotive Chassis Marriage, but over the past five years Fori has leveraged its AGV experience to transfer existing automated vehicle technologies to its Chassis Marriage systems. The automated vehicle technology provides a Chassis Marriage system that decreases the required plant infrastructure. Whereas the traditional RGV based system requires an in floor track and power transfer system. The AGV system removes this requirement by utilizing an on board, battery based power supply and magnetic tape or bar guidance for vehicle tracking and positioning. Overall these improvements decrease facility work and associated cost, and allow for decreased installation times and provide long term flexibility for changing production needs.

The battery powered Chassis Marriage AGV includes dual independent Fori patented chain lifts capable of lifting and transporting 4,000 pounds in order to install the front and rear suspension and drive train modules to the vehicle Chassis. The battery based Chassis Marriage AGV was developed to support the end users lean automated manufacturing methodology, decreasing the total in plant infrastructure required for the system. Not only will the AGV enable the end user to reduce their plant hardware investment, there will be significant long term flexibility in the assembly process. The guidance system of the AGV and reduced plant infrastructure allow the AGV to easily interact with other systems and processes.

The AGV is outfitted with multiple safety measures that ensure collision avoidance. Safety scanners are included on the front and rear of the vehicle that will slow down and stop the vehicle as objects enter the scanning field. The Chassis Marriage AGV also includes indicator lights in each corner, (4) e-stops, safety pressure bumpers on the perimeter of the AGV and an on board HMI for vehicle status and diagnostics.

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Automated Guided Vehicle (AGV) for Chassis Marriage utilizing Magnetic Tape Guidance

The Chassis Marriage AGV is responsible for accurate and repeatable location of product in station for a reliable chassis marriage process. The AGV will provide increased flexibility, safety and decreased product damage, thus increasing profitability within the project for the end user.

For more information on Fori’s Chassis Marriage AGVs, please visit our website.

 

Automated Guided Vehicles (AGVs) – Tunnel AGVs for Pallet Transfer

Fori recently designed and built a Tunnel AGV to support its global customers. The Tunnel AGVs are utilized for transporting product and dunnage throughout the production process.

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The Tunnel AGV pictures includes a Roller Conveyor companion cart for Pallet Transfer.

Features:

  • Guidance Technology: Magnetic bar, inertial with pencil magnets
  • Capacity: Up to 10,000 lbs./4,545 kg. (can be increased upon request)
  • Safety: Safety scanners and bumpers, Siemens safety PLC, system interlocks
  • Controls: Siemens open architecture, vehicle management system
  • Keys to Success: Custom designed chassis, highly accurate and repeatable
  • Results: Improved flexibility

The Fori Tunnel AGVs are capable of automated docking and transport of companion carts carrying up to 10,000 pounds. The design intent was to build a vehicle that was modular and interchangeable. In order to increase process flexibility the Tunnel AGVs are capable of docking to various companion carts, each serving a unique purpose.

Applications include pallet transfer via roller conveyors, lift tables and powered trunnions. Automated docking to the companion carts is completed with two docking or hitch pins. The docking pins ensure proper alignment to the companion cart for repeatable pick and drop.

The Tunnel AGV was designed to provide a high capacity material handling solution in the smallest footprint possible. The vehicle is comprised of two fixed drive wheels allowing for bi-directional travel and zero turn capability.

Fori - Tunnel AGV 3

A Fori Vehicle Management System (VMS) is utilized for scheduling of vehicles and traffic management of the system. The vehicle controls are based on an open architecture utilizing a Siemens safety PLC, eliminating the black box technology that is commonly used across the industry. The Tunnel AGV has proven to be a cost effective and reliable material handling system for a variety of applications.

For more information on Fori’s automated material handling products, please visit our website.

 

Automated Guided Vehicles (AGVs) for Horizontal Wing Assembly

Fori recently provided six high capacity Aerospace Tugger AGVs for the automated transport of tooling, supporting the horizontal build line for wing assembly. 

Features:

  • Guidance Technology: Magnetic bar, inertial with pencil magnets, natural feature and laser contour
  • Capacity: 120,000 lbs./54,545 kg.
  • Safety: Safety scanners and bumpers, Siemens safety PLC, system interlocks
  • Controls: Siemens open architecture, vehicle management system (VMS)
  • Keys to Success: Vehicle synchronization, custom designed chassis, highly accurate and repeatable.
  • Results: Improved flexibility, decreased crane usage

The six high capacity Tugger AGVs (capable of automated docking and transport of tooling up to 120,000 pounds) have been designed to accommodate projected production. The AGVs will be the primary method of transporting the tooling and product through the assembly process.

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The AGVs were developed to support a lean automated manufacturing methodology. The design intent was to build a vehicle that was modular and interchangeable. The AGV system is required to transport nine different tools, all with different weights and footprints. Due to tools exceeding lengths of 100 feet, the AGVs are required to dock at each end of the tool and move in tandem.

The automated docking utilizes a natural feature and camera based guidance system, which accommodates unexpected movement of the tooling. The system measures the surface of the tooling to generate angular offsets and utilizes a SICK camera and reflector based system for final location. Once positioned, servo driven couplers automatically pin spring loaded receivers mounted to the tooling. The tooling is also outfitted with safety scanners powered and controlled by the AGV.

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Responsibilities of the AGVs include: automated docking, tooling identification and transport throughout the facility. A Fori Vehicle Management System (VMS) has been provided to monitor system I/O, communication between the AGVs, tooling, and automated assembly stations. Scheduling of moves also occurs between the vehicle Siemens Mobile Panel and the Fori VMS.

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

 

Automated Guided Vehicles (AGVs) for Aluminum Ingot & Coil Handling

Fori recently supplied three high capacity AGVs for the automated transport of aluminum ingots for aluminum coil production. 

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Features:

  • Guidance Technology: Magnetic bar, inertial with pencil magnets
  • Capacity: 250,000 lbs./113,636 kg.
  • Safety: Safety scanners and bumpers, Siemens safety PLC, system interlocks
  • Controls: Siemens open architecture, vehicle management system
  • Keys to Success: Custom designed chassis, highly accurate and repeatable
  • Results: Improved flexibility, decreased crane usage

The (3) high capacity automated guided vehicles (AGVs) were supplied to replace a legacy system that was over 20 years old. The Fori AGVs will be the primary method of transporting the aluminum ingots through the finishing process. Traditional handling systems rely heavily on overhead crane utilization, but the AGV based solution reduces reliance on cranes.

The AGVs were designed to fit within the existing plant and process. One of the biggest challenges on the project was packaging eight drive wheels and (2) 100 ton capacity lifts within the existing vehicle footprint. Each drive wheel was outfitted with a suspension system to ensure proper radial loading and equal load distribution between the (8) drive wheels. Another improvement on the Fori system was ball screw based lift jacks that included integrated load cells for measuring fore/aft and side to side loading of the ingot. If the ingot is loaded outside of an acceptable range, the AGV stops immediately and sets down the ingot.

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The Fori AGV utilizes a 72VDC sealed lead acid battery as a power supply.  The vehicles utilize PMAC motors that provide improved control and efficiency over the previous system which utilized DC brushed motors. Each vehicle had a safety bumper front and rear, as well as six safety scanners around the perimeter of the vehicle to provide added safety coverage.

A Fori Vehicle Management System has been provided to monitor system I/O, manage communication between the AGVs and scheduling of moves for production.

For more information about Fori Automation’s high capacity AGV capabilities, please visit our website.

 

 

Automated Guided Vehicles for Robotic Drill & Fill System

Fori recently provided two high capacity Aerospace AGVs for the automated transport of a mobile robotic drill and fill system.

Mobile Robot for Automated Drill & Fill
Image Source

Features:

  • Guidance Technology: Magnetic bar, natural feature/laser contour
  • Capacity: 40,000 lbs./18,181 kg.
  • Safety: Safety scanners and bumpers, Siemens safety PLC, system interlocks
  • Controls: Siemens open architecture
  • Keys to Success: Custom designed chassis, highly accurate and repeatable
  • Results: Improved flexibility

The two high capacity AGVs (transporting mobile robotic platforms with weights up to 40,000 pounds) have been designed to accommodate projected production. The Fori AGVs will be the primary method of transporting the mobile robots between each of the necessary drilling stations.

The AGVs were developed to increase system automation, flexibility, and remove the traditional monuments that are generally required for automated drilling applications. The design intent was to build a vehicle that was modular and interchangeable. The AGVs were designed to accommodate multiple mobile robots, the software is modular, and simplifies the communication between the Fori AGV and mobile robot.

EI - Midbody AGV (15604) - 1

The Fori AGV is required to locate within +/- 5mm to an existing fuselage transporter. The Fori system utilizes a natural feature and camera based guidance system, which accommodates unexpected location of the transporter. The Fori system overcomes the variability of the fuselage transporters accuracy by measuring the surface of the transporter to generate angular offsets and utilizes a SICK camera and reflector based system for final location. Once positioned, the mobile robot automatically docks to the transporter for power, communication, and pneumatics.

Automated movement is handled through the tethered Siemens Mobil Panel. The operators are able to select drill positions on either the Fori HMI or robot HMI. Once selected the Fori AGV is responsible for safely and accurately lifting and transporting the two mobile robots between 16 different drill positions.

For more information about our drilling platform AGVs, please visit our website.

 

Automated Guided Vehicles (AGVs) for Composite Wing Assembly

 Fori recently provided seven high capacity Aerospace AGVs for the automated transport of tooling for spar assembly, supporting the production of composite wing assemblies. 

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Features:

  • Guidance Technology: Magnetic bar, inertial with pencil magnets, natural feature/laser contour
  • Capacity: 120,000 lbs./54,545 kg.
  • Safety: Safety scanners and bumpers, Siemens safety PLC, system interlocks
  • Controls: Siemens open architecture, vehicle management system
  • Keys to Success: Vehicle synchronization, custom designed chassis, and highly accurate and repeatable.
  • ResultsImproved flexibility and decreased crane usage

The seven high capacity AGVs, capable of auto-leveling and synchronized transport of tooling up to 120,000 pounds have been designed to accommodate projected wing production. The Fori AGVs will be the primary method of transporting the tooling and product through the assembly process.  Traditional assembly systems rely heavily on overhead crane utilization, the AGV based solution eliminates the reliance on cranes.

The AGVs were developed to support a lean, automated manufacturing methodology. The goal of the project was to automate the entire material handling process for the assembly of the spars. Notably, the load and unload of the autoclaves used for curing the composite wing spars. The loading of the autoclave is completed utilizing a natural feature guidance system, the AGV uses the walls of the autoclave for the guidance in and out, while still maintaining +/- five mm accuracy.

The design intent was to build a vehicle that was modular and interchangeable. The AGV system is required to transport many tools of different lengths and weights. The AGV system needs to be able to accommodate synchronization of up to three AGVs during the lift and transport from assembly stations.

Each of the AGVs is outfitted with four servo based lifters and a laser alignment system which provides measurement feedback to the on-board PLC for the dynamic leveling of the tooling during transport. The system must maintain levelness within +/- 1/8” from each end of the tool.

A Fori Vehicle Management System has been provided to monitor system I/O, communication between the AGVs, tooling and automated assembly stations. Scheduling of moves also occurs at the Fori VMS.

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