the ubisense assembly control solution for bmw many attempts to solve the problem using infra-red,...

The Ubisense Assembly Control The Ubisense Assembly Control Solution for BMWSolution for BMW

Terry PhebeyRTLS in Manufacturing Workshop

RFID Journal Europe Live!Darmstadt, 2nd November 2010

Terry PhebeyRTLS in Manufacturing Workshop

RFID Journal Europe Live!Darmstadt, 2nd November 2010

© by Ubisense 20092

The Ubisense Precise RTLS ProductThe Ubisense Precise RTLS ProductWorld leading precise Real-time Location System (RTLS)Ubisense delivers a precise real-time location system (RTLS) utilizing ultra-wideband (UWB) technology that locates assets and people precisely in 3D up to 30 cm spatial accuracy generating up to 10 positions per second

The Ubisense RTLS consists ofHardwareMiddlewareApplications

and is generating data, process visibility and control at new levels of granularity

Precise RTLS Requirements in Automotive Final AssemblyProduction line automation

• Tool control– Eliminate bar code scan of vehicle– Enable / disable wireless tool depending on location– Ensure tool operations related to correct location on vehicle– Associate control data to vehicle

• Event triggering– Trigger events when vehicles reach pre-defined points along

the assembly line using vehicle identification (e.g. tool enable / disable)

• Identification– Initiate PLC with vehicle production data

• Relate component to production unit– Eliminate bar code scan of vehicle

• Quality control of critical processes– Electronic signature for completed tasks

Finishing process• Process monitoring

– Find vehicles– Visibility of vehicle status– Alert if vehicle out of sequence– Recording and reporting

• Identification– Initiate PLC with vehicle production data

BMW Plant 6 in RegensburgBMW Plant 6 in Regensburg>1,000 vehicles produced per day in two shifts running from 5:00 to 24:00 5-6 days per week1 series, variants of the 3 series (e.g. M3, Coupé) and the Z4 roadster are produced on the same 1.8 Km long assembly lineVehicles are manufactured in the sequence in which orders are processed by the ERP system• On the assembly line a 1 series may be

followed by a Z4 and then by an M3 requiring the DC tools used along the line to be reprogrammed for each vehicle at each station

BMW uses the International Production System (IPS) as the Manufacturing Execution System in all plants. The module IPS-Q, developed by IBS AG of Höhr-Grenzhausen in Germany, handles quality control and in particular tool control


Copyright © 2010 Ubisense5

BMW objectives for Plant 6 in RegensburgBMW objectives for Plant 6 in RegensburgIncrease efficiency of assembly process by eliminating unproductive seconds taken to scan the Vehicle Identification Number barcode for every tool interaction

• In Regensburg per day 1000 cars * 150 tools * 6 Seconds

Simplify process by reducing the need to use barcode scanners

• Less chance of error

Permanently track vehicles in the production process

• Use car position to trigger PLCs at tacts along the line• Use same tag on the vehicle to trigger PLCs off line

One infrastructure, multiple applications in the plant• Reduce IT cost by reducing number of different

location / identification systems supported in the plant

HistoryHistoryMany attempts to solve the problem using Infra-red, ultra-sound, passive and active RFID technologyTrial with Ubisense UWB system in 2006 led to purchase in 2007 for the Regensburg plantSystem went live in Q4 2008 covering entire production line with 150,000 tool operations per day being controlledSeveral reconfigurations as assembly line has evolved to meet new requirementsNew applications to drive PLCs on and off line introducedUbisense system introduced into the Spartanburg plant on the new line to manufacture the new X3 in summer of 2010



Rx

Tx

reflectedsignal

directsignal path

signal strength

time

3~5m error 200ps = 6cm resolution

time

signal strength

reflectedsignal

-41.3dBm/Mhz

With UWB the direct path signal can be distinguished from the reflections, making

accurate pulse timing easier

With conventional RF, reflections in in-building environments distort the direct path signal, making

accurate pulse timing difficult

Why Ubisense Precise Location Tracking is based on UWBWhy Ubisense Precise Location Tracking is based on UWB

Locating precisely in real-time especially insidebuildings is a difficult problem

• Determining location with radio is done by measuring the path from transmitter to receiver

• Only the direct path signal determines the true location, reflections are errors


Conventional RF

Ubisense Precise Location Tracking principles (1)Ubisense Precise Location Tracking principles (1)

Sensors within the cellular Ubisense network communicate with the Tags on conventionalradio and ask to generate a UWB pulse depending on their profile up to 20 times a second

New radio technology ultra wideband (UWB) delivers up to 30 cm accuracy of location in 3D even in challenging environments

MasterSensor

SensorTiming Synchronization via Cable

Tag

α1

α2

t1t2

UWB Pulse

UWB signals are received at the sensors and are used to calculate the Angle of Arrival (AOA). So only 2 Sensors receiving a tag signal deliver a location.

Software of the third generation enables tuning and configuration of the system to increase stability and reliability using e.g. motion model filters

If Sensors are synchronized, then Time Difference of Arrival (TDOA) between each pair of Sensors is calculated. This makes the location robust.

Sensors installed along line in zigSensors installed along line in zig--zag pattern zag pattern –– e.g. line 44e.g. line 44


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Tagging production objectsTagging production objects


Industry tags fixed to products (e.g. car bonnet)• Custom mounting brackets (magnetic, adhesive, …)• Define tact / station for tag-product association and

dis-association• Tag remains on product if off-line monitoring /

control required

Fix tags on devices• Compact tag attached to cable

• Tag module embedded in tool vendor accessory

Radio interference investigationRadio interference investigation

Ubisense system fits inside any radio strategy• UWB transmissions at 6.4 – 7.6 GHz• 2.4 GHz control telemetry narrow band (600 kHz) at any convenient slot


Ubisense Channels [MHz]WLAN Channels [MHz]

BMW 2.4 GHz

Usage

12412

52432

92452

132472

22417

42427

82447

102457

32422

72442

62437

112462

122467

142484

12402.5

22422.0

32442.0

42462.0

52476.0

62477.5 7

2479.0

82480.5

f/MHz2400 2483.5

Eliminate bar code scan to identify vehicleEliminate bar code scan to identify vehicle470 sensors installed along the 1,800m line

Tags placed on vehicles to track their position as they move along the line. Tags removed at end of line

• Associate tag ID with Vehicle Identification Number (VIN)• Define expected movement of vehicles in each segment

Tags fixed to 165 DC tools to generate events when they approach vehicle for fastening operation

• Tag ID associated with tool ID / controller

Define product type and spaces (spatial zones defining where tools may operate on product)

Send IP telegramme to IPS-Q with VIN / tool ID when tool enters product space


On and off line identificationOn and off line identificationMultiple sensors can cover an area with several stations to be activated when the vehicl arrives at the correct location

Alternatively a single sensor can control one discrete station and recognise when the tagged vehicle arrives and use the associated VIN to initiate a production step


car data

PLC

Industry tag

Sensor

zones

© Ubisense www.ubisense.net

14

Advantages of the Ubisense technology at BMWAdvantages of the Ubisense technology at BMW

The detection of the co-incidence of tool and vehicle is not dependent upon a single radio transmission between the vehicle and the tool which can easily be disturbed (as is the case with passive or active RFID)The continuous location of tools and vehicles is accomplished with high precision (30cm)High reliability and robustness of the location measurement due to the fact that only two sensors need to detect the signal from the tag in order to generate a 3D locationThe usage of the system may easily be expanded to other aplications using the same infrastructure by simply defining new spatial relationships and eventsThe location system is based on a fully distributed architecture (each sensor is a processor in its own right) and therefore scales easily with increased usage

Summary of Assembly Control System FunctionalitySummary of Assembly Control System FunctionalityFlexible product identification / tracking along assembly line, sending product ID when product reaches any defined location along the lineControl tethered tools, ensuring that they are enabled and programmed for specific productControl wireless tools, ensuring that they are being used in correct location and on correct productAutomatic association of data captured with scanners and PDAs to specific productAutomatic association of button press with task / operator / product

Track vehicles delivering materials to line to ensure quality and timeliness

Actuate other control systems on and off line when product in correct position

Proven extremely high reliability > 99.9998% of events without defect


Benefits of introducing the Ubisense Assembly Control System

Eliminate time used to scan vehicle ID to enable / program toolsEliminate time used to scan vehicle ID to relate to scanned componentsEliminate paper based sign-off to record successful task fulfillment (e.g. installation of safety-critical component)

Improve quality by restricting use of tools to permitted areas of vehicleEnable quality by restricting use of wireless tools to permitted areas

Reduce IT and maintenance costs by replacing legacy active and passive identification systems with one flexible infrastructureImprove flexibility of line design by liberating tools from tacts / stations

Virtual Car TrackingVirtual Car TrackingBMW SpartanburgBMW Spartanburg

Russ ChandlerRuss ChandlerCEO Americas, UbisenseCEO Americas, Ubisense

BMW Spartanburg: Quick FactsBMW Spartanburg: Quick Facts

X5’s and X6’s currently built in Hall 50New hall 52, a second plant built in Spartanburg in 2009180+ sensors covering 14 bandsTotals 2010:

* Total X3 Units: 2,086* Total X5 Units: 8,281* Total X6 Units: 3,820

Current production in Hall 52: about 200 cars planning to produce 250/day.


*

Ubisense Implementation of Virtual Car TrackingUbisense Implementation of Virtual Car Tracking

BMW LIS “ACS Lite” – tracking vehicles as they enter each takt (station).Vehicles are tracked but not the tools.Integrated with IBS Tool Controller and sends VIN location events to IBS.Tool torque instructions are automatically adjusted to the specifications of each car based on VIN number. Integrated with about 50 tools currently.


Production Management SystemProduction Management System

DC Tooling

Virtual Car Tracking

Virtual Car Tracking

IBS Tool ControllerIBS Tool Controller

Ubisense Implementation of Virtual Car TrackingUbisense Implementation of Virtual Car Tracking

Virtual Car tracking enables additional features to be incorporated to the line, such as a camera station, which takes pictures as the car in near the end of the assembly line.LIS system also planned for logistics trains, in order to gain a better understanding of time it takes to cover routes.


Key BenefitsKey Benefits

Ubisense solution able to identify vehicle in time to activate tools with correct torque settings.

Plant is enabled to support full Assembly Control System functionality = complete LIS tool assistance similar to Regensburg.


the ubisense assembly control solution for bmw many attempts to solve the problem using infra-red,...

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