volume 4, number 1 ori fori automation global ... v4 email.pdf · n fori automation global...

Volume 4, Number 1

Fori Automation Global LocationsFori Automation Global LocationsFori Automation Global LocationsFori Automation Global Locations

NE WSNE WSFori Automation Newsletter

New Products - New Web Site

Visit Fori’s website to see its expanded product offering www.foriauto.com

In This Issue

ORI INC.

Global Design & Builder of Assembly, Welding &Testing Equipment

Who We Are:

Sales, Engineering (Mechanical / Controls /Software), Manufacturing, Assembly, Full SystemIntegrator & Installation & Service on 5 Continents

Our Capabilities:

Locations in The USA, Mexico, Brazil, Germany,India, China & Korea

Global Company

ISO 9001:2000 ISO 14001:2004 Certified 50955 Wing Drive, Shelby Township, Michigan 48315 Phone: 586-247-2336 Option 4 Fax: 586-566-6773 www.foriauto.com

www.foriauto.com When Innovation & Performance CountWhen Innovation & Performance Count ISO 9001:2000 ISO 14001:2004 CertifiedISO 9001:2000 ISO 14001:2004 Certified

New Products & New Website

3-D Wheel Aligner

Global Corroboration at VW IndiaFori Mexico

Fori Brazil

Fori Korea

Fori Technical News

Contact

Aerospace Systems

Panoramic Glass Roof Assembly

Manifold Press AssemblyTrailing Arm Weld System

Pedal CheckerModule Assembly & Alignment

Module Alignment Specifications

Load Apply Wheel Aligner

TKT Frame Welding SystemWindshield Installation

QMC Underbody Welding & Seal

Wheel Aligner UpgradesRear View Camera Calibration

Front Axle Assembly SystemChassis Marriage System

Fiat

Fori Germany

Fori China

Featured ProductFori Company Info

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Aerospace Automated Guided Vehicle SystemsFori Automation has developed an Automated Guided Vehicle (AGV) for the aerospace industry that automatically drives and tracks apredetermined magnetic path. Two induction sensors on the bottom of the vehicle read the AGV's position cross vehicle relative to themagnetic path. Induction sensors send continuous feedback to the CPU to correct the path using the dual servo drive/steer mechanism.Each drive/steer motor contains its own internal encoder which retains its position in the PCs memory during power off. The drive/steerspeed, acceleration, and deceleration rates are customer programmable. The vehicles can be driven automatically or manually with awireless joystick in a forward, reverse, or side to side direction (crab walking). The system is powered between work zones and duringmanual joystick manipulation by batteries equaling a high efficiency, 300VDC system. The ForiAGV system isreadily adaptable to many different power sources including induction and lithium based emerging batterytechnology. The batteries are recharged at each stop or work station and vehicle has an intelligentbattery charger to optimize battery life. Each vehicle also has its' own control CPU and HMIscreen that generates fault messages, allows for manual mode interface, and allows forindividual vehicle system programming control.All vehicles can be monitored for theirexact positioning and control status by a single traffic control PLC. The traffic controlPLC has an HMI which will allow commands to be sent to each vehicle via wirelessRF signals. The HMI screen will display the location of each vehicle, the status ofeach vehicle (such as any current fault status, and battery levels). Fori Automationwill configure and design yourAGV based on your specific application. Fori Aerospace

Automated Guided Vehicle

ORI AUTOMATION do BRASILLTDA


ORI KOREA LTDORI GERMANY

ORI INC. ORI SOUTH AFRICAORI CHINA ORI INDIA

ORI AUTOMATION de MÉXICO

Windshield & Back Lite InstallationFori Automation USA has completed theinstallation of a glass installation systemfor Chrysler St. Louis Missouri. Thisrobotic system installs the windshield andrear back light glass with an invertedurethane dispense system controlled by bythe robots 7th axis. The end effectors werecustom designed for the Dodge Ram truckglass style. The dual cell system isdesigned so each cell backs up the other.The system is capable of 60 jph with ayearly capacity of 250,000 cycles.

Robot moves the glass under the urethane tipthen transfers second to robot for installation

Fori Automation USA is currently finishing the first of fourMIG weld and machining lines to be installed in the UK.ThyssenKrupp Tallent of Newton Aycliffe, England awardedFori Automation USA the project in July of 2008 after threemonths of intense process reviews. The product is the frontcradle for the Ford Focus / Escape, the process is capable ofproducing four variants for a total of 1,000,000 cradles peryear off four lines. The Fori Automation proposal included agreat deal of unique features to separate themselves from thecompetition as well as leveraging a global presence involvingthe utilizing of Fori Mexico for manufacturing. To name a fewfeatures are enclosures designed for reduced draftrequirements, diamond plated flooring for ease ofmaintenance, simple / effective tooling designs, distinctivelayout in regards to safety guarding and material flow, and adistinguishing part presence laser / vision system. Furtherdevelopment includes a message / Quality Alert system to beintegrated into the operator HMI allowing TKT engineeringto provide production the most up-to-date informationquickly and easily, even from their office computers. Mostnotably the laser / vision system will improve overallequipment efficiency (OEE) by at least five percent byeliminating fixed part present switches on the MIG weldingfixtures. Finally, the system includes a Fori designed state ofthe art machining system capable of piercing and holdingwhile machining vertically and horizontally to produce themost dimensionally accurate machined cradle created to date.

TKT MIG Weld System ORI INC.

TKT Weld System




ORI AUTOMATION de MÉXICOORI AUTOMATION do BRASILLTDA

QMC Underbody Weld SystemFori Automation USA delivered its first low volume underbodyproduction system in the 3rd Quarter of 2008. Quality Metal Craft ofLivonia, Michigan awarded Fori Automation USA the project in Januaryof 2008. The product is the rear underbody for the General Motors,Cadillac convertible CTS. The process is capable of producing 5,000underbodies per year. The Fori Automation proposal, while initiallyconsidered aggressive, has proven to be one of the most flexible systemsproduced. One of the most notable features is the fact that there is onlyone spot weld gun design for all four welding robots. The systemincludes: welding the structural spider and all of its sub assemblies, theunderbody pan and its sub assemblies, adhesive and sealer apply as wellas well as strategic CMT MIG welding as proposed by Fori.

Under Body Weld & Seal Apply System

Fori Automation do Brasil installed the first 3-D wheel alignment /headlamp aiming system for Fiat in Cordoba Argentina. This system isthe first of its kind in South America. The 3D measurement is a brandnew process developed by Fori Automation, using laser measurementmodules. Software and system interface improvements resulted in amore precise static / dynamic measurement with better resolution aswell as making the system more reliable. Other features include an aircylinder pull down system for brake valve adjustment, ABScommunication, digital headlamp camera and servo motors forpositioning of the wheel base and headlamp vertical / horizontalmovements. This new 3-D wheel alignment machine is a fast flexibleand highly accurate system running 40 JPH which will cover allproduction needs and any new projects planed for the next few years.

3-D Wheel Alignment System for Fiat

Fiat 3-D Wheel Alignment

Panoramic Glass Roof AssemblyFori Automation USA is in the final completion stages of a roofmodule assembly system for Webasto Roof Systems based inRochester Hills, Michigan. Fori was chosen because itdeveloped a process of holding stringent tolerances for Webastowhich met Honda's requirements. The system assembles thepanoramic roof system, (when the sunroof is closed the entireroof will be deeply tinted glass). The process involvesassembling all components of the housing which supports thebody structure after installation, robotic urethane apply andplacing the glass into position. An electronically controlled sunshade allows the front and rear roof system to block out sunshine when desired. This system also included a sound booth fortesting. The system is capable of producing 50,000 roofs peryear.

Glass Roof Assembly System

ORI INC.





Fori Automation GmbH based in Germany,recently completed an upgrade and retrofit oftwo wheel alignment systems for Opel Eisenachin Germany. The updates included new digitalmeasuring heads, Siemens PLC upgrade,adjustment system and new servo centering.

Wheel Aligner Upgrades ORI GERMANY GmbH

Fori Automation GmbH based in Germany,recently completed an upgrade and retrofit of awheel alignment systems for VolkswagenEmden. The upgrades include new digitalmeasuring heads, a Siemens PLC update and rearview camera calibration for the VW Passat.

Flip Down Calibration Unit

Wheel Aligner with Rear View Camera Calibration

Flip Up Calibration Unit

Wheel Alignment Upgrades for Opel Eisenach

Fori Automation used companies on fivecontinents to provide sales throughinstallation of 3-D wheel alignmentsystems and in-floor headlamp aimingsystems. In order for Fori to provide themost cost effective and highest qualitysystem five (5) Fori companies wereinvolved: Fori USA, Fori Mexico, ForiGermany, Fori China & Fori India. Fori’sglobal sales team developed the quote andonce accepted the global design teambegan the project. By utilizing it’s globalnetwork, the Fori companies were able toleverage the talents of their individualcompanies to design, build and install themost advanced wheel alignment /

headlamp aiming system in the world. With design and manufacturing on 4 continents the cost was reduced without affectingproduct integrity. The installation was coordinated by Fori India with support from Fori USA& Fori Germany.

Worldwide Design & Corroboration for Systems in VW India

In-Floor Digital Headlamp Aimer & 3-D Wheel Alignment





Fori México with a joint effort with Fori USA recently installed a coolingmanifold assembly system for BEHR America. With vehicle volumesdeclining, BEHR decided to utilize existing manifold assembly capitalequipment and only invest in new tooling. The engine cooling manifoldattaches to the side of the Radiator/Condenser. The manifold attaches allthe hoses from the condenser to the engine of the vehicle. The systemvolumes are 210,000 for the Chrysler WD, Jeep Cherokee , 170,000 for theFord P473, Ford F250. This system has been installed and BEHRmanagement is very pleased with the integrity of the tools as well as theproject execution.

Cooling Manifold Press ORI AUTOMATION de MÉXICO

Cooling Manifold Assembly Press

Fori Automation de México participated with Fori Automation USA in therelocation of the Mazda J-56 front suspension trailing arm weld line fromthe Martinrea in Hopkinsville, Kentucky to the Martinrea plant inHermosillo, Mexico. The project consisted of the teardown, ship,reinstallation, up-speed, and startup/debug of (6) robotic weld cells and oneHydraulic pierce station. The upgrade of the equipment includedintegrating additional new tooling and robots to reduce the cycle time bynearly 50%. The entire project, from design to final buyoff on the receivingplants floor, was completed in two months. In order to ensure an on-timedelivery, Fori Mexico & Fori USA, established a project team on both sidesof their respective borders. Local contractors in each country were utilizedunder the close supervision of Fori personnel. To ensure a smooth transferof the equipment both entities were involved in the disassembly and thereassembly. The new tooling was designed using Fori USA's engineeringdepartment and all the manufacturing and assembly took place at the ForiMexico plant in Saltillo, Mexico. Try-out and run-off was performed byFori Mexico personnel.

Trailing Arm Weld Line

Trailing Arm Welding Line

Pedal Checking SystemForiAutomation do Brasil designed and built a pneumatic pedal checker for the Iveco plant in Brazil. This system is unique inthe fact that it has to operate in a small area as well as be diverse enough to accommodate 14 different vehicle models at 30jph. The operating system is Windows XPwith a user friendly easy to use interface.


Pedal Checking System Pedal Checking Bracket


Systems

Dual Roll & Brake System




Module Assembly & AlignmentF o r iA u t o m a t i o nUSA helped tod e v e l o p at u r n k e ys o l u t i o n t obuild and alignthe Epsilon IIR e a rS u s p e n s i o nM o d u l e f o rWoodbridge.This processused the ForiO v e r / U n d e rTwin StrandC o n v e y o rSystem. TheEpsilon II module presented Forisome challenges due to thecomplexity of the 4-Link and H-Armrear suspension. The task was tomake a pallet that would handle thevarious differences for each moduleand still allow access for the joints tobe torqued.

Robot Load / Unload Rear Module Aligner

Twin Strand Conveyor & Assembly Build Pallets

Module Being Aligned

Fori also developed a turnkey solution tobuild and align the suspension modulefor Martinrea. The module lines were developed to assemble and align the Camaro -Zeta Modules, including the front vertical, the front horizontal & the rear suspensionmodules. Other operations on this line includes, leak test of brake hoses & continuitytest of wheel speed sensors. The rear module build process assembled all thecomponents to the cradle. A unique deign feature on the pallet is the three positionwheel for handling the different curb height positions.

ORI INC.


Manufacturing: 17,000 sq. ft. / 1,580 sq. m




Module Alignment Specifications

Jounce load: 2,000 lbs / 910 kg or actual spring forceat jounce

60-80 second cycle time / vertical module cycle time &jounce + stroke of jounce pending sequence

Programmable servo driven jounce travel -Jounce speed =1 ft per second / 225mm per second

Measuring head servo drive slide maximum travel:41 in / 1041.1 mm

Main center slide maximum travel : 47 in / 1,193.8 mm

Machine dimensions:150 x 86 x 141 inches / 3,810 x 2,184 x 3,575 mm

Standardized structural design

In a typical sequence the module is loadedinto the machine and lowered onto the fixture.The main center slide lowers down to within5-10 mm above the body mount bushings.Locking cylinders in the lower fixture raise themodule up until the body mount bushingscontact the upper locators. The alignmentheads locate and secure the wheel cornersand move them up to vehicle curb / height.Locking cylinders in the strut / spring locatoradvance and position the strut / spring in theproper position. Camber and or toe toolingadvance and engage the bolts while thealignment heads begin jouncing. Themeasuring heads can move a total of 9.8 in /250 mm to simulate vehicle jounce. When thejouncing is complete the measuring headsrotate the corners and measure toe, camberand run out. The camber and toe tooling thenautomatically adjusts the module to withinspecification. The measuring heads andtorque tools then release and return to theirhome positions. When all units are home themodule is removed either by manual liftassist, conveyor or robot. Modules can enter the aligner from four (4) different directions.

Three (3) independent Vertical Slides

Machine height is adjustable by adding columns, whichwould allow a conveyor to pass through

Main servo driven center slide maximum travel :47 in / 1,193.8 mm for part load & unload access

System can be loaded by robot, floor level conveyor or table top conveyor in all four (4) directions

Independent Vertical Slide

4 Way Part Orientation

Fori Automation Dynamic Module Alignment System

ORI INC.

When Innovation & Performance CountWhen Innovation & Performance Count ISO 9001:2000 ISO 14001:2004 CertifiedISO 9001:2000 ISO 14001:2004 Certifiedwww.foriauto.com




Fori China recently completed the installation of a front axle assembly line and a chassis marriage line for the ShanghaiVolkswagen Nanjing Plant in China. By utilizing it’s global resources in Korea, China and the United States, the Foricompanies were able to complete the product launch in less than four months, which is the fastest launch in ShanghaiVolkswagen history. The system included new and refurbished equipment covering the following: twenty station front axleassembly line, six front decking carts, conveyor system, one rear decking cart with articulating arm, one secondary tighteningsystem for the rear module and one repair system for the rear module.

ORI CHINAFront Axle Assembly System

Fori USA designed the conveyor. Fori China built the conveyor, coordinated theproject management, refurbished 25 engine pallets, built the decking carts andinstalled all the equipment. Fori Korea managed the engineering services andmanufactured the rear module equipment.

Chassis Marriage SystemShanghai Volkswagen Front Axle Assembly Line

Shanghai Volkswagen Chassis Marriage CartShanghai Volkswagen Chassis Marriage System





Fori Korea has completed the installation of a non-contact wheel aligner for Nissan in Avila, Spain. This system isunique in the fact that it has an artificial load application for the F91A & F91B Nissan truck at 15 jph. After the vehicleenters the system the load is placed on the vehicle and the system reads the values, the load is lifted and the wheelalignment cycle begins.

ORI KOREA LTDLoad Apply Wheel Aligner

Load is Applied to Vehicle Wheel Aligner Load Apply Overhead Structure

Fori Korea is installing a cockpit installation system forVolkswagen in Pune, India. Fori Korea designed and built thesystem while Fori Automation Gmbh and Fori India Installed thesystem. The system uses a large ergonomic lift assist to place thecockpit into the vehicle were it is then fastened.

Cockpit Installation

Cockpit Installation Cockpit End Effector





ORI INC.

Data Collection System

Fori Automation Technical News

Fori has developed its owndata collection system toincrease productivity with theability to access all productdata such as;

Product Brith Certificate

Error Proofing

Plant Floor Management

Comprehensive OperatorInformation Strategy

FORI TECH

The data collection system consistsof a Data Collection Module (DCM)which communicates with alldevices in the assembly system. Themain assembly line PLC places thedata, received by the DCM, intoeach job record that is kept duringthe assembly process. The jobsmove from station to station on apallet that serves as the assemblyfixture. An RFID tag is attached toeach pallet that serves as a uniqueassembly number tracked by thePLC. All error proofing andassembly sequence information iscontrolled by the main PLC. The

operator is prompted stem by step throughout the assembly sequence. When each Job exitsthe assembly line, the entire job record is transmitted to the customer for their needs.

Laser Lines are cast over specific areas and cameras “see” if the parts are in the correct location. Each camera consists of anInspection Part Detection (IPD) system which is interfaced with a digital input / output (I/O) for camera selection and partinspect program. The IPD system controls Pass/Fail signals wired to the Station PLC. The IPD is used to verify eachassembly step prior to the Welding and assembly process at each station. The IPD system is installed in each OperatorInterface (HMI) panel and has a VGA output interfaced directly to the HMI to display the live inspection screens. Each IPDhas a keyboard/mouse interface located inside the HMI and can be taught at each station. Communication and or

programming can be accessed through ENET oran internet webpage.

Vision Inspection - Part Present Detection

Lasers are Cast Over the Part Present Detection Areas Lasers and Cameras on the Overhead Fixture

Module Assembly System with Fori’s Data Collection






Fori’s Crab Drive AGV

ORI INC.FORI TECHFori Automation Featured Product

ForiAutomation has designed a new crab driveAutomated Guided Vehicle (AGV).

Maximum SpeedDrive up to 20 in / 508 mm per second*

Drive Type: 2.2 KW, DC Servo motor with safety brake*

Position Feedback: Incremental encoders with magnetic floor zonemarkers. See below for magnetic sensor details.

AGV Maximum Load: In excess of 30,000 lbs / 13608 kg - With optional drive wheelload tensioner*

Drive Features

Fori’sCrab drive

AGV System withPatented Electric Lifts

Rotation any directionCapabilities: Continuous revolutions in

Steering Features

Rotation Speed: .98 revolutions per second

Drive Type: .43 KW, DC Servo *

Steering Feedback: Absolute encoder with floor magnet positioncorrection

Magnetic Sensor Details

Servo driven Steering Mechanism

32 Hall Effect sensor array.On board amplification and A/D conversion.AVR MPU converts analog data and allows for RS-485communication to host.

RS-485 communication ensures noise-free datatransmission of field intensity values.Programmable for future capability, data protocols,etc.

All field intensity values from all sensors available to the host.Allows the host to calculate centerline profile.Allows host to observe magnet markers for zone control.

Range +/- 1 in / 25.4 mm standoff: .5 in / 13 mm ideal.Single board unit length 12.8 in / 325 mmInternal circuit boards can be cascaded to a total of 8 units up to102.4 in / 2,601 mm sensing area.Sensor calibration values are stored on-board and areadjustable.

* Fori’s 10,000 lb / 4536 kg AGV model

ORI KOREA LTD

ORI GERMANY GmbHORI AUTOMATION do BRASILLTDA

Beijing, BDA, 100176 ChinaTel: 86-10-6780-2940Fax: 86-10-6780-2945

Fori Automation China

email: [email protected]

Shelby Twp., MI, USAFori Automation inc,

Tel: 586-247-2336Fax: 586-566-6773email: [email protected]

Sihung-Si, KoreaFori Korea Ltd.

Tel: 82-31-496-3400Fax: 82-31-431-5280email: [email protected]

Fori Automation de México

Tel: 52-844-416-8918email: [email protected]

Saltillo, Coahuila, Mexico

São Paulo, BrazilFori Automation do Brasil

Tel: 55-11-4124-7624Fax: 55-11-4337-3172email: [email protected]

Primrose, South AfricaFori South Africa

Tel: +586-247-2336Fax: + 586-247-6773email: [email protected]

Pune, IndiaFori Automation India

Tel: +91-20-3022-4584 / 85Fax: +91-20-3022-4586email: [email protected]

ORI INC.

50955 Wing Drive, Shelby Township, Michigan 48315 Phone: 586-247-2336 Option 4 Fax: 586-566-6773 www.foriauto.com

To provide our customers with sound, imaginative and competitive solutions to their production needs, applying innovative technology inpractical ways. To provide rewarding employment with personal growth and educational opportunities for our people, challenging theirresourcefulness to find better ways and encouraging them to take ownership; to be enthusiastic team players and to take pride in theiraccomplishments. To have a performance reputation that allows us to become “The Customer's Choice”.

ORI SOUTH AFRICA

ORI INC.

Worldwide Family of Companies

Fori Company

Fori Representative

Merzig, GermanyFori Automation GbmH

Tel: + 49 (0) 6861-70090Fax: + 49 (0) 6861-7009-210email: [email protected]


ORI CHINA


ORI AUTOMATION INDIAPVT. LTD.PVT. LTD.

Worldwide Locations

Mission Statement

volume 4, number 1 ori fori automation global ... v4 email.pdf · n fori automation global...

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