FORI AUTOMATION NEWSLETTER Issue 8 FORI … - Newsletter V8.pdf · moves into its next station and...

The offices were completely redesigned and an interior designer helped finalize the facility layout and look. The low cubicle wall plan improves interoffice communication and collaboration.

FORI AUTOMATION NEWSLETTER Issue 8

FORIAUTOMATIONNEWSLETTER

Version 8.3

NEW GLOBAL HEADQUARTERS IN THIS ISSUE

Fori USA has New Global Headquartersby Fori USA

State of the Art FacilityOpen architecture with Café's on each floor and 17 conference rooms.

Fori Automations Global Headquarters moved to a larger facility in the beginning of 2016. The building was completely renovated and designed for Fori's use. The new facility is more than double the size of the previous facility.

Open ArchitectureThe clean lines stand out when you enter the lobby. The main floor is home for the sales and purchasing departments. The main conference room is the first room you will see when arriving on the first floor. Each conference room includes a 60” HD TV and Wi-Fi access for any business need. There are five conference rooms on the first floor. The second floor has Fori's Project Management group, executive offices and three large conference rooms. The third floor is the home of Fori's mechanical and controls/software engineering departments.

The offices provide open access and low wall cubicles improve inter-office communication and collaboration

13231 23 Mile RoadShelby Twp., MI USA 48315

www.foriauto.com

586-247-2336

FORI AUTOMATION NEWSLETTER │ Issue 8 2

Unique Design

With over 100 cubicles and several glass enclosed offices, 17 conference rooms; each with unique qualities. Fori is positioned to support its continued growth.

Each of the three floors has a cafe for informal meetings with HD Smart TV’s for connectivity or presentations. Sit back and enjoy one of the many coffee options at the mini barista. Several high top tables allow informal meetings to occur in a relaxed atmosphere. If a more formal meeting is required scheduling is not an issue with 17 conference rooms all equipped with Wi-Fi, printer access, Smart TV’s and magnetic dry erase boards. Take note of the wood in the café areas, it has been salvaged from the Packard Motor Factory in Detroit, Michigan. It is over 100 years old.

STYLE & CLASS

The offices provide open access and low wall cubicles improve inter-office communication and collaboration

World Class Facility

All the walls and ceilings have been painted which allow the new LED l ights to i l luminate the faci l ity properly. The new management area houses the plant managers and s u p e r v i s o r s . C o n s o l i d a t i o n o f resources has improved our planning and communication.

The new machining area is larger than the previous facility. The increased space allows Fori to better organize the process flow of material and al lows for addition of new machines.

A new state of the art paint booth has been built to support any of Fori's products. The paint booth provides Fori with the a b i l i t y o f p a i n t i n g e p o x y, urethane and waterborne paint.

A demonstration area is also available to view Fori's most recent product developments and current R & D projects.

156,000 sq. ft. / 14,492 sq. m Four manufacturing bay's with high ceilings. Special heavy duty AGV bay.

The manufacturing area provides nearly double the space compared to the previous facility. With four manufacturing bays with over 26 foot under the hook height and high capacity cranes, we are able to support our customers projects.


Fori Korea ExpansionFori Korea recently expanded its operations by moving to a new, larger location. The building was built on land that was reclaimed from the Yellow Sea in a development called Multi Techno Valley (MTV). The area was developed for technical based companies and will eventually include a residential area along the sea. The building is 49,730 sq. ft. / 4,620 sq. m. With 25,400 sq. ft. / 2,360 sq. m of manufacturing and storage space and an additional 24,220 sq. ft. / 2,250 sq. m for the offices, cafeteria and employee lounge.

Aerospace Assembly

Automated Guided Vehicles (AGVs) for Power Plant Refurbishment

High Capacity halogen free AGVs for the automated refurbishment of a Nuclear Power Plant have increased safety and throughput.

The two high capacity Fori AGVs have been designed to work within a Nuclear power plant refurbishment project that runs 24 hours a day, 7 days a week, 365 days per year. The refurbishment is expected to take 12 years, starting in 2016.

Initial refurbishment plans included a rail and carriage system. Through further investigation it was determined that the AGVs would enable the end user to reduce infrastructure and increase flexibility.

The AGVs were designed around the current plant infrastructure, this dictated the overall dimensions and capabilities of the system.

The vehicles were required to locate within +/- 5mm and allow for finite manual adjustment while handling the nuclear refurbishment equipment. The AGVs utilize a lithium ion battery, which allowed for a decreased footprint of the vehicle. The LiNMC battery also increased throughput due to the increased charge rate. The vehicles have reduced infrastructure costs, increased flexibility of the refurbishment plan and improved safety.

Fori Germany Expansion

Fori Germany has recently expanded its operations by opening a new tech center in Osterburken, Germany. The new facility will support Fori Germanys customer base with engineering and project management. The office space is 5,170 sq. ft. / 480 sq. m. The tech center will be able to support up to 35 engineers, there are two conference rooms and one cafeteria. The property is 30, 140 sq. ft. / 2,800 sq. m, which allows for future growth.


Automotive Alignment Systems

Automated Alignment System Diamond Plot Study

End of Line System require the ability to transmit & review data for thousands of vehicles in order to document the quality of the vehicle produced.

In this case alignment data and how each module being aligned correlates to the target values and other modules. In order to accomplish this task Fori Automation controls engineers implemented a logic pattern software common to most OEM's as diamond pattern plots.

The program runs an automatic process that will find the high spot & low spot of the toe cam bolt profile locating it at its high and low spot and rotating the camber cam bolt 360° to produce a

diamond study graph. These results are plotted, so that they can be compared to detect difference in the modules being tested. The results in this case are an X - Y graph file showing capability of the part.

The average time to align versus the time the cart enters and is picked is directly correlated so that there is almost always an alignment cell available, meaning less wait time and a better overall throughput. For TRW the Diamond Plot software for the two new alignment cells were integrated early during the 3rd quarter of 2015. The Diamond Plot software for all eight aligners, five front & three rear modular assembly alignment machines was integrated the 4th quarter of 2015.


Automated Alignment System for Front Suspension Modules

The Automated Dynamic Alignment cell for Android is a drive through system that adjusts Camber & Toe. This unique aligner handles two vehicle models that have different geometry.

The summary of these challenges included:Ÿ Packaging additional tooling.Ÿ Limited module tryout.

Providing customized equipment such as this starts with a concept design phase. Fori engineering was first requested to provide a detailed engineering study to determine if the existing model could be aligned in the same aligner as the two new models. Once feasibility was determined, and only the two new models could be ran together Fori engineering through design, process & simulation was able to fit multiple tooling

for the two new models with different geometry. A challenging portion to any project is the ability to debug & tryout the process. This project had limited time of debug. The key to success was analyzing every failure mode with precision in order to correct & provide results that would normally require more debug time. Modules are aligned as a module enters the station. The aligner knows which model based on a broadcast from the OEM, as well as position sensors placed in the machine, automatically initiating the correct tooling combinations. This aligner is outfitted with unique per the vehicle frame locator clamps toe & camber adjust then secure tooling. This new drive through alignment cell was integrated in May of 2015.


Automated Alignment System for Rear Suspension Modules

Fori's custom End of Line System consisted of a main build line, two Module Alignment machines and a final assembly build line.

A unique characteristic of the system is that the modules were robotically loaded from the front side of the alignment cells & robotically unloaded back into sequence on the secondary assembly loop. A controls mezzanine above the aligners was built to keep foot print to a minimum due to customer constraints.

Modules are picked from their respective Rail Guided Cart (RGC) and placed into either alignment cell. As the module completes its alignment the equipment

tooling retracts and the module is removed by the unload robot whom places it back onto an RGC cart on a secondary loop. The module then moves into its next station and completes assembly.

The average time to align versus the time taken for the cart to enter is directly correlated so that there is almost always an alignment cell available. Meaning less wait time and a better overall throughput.

The two new alignment cells were integrated early during the 3rd quarter of 2015.



Automated Alignment System for Front Suspension Modules

The automated alignment cells that adjust toe, camber and caster simultaneously, while ensuring the balanced marker for the drivetrain for 4WD models is properly positioned for ease of vehicle assembly at the OEM.

The required changes to 2016 model year were accompanied by many challenges. Ÿ JPH increase.Ÿ Minimal downtime to add equipment.Ÿ Product complexity.Ÿ Change of model geometry.Ÿ Rework of three current production

alignment machines.

Fori was able to provide a solution that added two additional alignment cells each with a re-sequencing stand & integrated robot. In order to keep the flexibility of

maintaining these machines, keeping sequence of the modules being built and quality, additional logic and hardware had to be developed. Toe +/- 0.03 degrees from nominal.

Modules are picked on a first come, first serve basis. After alignment the robot places the completed module in its sequence stand. From there another robot on a track extending parallel to the conveyor line will pick and place the module to the pallet it was picked from.

The two additional alignment cells were integrated during the 4th quarter of 2015. One alignment cell was reworked to accommodate 2016 changes during the 4th quarter of 2015 while the remaining were reworked 1st quarter of 2016.


Automotive Assembly Systems

Battery and Scooter Assembly Line

Fori recently integrated a flexible assembly system. The line currently utilizes a scalable manufacturing methodology, enables our customer to increase automation as production requirements increase.

The assembly system is made up of a single assembly loop and two offline stations. The two offline stations consist of a battery assembly area along with a tire & wheel assembly area. A unique characteristic about this assembly loop is the manual carts are tied into a track that resides on the floor similar to Fori's Rail Guided Cart (RGC) track that guides the cart into pre-determined location.

Some of the more unique equipment provided to this customer included:

Ÿ Flexible production tooling pallets for the assembly of the scooter.

Ÿ A bushing press that hangs from a heavy duty torque tube for the front fork attachment of the scooter frame.

Ÿ A robotic sealant dispensing cell for the battery assembly area.

This line was integrated early during the 2nd quarter of 2015.

The Dock N' Lock AGVs were built to fit within existing plants and each plants respective material handling strategy. The AGVs were commissioned to replace non-value added material handling tasks. Specifically as a direct replacement for all of the fork lifts, creating a “fork free” environment.The Dock N' Lock A G Vs are responsible for auto-docking to the p i c t u r e d c o m p a n i o n c a r t s . Previous methodology utilizing fork lifts was not a safe or reliable option, the Dock N' Lock AGVs s o l v e d t h i s p r o b l e m . T h e automated locking feature is what differentiates the Dock N' Lock AGVs from standard Tuggers.

Automotive Assembly

Dock N' Lock - Automated Guided Vehicles (AGVs) for Product Delivery

Cost effective, flexible AGV solutions have allowed automotive companies to implement a safe, reliable and repeatable material handling solution within their build processes.

The AGVs were required to auto-couple to newly developed racks, doing so removed the need for operator interface and allowed the end user to relocate o p e r a t o r s t o v a l u e a d d e d activities. The vehicles were required to repeatedly locate within +/- 10mm and travel at speeds up to 200 feet per minute. A fully integrated, a u t o m a t e d V e h i c l e Management System (VMS) was also provided. The VMS handles the traffic routing between the 15+ vehicles that are currently operating within the system.


Automotive Assembly Systems

Rail Guided Cart Assembly System for Rear Suspension Modules

Fori supplied Assembly line consisted of a main build line, two module alignment machines and a final assembly build line. The main & final build line utilized Fori's new flex rail system for build on cart transportation.

Utilizing a flex rail system and RGCs provides the upmost flexibility for customers who need to be able to accommodate changes easily. The ability to be flexible in the automotive world means less downtime, cost & reduced infrastructure during installation. whether it be adding a station or a product impact change. This level of flexibility is now becoming the norm in majority of our Automotive

Assembly Systems. The RGC system provided to the customer can easily be modified, whether it be adding a station or a product impact change.

Overhead support for tooling in most cases were simple jib booms or inverted L posts that bolted to the floor to promote flexibility of the system. In one instance where sequence and repeatability were extremely important for final torqueing camber links to the cradle & knuckle, a robot was integrated to keep that consistency.

The RGC system & associated tooling were integrated during the 3rd quarter of 2015.

Automotive Assembly

Cab Pick and Cab Deck to Chassis Systems

Fori recently supplied a total of (3) Cab Pick and Cab Deck to Chassis Systems. The systems pictured were supplied during 2015.

The Cab Pick and Cab Deck systems were supplied to support a truck assembly process. The three systems were used to support the three different lines of trucks.

Each system consisted of a standalone structure, overhead rail system, overhead four point cable lift, custom end effector and a main control panel. The system included a PLC controlled primary system and backup system in the case of a catastrophic failure.

The operators were responsible for manipulating the cab with a Wireless control pendant. Each of the systems provided a custom designed end effector to handle the different cab styles and weights. The system is meant to increase safety of transfer for completed cab assemblies. The custom end effector ensures a rigid transfer and improves reliability of transfer and decreases potential for product damage during transfer.

The full rate production for the Cab Pick and Cab Deck system is 35 jobs per hour. Production began in the first quarter of 2016.


Automotive Safety Systems

Robot Safety System

The Robot Safety system features the new Fanuc 35iA collaborative robot for positioning various targets that are used for Long Range Radar (LRR), Night Vision Calibration (NV), Headlamp Aim Box and other devices used for End of Line testing.

When more than one device is required, an automatic tool change between the target, NV target and Headlamp aiming camera is included. The flexibility of the collaborative robot has enabled Fori to remove the conventional overhead gantry or in floor positioning systems that had

Robot Safety Systems are completely stand alone and can be integrated within existing wheel alignment systems.

previously been used throughout the industry for headlamp aiming and driver assist safety devices.

The integration of the collaborative robots has reduced the time required for installation, as well as the total facility installation required. The integrated safety and capabilities of the robot have also reduced safety concerns and decreased the total overall cost for integrating the safety cell systems.

Automotive Welding System

The single system assembly cell processes a complicated Cradle assembly that consists of numerous parts and sub-assembly components.

Due to the complexity of the assembly, Fori was required to utilize excessive processing skills and use “out of the box” thinking to present a complete solution. The equipment was integrated during the 3rd quarter of 2015 and is currently exceeding the customer's expectations for throughput and quality.

Each line possesses 15 MIG welding robots, four material handling robots and utilizes a minimum number of operators. The current assembly system runs consistently at 84 seconds. After

completion of the robotic welding, the critical component characteristics are formed with precision hydraulic pierce units and is followed up with a dual station machining center. Once assembled, the assembly enters a CNC validation and deburring station, followed by a vision system to verify and track quality.

Utilizing experienced resources, Fori was able to develop a viable process that has exceeded the end users expectations. The integration of the MIG welding and material handling robots has decreased cycle time and increased throughput.

Automated MIG Welding Assembly System for Front Suspension Cradles

Automotive Welding System

Automated MIG Welding Assembly System for Rear Suspension Cradles

Highly flexible, automated robotic MIG welding assembly cells, consist of three similar lines that accommodate nine different model variations.

The rear suspension cradle satisfies approximately 90% of the vehicles in this family, with its model output accurately controlled and monitored throughout each robotic weld line. The equipment was integrated in 2014 and has exceeded the customer's expectations for throughput and quality during 2015.

Each line possesses 21 MIG welding robots, three material handling robots and utilizes a minimum number of operators. The current assembly system

consistently between 181 second and 150 seconds depending on which model is being processed. After completion of the robotic welding, the critical component characteristics are machined with a pair of precision, custom machining centers.

The integration of the MIG welding and material handling robots has decreased cycle time and increased throughput. Utilizing highly accurate machining stations and a repeatable process has also reduced waste and the quality of the final product has been greatly increased.

End of Line Testing

High Speed Audit Wheel Aligner

Fori recently supplied a High Speed Audit Wheel Alignment System.

The Wheel Alignment System services five different types of a trucks at a production rate of 60 JPH.

The wheel aligner is located in a shallow pit, does not have any adjust capabilities and consists of the following major features: caster sweep measurement, ride height measurement utilizing fixed lasers to measure front and rear points on the frame rail and vehicle weight measurement utilizing load cells integrated into the floating plates.

The new audit aligner was purchased to replace the existing Fori aligner due to age and component obsolescence. Fori supplied the other five production wheel aligners and headlamp aimers currently in production in the plant.

Fori's global presence has allowed them to provide complete, turnkey systems all over the world. The High Speed Audit Wheel Alignment System was a collaboration between Fori USA and Fori Mexico.


End of Line Systems

Trailer Back Up Assist Testing

Fori recently provided a Trailer Back Up Assist Testing System.

The Trailer Back Up Assist System was provided in order to test the camera based driver assistance system. The system provided included target boards, calibration lasers and the associated software.

The most important part of the project was the ability to accurately and reliably record the values of the camera settings. All of the data gathered was passed along to the customer's quality information system.

Fori was required to integrate the Trailer Back Up Assist Testing system into existing equipment. A total of seven systems across the two plants have been installed as of January of 2016. The total jobs per hour across the two plants is 74.

The supplied testing equipment is another piece of the ever growing Fori End of Line Testing portfolio.

End of Line Testing

Wheel Aligners / Headlamp Aimers / Semi-Auto Front Toe Set

Fori recently supplied five wheel alignment systems with integrated single mast headlamp aim systems.

The wheel aligners and headlamp aimers consist of the following major assemblies: semi-automated front toe set with dual socket gear heads (Fori patented) to accommodate two different size tie rods. A semi-automated rear toe and camber secure tooling, caster sweep audit capability and ride height measurement.

A headlamp aimer box with integrated light source and auto tilt positioning was provided for measuring and manually aligning the vehicle adaptive cruise

control module. The Vehicle lane departure warning camera was calibrated via fixed target boards.

The system also included a vehicle communication interface through the OBD connector with the following modules: lane departure warning, electronic power steering, ABS and 9 speed transmission.

These wheel aligners are not the “typical” systems supplied in the past. Fori's strong engineering group and past experience enabled us to take on these requirements and successfully implement them into the equipment.


End of Line Systems

Wheel Aligners / Headlamp Aimers / Robotic Toe Set & AutomatedTooling Changeover

Fori USA has recently installed two new robotic wheel aligners with integrated dual mast headlamp aimer.

To achieve the cycle time requested Fori utilizes a system called “Predictor Mode” for virtual real time Toe and Camber measurement. Once the initial tire run out is performed and mapped, all subsequent measurements are predicted based upon the known run out. Eliminating the typical three second update time required after an adjustment is made, enabled us to eliminate on average 10 seconds per machine cycle. A total of four robots with Toe set gearheads are utilized for setting Toe +/- 0.03 degrees from nominal.

Front Toe is set by adjusting the tie rod with a Fori patented integrated socket gear head which is driven by a nutrunner. Rear Toe is set by adjusting a cam bolt with a servo driven gear head.

The equipment needed the ability to align three different vehicle models with uniquely different suspension configurations. Based upon the vehicle model identified prior to the alignment station, the robots will automatically disconnect and drop off the existing gear heads into fixture holding stands (R/L sets). The time required for this process simultaneously occurs while the current vehicle is driven off, and the next vehicle is driven into the alignment station.

End of Line Systems

3-D Wheel Alignment with In Floor Headlamp Aimers

Fori will be integrating seven 3-D Wheel Alignment Systems during the first half of 2016 that are capable of supporting nine different vehicle models on three separate assembly lines.

Each of the Wheel Aligners features the latest 3-D Camera and digital headlamp aiming camera system that Fori offers. The Wheel Aligners accommodate various tire styles in the 13” to 17” range and up to 400mm of tread-width variation. The 1.100 m of wheel base adjustment allows the machines to handle the nine different vehicles.

The Wheel Aligners will be used for measuring Toe and Camber on all wheels,

adjusting the front toe, measuring and adjusting ECE headlamps and fog-lamps. The Wheel Aligners will also be capable of Caster sweep measurement for auditing purposes. These precise static and dynamic measurements are made possible by the 3-D cameras and associated software.

The wheel aligners include wireless torque wrench systems by Atlas Copco for securing the front tie-rod-jamb nuts and storing torque data. Each machine will accommodate all vehicle models produced on three separate assembly lines for a total throughput of 180 jobs per hour.

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Fori Korea also supplied the marriage body hold down, the centering unit and body bolt tightening manipulator.

Fori China designed and built the all the conveyors, control systems and completed the turnkey installation as their robotic wheel alignment expert.

Automotive Assembly System

Complete Turnkey Assembly and Chassis Marriage System

Fori China recently installed a complete turnkey assembly line, including a chassis marriage system.

The Fori supplied system consists of an Engine to Gearbox line (Palletized Fori Twin Strand), Engine Dress Line, (Friction Drive Conveyor) Front and Rear Module Assembly Line (Palletized Fori Standard Roller Conveyor) and the Decking Line utilizing Fori Standard Silent Chain Conveyor.

Fori Korea was responsible for design and build of the front and rear module pallets and the super pallet including the center module.

Suspension Module Assembly & Alignment

Rear Module Assembly Line

Fori China recently designed, built and integrated an assembly line which included China's first wheel aligner.

Fori China recently installed the a Rear Module assembly line complete with and a mezzanine storage system which feeds pallets to and from the main marriage line.

The conveyor system consists of the following:

Ÿ Fori twin strand palletized over/under conveyor system for rear suspension assembly – 23 stations

Ÿ 26 Rear suspension assembly palletsŸ Fori twin strand palletized “flow

through” conveyor system to deliver the assembled rear suspension into and out of the Fori rear module aligners.

Ÿ Integrated lift and locate tooling to accurately present the suspension to the aligner.

Ÿ Fori twin strand palletized conveyor system to deliver the aligned suspension to the overhead storage line and chassis marriage system

Ÿ Four elevator / lowerators with a 4 M lift stroke to transport the pallets between the floor and mezzanine level


Automotive End of Line Systems

3-D Wheel Alignment, Headlamp Aiming & Roll & Brake Testing Systems

Fori China designed, built and installed (3) complete sets of End of Line (EOL) test equipment. System included Wheel Alignment, Headlight Aimer and Roll & Brake Testing.

The Fori China systems are designed for to support six different vehicle configurations. The equipment was installed across two plants, both plants are capable of operating up to 60 JPH.

Fori was able to earn the project due to its experience with EOL systems within other plants. Within the EOL systems, Fori also provided Long Range Radar and Lane Departure Warning Systems.

The EOL system provided have improved reliability of testing and enabled our customer to better track their EOL data in order to track quality of their production vehicles.

Over the past 30 years Fori has increased its EOL products in order to be an all- around solution provider for its customers globally.

Chassis Marriage System

Air Bearing Based Chassis Marriage System & Tooling Fixtures

Fori India recently supplied an Air Bearings Based Chassis Marriage System with integrated lifts.

Both of the Air GVs include 02 nos. Electro-hydraulic tandem scissor lifts for lifting the front, rear and center components together for decking on the vehicle. The Air GV moves with minimum push-pull effort and is operated by 1~2 operators while moving from the loading area to decking area & vice-versa.

Fori India installs an air-bearing based chassis marriage system with integrated lifts.

Fori India also supplied the associated tooling for the Front Sub-Assembly, Rear Sub-Assembly, Center Tooling, Engine Sub-Assembly, Corner Module Sub-Assembly and Gearbox Assembly Systems to the customer on both these occasions.


Automotive Assembly

Chassis Marriage AGVs have enabled Automotive suppliers to decrease plant infrastructure and installation costs while increasing flexibility for their Chassis Marriage processes.

Fori Germany recently design, built and integrated a Chassis Marriage AGV System that includes a total of six vehicles running at 10 JPH. The AGV integration was completed during the 3rd quarter of 2015.

TThe six Lithium Ion Battery Powered AGVs are capable of transporting 6,000 lbs. / 2,721 kg. at speeds up to 18”/ 457 mm per sec. Chassis Marriage AGVs, which normally have the lifts integrated into the vehicle were removed. Instead,

Fori provided a station with one set of lifts in order to reduce the vehicle power consumption and overall system cost.

Continuous magnetic bar was the preferred guidance method. By utilizing magnetic bar guidance versus the previous rail guided methodologies, installation cost and time was decreased substantially. Magnetic bar guidance is not only the most reliable guidance method, but also lends itself to increased flexibility by simplifying the time and install associated with making changes to the path.

Automated Guided Vehicles (AGVs) for Chassis Marriage

Automotive Assembly

Equipment for Vehicle Assembly

Fori Germany was responsible for supplying (13) different pieces of equipment for an automotive assembly line.

The four most notable pieces of equipment included the semi-automatic cockpit manipulator, front end module equipment, and seat and chassis installation equipment.

Ÿ Cockpit installation included a semi-automated cockpit manipulator equipped with a Siemens PLC and two drives for positioning the cockpit in the Y & Z Axis.

Ÿ Front end installation is performed

manually be the operator. Utilizing the Fori Germany supplied equipment simplifies material handling and ensures repeatable positioning each time.

Ÿ The installation of the front seats will be performed via manual controlled manipulators at both sides of the assembly line. System utilizes custom designed grippers.

Ÿ Chassis pre-assembly utilizes cranes and a rail system. Load carrying devices with storage for the front axle, rear axle and corner module.

Fori Germany delivered all of the equipment during the first quarter of 2016.


The facility, capable of producing 300,000 vehicles a year is scheduled to open in the first half of 2016 and produces small cars.

Automotive Assembly

Automated Guided Vehicles (AGVs) for Chassis Marriage

Fori Korea recently designed, built and integrated 11 custom Chassis Marriage AGVs. Custom tooling plates accommodated the five different frame styles.

The Chassis Marriage system was based on a flexible, magnetic bar methodology. Previously, the standard was Rail Guided Vehicles (RGVs) with in floor or above floor track utilizing a bus rail for power and communication.

Utilizing a 48V Lithium Ion powered system and wireless for communication has enabled Fori to reduce infrastructure costs and increase flexibility.

One of the most important features of the Chassis Marriage AGV was the utilization of Lithium Ion batteries. Lithium Ion allows for much high charge and discharge current and a much longer life in comparison to lead acid options. The vehicles utilized an opportunity charging scheme in assembly stations, ensuring uninterrupted production.

The Omni-directional AGVs utilized a continuous magnetic bar guidance method, which is highly accurate and reliable. Accuracy achieved was +/- 10 mm, moving at speed up to 50m/min. The final differentiating feature against our competition was the 100% PLC based system, providing an open architecture.

Fori Korea recently installed three complete sets of End of Line test equipment at a new plant in Monterrey, Mexico.

The End of Line System included three: Wheel Aligners, Headlamp Aimers, Roll and Brake Testers and Under body checkers.

One of the unique design features was the vehicle weight measurement system, which resides on the wheel aligner. Sixteen weight measurement transducers are integrated into the four floating plates the vehicle during the alignment process. Doing so eliminates the need for a separate weight measurement station.

Automotive End of Line Systems

Wheel Aligner, Headlamp Aimer, Roll & Brake Test for End of Line System


Aerospace Assembly

Automated Guided Vehicles (AGVs) for Automated Drill & Fill System

Manual riveting has been a topic of contention within the Aerospace industry due to health and safety concerns. Utilizing high capacity Aerospace AGVs with integrated Drill and Fill systems has solved that issue.

The AGV pictured was built for drill and fill tooling for the Aerospace industry. The Automated Drill and Fill system will be used for the Panel build of the Airbus A350 XWB Fuselage.

Fori Automation had previously supplied two high capacity AGVs for a similar operation in 2010.

The additional vehicle is in support of the production increase projected for 2016, with full rate production beginning in 2017.

The Fori AGV was responsible for auto lift and leveling once the AGV arrived in the production station. Fori was required to position the AGV within +/- .005” and level within +/- .16 degrees. The AGV frame deflection was also required to be less than .03” during transport.

The AGVs and Drill and Fill System have reduced the safety and health concerns, while increasing throughput.

End of Line Testing

Cab Transfer System

Fori recently supplied a Cab Transfer System to aid in the assembly of a large truck in a Mexico assembly plant.

The Gantry Cab Transfer System transfers the various model truck cabs from the Paint Shop delivery line conveyor to the parallel Trim line conveyor to continue the assembly process. The system consists of an overhead gantry and cab transfer carrier system that spans the two lines.

The cab is automatically raised off the delivery conveyor (stop station) and lowered onto the Trim conveyor (moving line) with operator assistance via a servo driven ball screw.

The cab transfer process is accomplished automatically utilizing a servo driven belt shuttle. This project is a successful collaboration between two of the Fori Global companies. Fori USA designed the system and Fori Mexico was responsible for manufacturing and turnkey installation.

The Cab Transfer System will be in production the first quarter of 2016.


Product Development Automated Guided Carts

Automated Guided Carts (AGCs) for assembly and material handling systems.

Fori Automation has developed an Automated Guided Cart (AGC) for production use within their assembly and material handling systems.

The overall capacity of the Fori AGC is 4,000 lbs. / 1,814 kg. capable of speeds up to 2 ft. / 50.8 mm per minute. Each AGC is outfitted with a safety scanner for collision avoidance. Fori magnetic guidance sensors are used to ensure accurate and repeatable guidance, achieving up to +/- 5mm accuracy. The AGC is Siemens PLC based, resulting in an open architecture. AGCs provide long term flexibility and decrease infrastructure costs for assembly and material handling systems, while increasing safety and reliability.

Automated Guided Cart (AGC)

Rail Guided Carts

Rail Guided Carts (RGCs) for assembly and material handling systems.

Fori Automation’s Rail Guided Cart (RGC) product line has now become a cost-effective, flexible replacement for traditional conveyance systems.

The overall capacity for the Fori RGC is 1,500 lbs. / 680 kg. capable of speeds up to 2 feet / .6 m per minute. The RGC is Siemens PLC based, resulting in an open architecture. The RGC utilizes an above floor rail, roughly 3” x ½” / 90 mm x 12.7 mm. Utilizing an RGC with a custom designed pallet has enabled Fori to reduce plant infrastructure costs and increase long term system flexibility within their assembly systems.

Product Development

Rail Guided Cart (RGC)


Product Development Dock N’ Lock

Dock N' Locks are replacements for conventional fork lifts or automated tuggers, they do not require operator interface for hitching carts.

The Fori Automation Dock N' Lock is a unique Automated Guided Vehicle (AGV) product line meant to replace a fork lift or standard Tugger for material handling. material handling systems.

The Dock N' Lock features an automatic coupling assembly that enables the vehicle to hitch and transport carts without requiring operators. The coupling method utilized for the Dock N' Lock allows the vehicle to be bi-directional. The Dock N' Locks overall capacity is 20,000 lbs., capable of speeds up to 200 feet per minute. The Dock N' Lock utilizes inertial and magnetic bar guidance. A Siemens PLC is used for safety and navigation, resulting in an open architecture. The Dock N' Lock is meant to be used for non-value added material handling tasks, while increasing safety, throughput and reliability.

Dock N’ Lock AGVs

Tugger AGV

Tugger AGVs are used for bulk material handling. The Tugger AGVs are capable of pulling multiple carts totaling 20,000 lbs. / 9, 071 kg.

Fori Automation's Tugger AGV is a low cost material handling solution that increases safety and throughput.

The Fori Automation Tugger AGV is based on the same architecture and design as the Dock N' Lock. The only difference between the Dock N' Lock and Tugger is removal of the coupling assembly. The Tugger design allows for upgrades if required. The Tugger requires operator interface for hitching the carts. Fori is able to custom design the Tugger AGV for any application.

Product DevelopmentTugger AGVs


Fori Automation Product Overview

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Heavy Capacity AGVs

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FORI AUTOMATION NEWSLETTER Issue 8

GLOBAL LOCATIONS

Fori Automation Inc. Global Headquarters Shelby Twp., MI, USA 48315 Phone: 586-247-2336 Fax: 586-266-6773

Fori Automation China Beijing, BDA, 100176 China Phone: 86-10-6780-2940 Fax: 86-10-6780-2945 email: [email protected]

Fori Automation do Brasil São Paulo, Brazil Phone: 55-11-4124-7624 Fax: 55-11-4337-3172

Fori Automation GmbH Merzig Germany Phone: + 49 (0) 6861-7009-0 Fax: + 49 (0) 6861-7009-310

Fori Automation de México Saltillo, Coahuila, Mexico Phone: 52-844-416-8918

Fori Korea Ltd. Sihung-Si, Korea Phone: 82-31-496-3400 Fax: 82-31-431-528

Fori Automation India Pune, India Phone: +91-20-66140925/26

Fori Automation

13231 23 Mile RoadShelby Twp., MI USA 48315

www.foriauto.com

586-247-2336

ISO 9001:2008 ISO 14001:2008 Certified ITAR Certified Cage Code M20746Publish Date: Version 8.1 June 1��, 2016

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