ORI Fori Automation INC. NEWS Assembly… V6 email.pdf · · 2014-03-20Integrator & Installation...

ISO 9001:2000 ISO 14001:2008 Certified ITAR Certified Cage Code M20746 World Headquarters 50955 Wing Drive, Shelby Township, Michigan 48315 Phone: 586-247-2336 Option 4 Fax: 586-566-6773 www.foriauto.com

In the spring of 2010 Lockheed Martin (Marietta, Georgia) awarded Fori Automation the contract for the F-35 Joint Strike Fighter Center Wing Transport System. The F-35 Program will include (3) variants which will serve all branches of the Unites States Military. Projected production rates of one plane/day with a total planned production run of over 2,400 planes required Lockheed Martin to develop a new state of the art manufacturing system. Critical to this process was the transport of the Assembly Jig Transport Fixture (AJTF) loaded with the Center Wing. The (3) Fori Automation AGVs efficiently, safely, and autonomously accomplished a synchronized line move of (14) 11,100 lb tool/aircraft assemblies through the (16) stations in less than 4 hours. This AGV transport system accomplishes this task without human intervention, while interfacing with critical safety interlocks associated with each process station, autodrill machines, tooling and the flow line infrastructure. In addition to the (3) AGVs, Fori Automation also supplied 96 TOACs (Tooling Accessories) (6 in each of the 16 stations). These TOACs featured precision cone and cup details and locking arbors to ensure the AJTF was precisely located and secured in each station. In July of 2011, the f inal assembly

flow line became operational, and by November 2011, the transport system was certified for full rate production. Each AGV incorporated Fori Automation's locking servo lifters, RF communication, patented servo drive steer, and magnetic guidance system which delivers positional accuracy of +/- 5mm (x/y).

Volume 6, Number 1

NE WSFori Automation Newsletter

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

www.foriauto.com When Innovation & Performance Count ISO 9001:2000 ISO 14001:2008 Certified

Water Covers Two Thirds ofthe World, We Cover the Rest

Global Design and Build of TurnkeyAssembly, Testing and Welding Systems

www.foriauto.com

Fori AutomationGlobal Locations

Aerospace AGV’s

LockheedMartin AGV Aerospace Assembly System

Aerospace AGV’sCamryn Assembly Systems

Chrysler Module AlignersHonda Robotic To Set Tooling

Gestamp Tallent Welding SystemBombardier AGV’s

Ford Worldwide Chassis Marriage SystemsFori - VW Chattanooga Systems

Fori Germany - VW Emden Headlamp AssemblyFori Korea - Kia End of Line Systems

Fori Korea - Beijing Hyundai Chassis MarriageFori Korea - Vina-Mazda End of Line Systems

Fori Korea - GM Shanghai End of Line SystemFori China - Ford Thailand Chassis Marriage Fori China - Shanghai VW Chassis Marriage

Fori Mexico - Chrysler Engine ManipulatorFori Mexico - Magna Transmission Gauge System

Fori Mexico - Webasto Sun Roof Assemble & InstallationFori India - Caterpillar Axle Mover

Fori India - GM - RGV Chassis MarriageFori India - TATA / Jaguar Chassis MarriageFori Brazil - Michelin Tire Handling System

Fori Brazil - Fiat End of Line SystemFori Worldwide Company Information

- 1- 2- 2- 2- 3- 3- 4- 5- 6- 6- 7- 7- 8- 8- 8- 9- 9- 9- 10- 10- 10- 11- 11- 12

Fori Automation AGVs assist withassembly of the F-35 Joint Strike Fighter

In This Issue

TOAC’s for LockheedMartin

When Innovation & Performance Count ISO 9001:2000 ISO 14001:2008 Certified

ORI INC.

Rear Module Aligner

Camryn Industries contracted Fori to provide assembly systems for components to feed the Chrysler Fiat Belvidere Illinois Assembly Plant for the new 2012 PF vehicle, (Dodge Dart). Installed in September 2011; Assembly lines for the Front Coil Over Shock units, Front Brake Corners and Rear Brake Corners will produce right and left side units at a rate of 42 seconds per pair (85.7 jph gross volume). Utilizing proven designs from many similar projects, Fori was able to efficiently integrate assembly fixtures, torque devices, lateral run-out testing, press stations, and ergonomic devices. These systems are the result of detailed second by second operator and machine Process Engineering that enables the launch of systems that will meet the required production volume upon system start-up. As with all our proposals, Fori provides initial system planning, processing, layouts, operator allocation, dunnage spacing, projected floor space required, and a detail quote. This enables our Tier One suppliers to submit turnkey system bids for OEM supply projects.

Three (3) new rear Suspension Module Aligners were provided for the Dodge Dart. Two (2) aligners are used to maintain the 72 jph production rate. The third aligner is a back-up. Once the rear suspension is assembled it is then manually loaded into the module aligner. The aligner automatically clamps onto the wheel ends and jounces the suspension to exercise the joint, springs and bushings. The measuring heads then rotate to wheel ends to dynamically measure toe and camber utilizing three (3) linear transducers that contact the rotor surface. Camber is automatically set by utilizing a servo driven gear head that engages and adjusts the suspension cam bolt. Once the suspension is aligned it is placed onto a Fori over/under twin strand conveyor for delivery to the Fori chassis decking system.

Fori USA recent ly instal led two (2) new Wheel Aligners/Headlamp Aimers with front and rear robotic toe set tooling at the Honda East Liberty, Ohio assembly plant. The plant produces the RDX Crosstour and CR-V at a production rate of 55 jph. Fori was awarded the contract based upon its proven and reliable robotic toe set tooling that has been running at the Honda Alabama and Indiana assembly plants the past four (4) and two (2) years respectively. Four (4) robots (2 front (R/L), 2 rear (R/L)) are used per aligner for setting front and rear toe to a +/- 0.03º of nominal. Front toe is set by adjusting the tie rod with a Fori patented integrated socket gear head. Rear toe is set by adjusting the cam bolt with a servo driven gear head. Due to the tight window of access a vision system had to be mounted onto each robot end of arm tool to properly locate the tie rod and cam bolts. Once they are located the coordinate information is passed to the robot and the engagement path is adjusted accordingly.

ORI KOREA LTDORI GERMANY

ORI INC. ORI SOUTH AFRICAORI CHINA ORI INDIA

ORI AUTOMATION de MÉXICOORI AUTOMATION do BRASIL LTDA

www.foriauto.com

Camryn Industries

Rear Corner Assembly Line

Chrysler Belvidere

Honda East Liberty

Front & Rear Robotic Toe Set System





Systems

Gestamp Tallent of Cannock ORI INC.

Fori Automation USA in coordination with Expert Automation of Coventry England has designed, built and installed the first line of two spot weld systems including one MIG weld cell for the A-Pillar, B-Pillar Deck lid and panel welding. Gestamp Tallent of Cannock, England awarded Fori Automation USA the project in February of 2011. The product includes a number of body in white subs for the Toyota (519W) Yaris, the process is capable of producing both two and four door versions of the vehicle. Tack times range from (69) seconds to (156) seconds. The second line was delivered starting in January of 2012. Fori Automation's global presence ultimately secured the order. Fori USA completed the system design while Fori Mexico produced the customer's standard robot bases and other large fabrications which were sent directly to Expert Automation for integration. Most notably the project includes a projection stud multi-welder capable of quick change for either model. This unique design can be used for future applications of a similar nature.

Bombardier MontrealWithin the framework of the development of the new commercial aircraft “C Series”, Bombardier aimed at optimizing the transportation network of all aircraft components, (nose, forward fuselage & aft fuselage) and tooling based on the “just in time” philosophy. This requires a robust fleet of vehicles that were chosen based on optimal scheduling and the ideal transportation flow within the facility with a maximum load of 18,000 lbs / 8,165 kg. By implementing an assembly process moving line, (10” / 254 mm per second empty - fill load 6” / 152 mm per second) Bombardier is trying to eliminate the non-value added manipulation of tooling and product. Most important is the removal of

large overhead cranes which are traditionally used in aircraft assembly. Fori Automation was selected by Bombardier to develop and integrate Automatic Guided Vehicles based on its technological advantages over the competition. Over 20 AGVs will be delivered to Bombardier near Montreal Canada over the coming years supporting the upcoming C-Series production and ramp-up activity. Some of the AGV requirements included supporting a maximum production rate of one (1) aircraft per day. AGV's will be used to transport aircraft components/tooling from the Satellite/store area to their respective pre-determined shop floor loading area 2 hours prior to the start of the new work shift.

Walk Through AGV with Locking Lifting Arbors





ORI INC.

Fori Automation Shelby Twp in coordination with Ford Motor's “ONE Process - Team Strategy” is expanding the Fori Global RGV Decking Technology with installation in Europe, Brazil, and Asia. Originating in 2003 with Ford's acceptance of Fori's Patented Electric Chain Lift Technology for implementation in Hermosillo Mexico, systems have multiplied annually in North America to include Oakville Ontario, Chicago Illinois, Cuautitlan Mexico, and most recently Michigan Assembly Plant. Initiated by award of a Ford Global Bundle Buy Agreement in 2010, Fori RGV installations now include additional systems for Thailand, Romania, Spain, and Brazil. Specification additions/changes to accept Europe Certifications (CE), Component Standards, Safety Redundancy, and High Speed Part Deliveries (EMS) for volumes exceeding 100 jph and 20+ Vehicle/Powertrain combinations have pushed Fori to gain Regional Acceptance. Ford Vehicles produced using Fori's RGV – Chain Lift Technology today include Fiesta, Fusion, Mustang, Taurus, Edge, Explorer, and Flex with soon additions of Mondeo, S-Max, C-Max, KA, Passport among several others set for introduction. Fori's RGV Chain Lift positions Fori as a World Class Supplier of Process Assembly Systems in terms of critical Safety, Reliability and Flexibility.

Ford Worldwide

Chassis Marriage Cart Chassis Marriage Tooling Plate with Engine

Chassis Marriage High Speed Transfer and Pallet transfer with Lift & Rotates and Diverters





Volkswagen Chattanooga

VW Style Chassis Marriage System

The Volkswagen Group of America is in the process of introducing a new mid-size sedan to the US market. The model is based on the VW411 platform and will be built in a brand new, state of the art assembly facility in Chattanooga, Tennessee. As part of this endeavor, Fori Automation GmbH successfully earned a contract from the Volkswagen Group in Wolfsburg, Germany to build a variety of equipment, tooling and automated systems for this VW assembly plant, which is divided into 7 assembly line segments. Fori Automation is tasked to design, build and integrate state of the art turn-key systems to the specific VW standards utilizing Siemens Controls System, considering DIN, EN and ISO n o r m s , w h i l e m e e t i n g O S H A requirements and local electric codes. Although Fori Automation is very familiar with the VW standards, the entire installation system has to be turned over to VW within a very stringent time frame while managing dozens of sub-suppliers located on several continents. The assembly systems supplied are; Doors off – Doors on, Automatic installation of Roof Dampening Reinforcements or DVD, Tilt/slide Sunroof installation or SAD. VIN stamping and Laser Marking, Gluing, Assembly and Installation, Window Gluing Application, Battery Installation, Front End Assembly and Installation, Wheel Installation, Front- and Rear Seat Installation, Transmission AGV system and a Chassis Assembly System.

Chassis Pre-Assembly System Cockpit Installation System

Engine Dress System

ORI INC.


Page 5 ORI KOREA LTDORI GERMANY



Volkswagen Chattanooga

VW Style Chassis Marriage System

The Volkswagen Group of America is in the process of introducing a new mid-size sedan to the US market. The model is based on the VW411 platform and will be built in a brand new, state of the art assembly facility in Chattanooga, Tennessee. As part of this endeavor, Fori Automation GmbH successfully earned a contract from the Volkswagen Group in Wolfsburg, Germany to build a variety of equipment, tooling and automated systems for this VW assembly plant, which is divided into 7 assembly line segments. Fori Automation is tasked to design, build and integrate state of the art turn-key systems to the specific VW standards utilizing Siemens Controls System, considering DIN, EN and ISO n o r m s , w h i l e m e e t i n g O S H A requirements and local electric codes. Although Fori Automation is very familiar with the VW standards, the entire installation system has to be turned over to VW within a very stringent time frame while managing dozens of sub-suppliers located on several continents. The assembly systems supplied are; Doors off – Doors on, Automatic installation of Roof Dampening Reinforcements or DVD, Tilt/slide Sunroof installation or SAD. VIN stamping and Laser Marking, Gluing, Assembly and Installation, Window Gluing Application, Battery Installation, Front End Assembly and Installation, Wheel Installation, Front- and Rear Seat Installation, Transmission AGV system and a Chassis Assembly System.

Chassis Pre-Assembly System Cockpit Installation System

Engine Dress System

ORI INC.





Independent Vertical Slide

Fori Korea has designed and installed a unique chassis marriage system at Beijing Hyundai Motor Company, China. The hinged cart design was applied to this marriage system because of a limited floor space and the need for tight radius corners. This concept will be helpful for the customer who wants to apply our RGV marriage system but has spatial constraints with a standard cart dimension. The nine cart system is capable of running the Xdc, EFc, JMc, MCc, RC & NFc models at 66 jph.

ORI KOREA LTDBeijing Hyundai Motors

Limited Space Chassis Marriage System - with Hinged Cart Limited Space Chassis Marriage System - with Hinged Cart

Vina - Mazda Automobile Manufacturing CompanyFori Korea has designed and installed a set of EOL test equipment to Vina-Mazda Automobile Company in Vietnam. The systems include: wheel aligner, headlamp aimer, side slip tester and a roll and brake tester with a static brake testing function. The systems are designed for the Mazda 2, 3, 6, CX-9 & BT 50 at 8 jph. This company is a joint venture of Mazda Motor Corporation in Japan and complies with the standard fixed by Japanese regulation. Fori has met and exceeded Mazda’s expectations and looks forward to expanding our presence within the Japanese OEMs.

Roll & Brake Testing System

Wheel Aligner with Integrated Headlamp Aiming System

When Innovation & Performance Count ISO 9001:2000 ISO 14001:2008 Certifiedwww.foriauto.com

ORI CHINAGM Shanghai

Ford Thailand

3-D Wheel Alignment System with Headlamp Aimer

Volkswagen Style Chassis Marriage System

Fori China has designed, built, and installed three (3) wheel alignment systems with gantry style digital headlamp aimers for GM Shanghai Dongyue plant in Yantai China that produces the Excelle. The 3-D system is capable of a 60 jph rate. A gear centering system was utilized to fulfill the customer's requirements.

3-D Wheel Alignment System with Headlamp Aimer

Fori China has designed, built, and installed a twelve (12) cart chassis RGV marriage system for Ford Thailand which produces the C346 Focus. Critical to the Fori RGV cart is the patented electric chain lift which includes a single piece aluminum cast housing and internal components including Guide Tubes (3), Worm Gear Drive, Self-Locking Lift Chain and Servo Motor. Redundant Safeties include internal servo brake and anti-backup driving worm gear for any power interrupt and/or mechanical failure.

Low Profile Chassis Marriage Cart

Shanghai VolkswagenFori China recently completed the design, build and installation of a chassis marriage system for Shanghai Volkswagen in CP4, Nanjing, China for the Passat at a 60 jph rate. This system was built with Fori's global design Team. Fori Korea supplied the design and build for the following components: system layout, tooling, EC & NR manipulators and the electrical design. Fori USA designed the DL1 lifter and aided in mechanical assembly. Fori China then took the components and built and installed the front module conveyor, five (5) silent conveyors, control panels and electrical installation and integration. This system demonstrates Fori's global resources and collaboration including their ability to design systems on a global level.








Chrysler Toluca ORI AUTOMATION de MÉXICO

Magna Powertrain de Mexico SA de CV

Engine Manipulator

Sunroof Assembly System

Robotic Sunroof Installation Station

Fori Mexico has designed and installed a transmission gauge station for Magna MPT Saltillo in Ramos Arizpe, Coahuila Mexico for the Jeep Cherokee and Jeep Patriot. The station is installed at the end of the production line. The transmission is lifted to engage a shaft that the operator manually spins. Two (2) height indicators make contact with the transmission shaft and record any misalignments on the shaft at a 45 jph rate.

Transmission End Effector

Transmission Gauge Station Transmission Gauge Station

WebastoFori Mexico has designed and installed a sun roof assembly line for Webasto, Irapuato, Guanajuato Mexico. The assembly system consists of eight (8) assembly stations and one test station for the Ford B299 model at a 30 jph rate. The assembly line has six (6) assembly stations, one test station and shares two (2) robotic cells of TOX and Butyl application from the VW Jetta A6 sun roof assembly line built previously by Fori Mexico in 2009. The work stations are designed for fast tooling change over for future sunroof models. The test bench verifies the motor processor and performs a fully open, partial open and closing force/ object detection

Fori Mexico has designed and installed one (1) engine manipulator and one (1) transmission marriage manipulator with eight (8) different end effectors at the Toluca Assembly Plant. The manipulator can handle eight (8) different vehicle transmission models at a 60 jph rate for the Dodge Journey 2.0 Lts. & 3.6 Lts. / Fiat SUV Freemont 3.6 Lts. / Fiat 500 1.2Std , 2.0 Auto & 2.0 Automatic Turbo / Fiat Abarth. The manipulator includes a pneumatic end effector tool changer, and has safety built into it by only allowing the manipulator to function when it is within the work area. Limit switches ensure the manipulator does not interfere with other line components such as the transmission rack elevator.

Fori Automation India Pvt. designed and supplied a rear axle assembly fixture to Caterpillar India Limited. The system included the main assembly fixture for mounting the left, center and right axle assemblies including tackles for lifting each of the components. Also included was the axle mover assembly for moving the assembled axle from the axle assembly system to the axle mounting Area. The axle mover assembly includes two axle mover sub-assemblies (LH & RH) with a connecting frame which connects them together. The axle mover assembly moves with the help of air bearings and air motor operated drive system for LH & RH at a rate of 2 jobs per day. This low volume production is for the 60T to 100T Dumpers.


ORI INDIA

General Motors IndiaFori Automation India Pvt. designed and supplied an RGV based Chassis Marriage System to General Motors India. The system included the Fori Standard RGV with an Electro-Hydraulic Scissor Lift and included an Allen Bradley PLC and HMI. The system was designed to accommodate the Aveo, Uva, Cruze, CN100 & N200 styles at 22 jph. Fori India managed the entire project including Mechanical Design, Electrical & Controls Design, PLC Programming, Fabrication & Assembly, Trials, Debug and Commissioning independently.

RGV Chassis Marriage System

Caterpillar India

Axle Mover Sub Assembly System

TATA - Jaguar / Land Rover Fori Automation India Pvt. designed and supplied an air-bearing based chassis marriage system (Air Guided Vehicle / Air GV) to Tata Motors for their prestigious Jaguar Land Rover project in Jan 2011. The concept design was provided by Fori USA. Fori India detailed the design of the system and tooling, etc. The marriage system included a pair of electro-hydraulic scissor lifts moving in tandem for front & rear assemblies at 2 jph. The front, center & rear tooling assemblies are all mounted on a common base plate so that they all lift and lower together. The Air GV moves with minimal push-pull effort and is operated by only 1-2 operators while moving from the loading area to the decking area.

Air GV Cart for the Freelander





Fori Automation Featured Product

ORI AUTOMATION do BRASIL LTDA

Michelin




Fori Brazil delivered a wheel alignment machine with integrated headlamp aiming to Fiat Betim Brazil assembly plant in December 2011. The machine features Fori's latest technology 3-D measuring system with digital headlamp aiming. It also includes a vehicle loading system with servo driven actuators that locate into the body location slots, and pull the vehicle down to a known load. This process is used for the adjustment of the rear brake valve on the Doblo, Idea and Punto vehicles. The system also features a direct communication to the vehicle ECU via OBDII for identifying and controlling the setting of various options such as, Xenon Lamps, ABS/ VDS Brakes, Hill-Hold and Side-View Sensors.

3-D Wheel Alignment System with Integrated Headlamp Aimer Vehicle Load Pull Down

M i c h e l i n a n d F o r i Automation have teamed up to develop a common g loba l p la t form for Michelin's Robotic Tire Palletizing Cells. Fori's Robotic Palletizer Cell (RPC) for Michelin in Resende Brazil, palletizes 9000 tires per day with rim sizes from 14 to 24 inches and tire section widths from 155mm to 335mm. The equipment is quickly adaptable to other tire size ranges both smaller and larger than the Pau Brazil Program production mix, a n d t h e s y s t e m i s developed as a base platform to adapt to all of Michelin's global tire storage pallet configurations. Forklift operators deliver folded storage pallets to the load station of the RPC, the folding pallets are automatically opened and positioned for robotic palletizing, the filled pallet is then automatically labeled before it is conveyed to the Forklift unload station. The first RPC has been delivered and installed in Brazil and is currently undergoing final validation. Fori's cell design and construction is developed as a global solution that Fori can manufacture, deliver and service from any of our global manufacturing plants to provide local support for Michelin Plants anywhere in the world. The end result is a configurable local solution adapted to the individual plant requirements, environment, systems and utilities, but has globally common network and information interfaces, common personnel interfaces, common spare parts, common operator and maintenance training.

Michelin RPC System

Fiat Betim

ORI KOREA LTD

ORI GERMANY GmbHORI AUTOMATION do BRASIL LTDA

Fori Automation ChinaBeijing, BDA, 100176 ChinaTel: 86-10-6780-2940Fax: 86-10-6780-2945email: [email protected]

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

Fori Korea Ltd.Sihung-Si, KoreaTel: 82-31-496-3400Fax: 82-31-431-5280email: [email protected]

Fori Automation de MéxicoSaltillo, Coahuila, Mexico Tel: 52-844-416-8918email: [email protected]

Fori Automation do BrasilSão Paulo, BrazilTel: 55-11-4124-7624Fax: 55-11-4337-3172email: [email protected]

Fori South AfricaPrimrose, South AfricaTel: +586-247-2336Fax: + 586-247-6773email: [email protected]

Fori Automation IndiaPune, IndiaTel: +91-20-30792679/80Fax: +91-20-30792681email: [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 in practical ways. To provide rewarding employment with personal growth and educational opportunities for our people, challenging their resourcefulness to find better ways and encouraging them to take ownership; to be enthusiastic team players and to take pride in their accomplishments. 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

Fori Automation GbmHMerzig, GermanyTel: + 49 (0) 6861-70090Fax: + 49 (0) 6861-7009-310email: [email protected]


ORI CHINA

ORI AUTOMATION de MÉXICO

ORI AUTOMATION INDIA PVT. LTD.

Worldwide Locations

Mission StatementITAR Certified Cage Code M20746

Publish Date: March 1st 2012

Fori Automation incWorld HeadquartersShelby Twp., MI, USA

World Headquarters

ORI Fori Automation INC. NEWS Assembly… V6 email.pdf · · 2014-03-20Integrator & Installation...

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