Vehicle Manufacturing Automation System Introduction Part 4 - EPS
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This document discusses an error proofing system (EPS) used in vehicle manufacturing. EPS integrates with the manufacturing execution system (MES), programmable logic controllers (PLCs), and automatic visual inspection (AVI) systems to help ensure correct parts and processes. Specifically: 1. EPS uses scanning, RFID tags, and position sensors to verify correct parts are picked and processes like torqueing and marking are completed accurately. Results are sent to the MES and line PLCs. 2. The line PLC receives real-time vehicle position from an encoder and AVI to control stations without direct RFID, stopping the line if errors are detected. 3. If issues arise, PLC
Vehicle Manufacturing Automation System Introduction Part 4 - EPS
- 1. Vehicle Manufacturing Automation System Introduction Part 4 - EPS Tallrain / Oct 2016
- 3. EPS = Error Proofing System, or Fail Safe System. EPS is designed for Manual/Machine/Material operations. EPS integrates with PLC. EPS integrates with ANDON/AVI systems.
- 5. Part Scanning: 1. Operator scans VIN Label. 2. MES client requests to refresh page. 3. MES returns part list and verification rules. 4. Operator scans Part Labels. 5. MES verifies labels, and alerts if wrong part labels are scanned. Part Scanning MES Server 2 3 Request Part List 1 VIN 4 Part S/N 5 Verify ID P/N S/N Length S/N Rule 1 BT12345 9 0-9 2 LT12346 9 0-9 3 CT12347 12 0-9,A-Z 4 QT12348 12 0-9,A-Z
- 6. Part Picking: Mainly used in Engine assembly: 1. When engine arrives, PLC reads Engine S/N via RFID Tag. 2. PLC sends VIN to MES. 3. MES downloads Part List and Rack ID list into PLC. 4. PLC turns on light for each Part. 5. Each time Operator picks a part, its light turns off by PLC. 6. After all parts are picked up, PLC uploads result into MES. Part Picking OPC MES Server ME PLC IT Layer Control Layer 1 5 RFID Reader 2 3 4 6 P/N Station Rack ID A0001 1001 1 A0002 1002 2 A0003 1001 2
- 7. Vehicle Torque Gun: 1. When vehicle passes through PBS Out station, MES broadcasts it to whole shop. 2. MES sends VIN and Torque Gun Command into Torque Gun Server. 3. When vehicle comes to Torque Gun station, Torque Gun Server sends Command into Torque Controller, which controls Torque Gun to operation accordingly. 4. Controller uploads Torque results into Torque Gun Server. 5. Torque Gun Server sends result into MES. Vehicle Torque Gun RFID Reader OPC MES Server Torque Gun Server Controller Torque Gun Command Result 1 Prepare 2 4 Command 3 Result5 PBS OUT PLC
- 8. Engine Torque Gun OPC MES Server ME PLC IT Layer Control Layer 1 5 RFID Reader 2 3 4 6 Controller P/N Station Gun ID A0001 1001 1 A0002 1002 2 A0003 1001 2 Engine Torque Gun: 1. When engine comes to station, PLC reads Engine S/N via RFID Tag. 2. PLC sends Engine S/N into MES. 3. MES downloads Torque Command, including: Torque Gun ID, Torque Count, etc. 4. PLC sends Torque Command into Controller, which controls Torque Gun to operate accordingly. 5. Controller sends actual Click Number and Value into PLC. 6. PLC uploads actual Click Number and Value into MES.
- 9. VIN Marking Marking 5RFID Reader OPC MES Server Mark PC taskfile Request Result 1 Prepare 2 3 6 taskfile 4 Feedback7 PBS OUT PLC PLC VIN Marking: 1. When vehicle passes through PBS Out station, MES broadcasts it to whole shop. 2. MES sends Marking Command into VIN Marking PC. 3. When vehicle comes to VIN Marking station, operator scans VIN Label. 4. Marking PC sends Command into PLC. 5. PLC controls machine to mark accordingly. 6. PLC sends Marking result into Mark PC. 7. Mark PC sends Marking result into MES.
- 10. Filling/Gluing Filling/Gluing: 1. When vehicle comes to station, PLC reads VIN via RFID Tag, and sends it to MES. 2. MES downloads command into PLC. 3. PLC controls machine to operate accordingly. 4. PLC uploads result into MES. OPC MES Server PLC IT Layer Control Layer 1 2 3 4 RFID Reader
- 11. 3 – EPS & AVI
- 12. RFID Tags are used in most vehicle plants for vehicle identification. But in General Assembly Shop, Plain- Chain Conveyors are used for most lines, which is always moving continuously, so it’s low efficient to read RFID in middle stations. EPS PLC integrates Encoder to calculate line speed and position, together with AVI reading in Line Head/End stations, to output each vehicle’s real time position. EPS PLC integrates position sensors, to output pulse signal of 0%/70%/100% position of station, which will be used for Alarm and Stop. RFID Reader OPC Server MES Server EPS PLCComing Vehicle Encoder Line Position Vehicle Sequence COUPLER Conveyor PLC Encoder Position Sensor Vehicle Position Line Position
- 13. 4 – EPS & ANDON
- 14. In General Assembly Shop, EPS result sends to Conveyor PLC via ANDON PLC: 1. When operation is completed, operation data will be sent to MES. 2. Control PLC/PC sends result(OK/NOK) into ANDON PLC. 3. ANDON PLC sends OK/NOK and 70%/100% position signals to Conveyor PLC, which stops line when condition matches. OPC MES Server Control PCResult Data 2 3 1 PLCANDON PLC PLC Stop
- 15. Thank you! 1