Factory Assembly Systems
Transcription
Factory Assembly Systems
Factory Assembly Systems Catalogue 2006 / 2007 Technologies . Systems . Solutions Issue date 01.09.2006 We reserve the right of technical changes in the course of continous developement of our products Layout & Realization: © awiwa communications www.awiwa.de Factory Assembly Systems Catalogue 2006 / 2007 Technologies . Systems . Solutions 1 Factory Assembly Systems FAS As an international partner of Our customers’ requirements Our main aim is to perpetually the automotive industry Dürr are the main focus of our activi- open new possibilities for our stands for leading edge techno- ties when working out optimal customers, to reduce their costs logy, high quality and customer process solutions and choosing per unit and to increase their proximity. suitable products in cooperation. competitiveness. With the business unit Factory To do this, we draw upon a Assembly Systems (FAS) Dürr comprehensive base of know- FAStplant® – the modular way takes also a leading position ledge and experience resulting of erecting, dismantling and within vehicle’s final assembly from customer relations with modifying a complete assembly and delivers high-end conveyor nearly all automobile manufac- line is only one example for technology, products and systems turers worldwide, ranging from innovation made by Factory for assembly processes in the mass production to up-market Assembly Systems. automotive industry. production or from compact car makers to light truck makers. solutions – Dürr FAS is optimally Our portfolio of products and services is based on extensive From planning through to deli- positioned to meet the demands process competence which very and service, FAS accom- that the assembly of future- translates into our products and panies the entire life cycle of a oriented and cost-conscious which in turn allow FAS to cover project. Our portfolio ranges automotive plants brings. more than 70 % of the total from minute items of equip- investment for equipment ment to turn-key delivery of required in a final assembly plant entire assembly shops. from in-house manufacture. Included are products such as With production sites on three marriage systems, axle assembly, continents and a most profes- filling systems, all kinds of con- sional project management we veyors, complete end-of-line consistently produce high quality equipment, glazing systems and products and ensure schedule handling equipment. and budget adherence. Our strength of innovation results from our high process competence. Thus, we are setting on intensive development activities in all fields. 2 Technologies, systems and Contents Factory Assembly Systems FAS 2 Conveyor Systems : : : : : : : : : : 4 Survey/ System Elements : : : : : : : : : : : : 6 - 9 Overhead Conveyors FAStrolley : : : : : : 10 - 17 Floor Conveyors FASfloor : : : : : : : : : : : 18 - 29 Final Assembly : : : : : : : : : : : : 30 Fluid Filling FASprofill : : : : : : : : : : : : : : 32 - 41 Assembly Equipment FASsembly : : : : 42 - 63 Testing Systems FAStest : : : :64 Wheel Alignment : : : : : : : : : : : : : : : : : 66 - 75 Headlight Aiming : : : : : : : : : : : : : : : : : 76 - 81 Driver Assistance Systems Testing : : : 82 - 85 End of Line Function Test : : : : : : : : : : : 86 - 95 In-Line Testing : : : : : : : : : : : : : : : : : : : 96 - 103 Automation : : : : : : : : : : : : : : 104 Survey : : : : : : : : : : : : : : : : : : : : : : : : 106 - 107 Basic Software and Components : : : 108 - 109 Elektronics Testing and Server Systems FAStronic : : 110 Survey : : : : : : : : : : : : : : : : : : : : : : : : 112 - 113 Server Systems : : : : : : : : : : : : : : : : : 114 - 121 Test Stations : : : : : : : : : : : : : : : : : : : : 122 - 125 Mobile Diagnostic Systems : : : : : : : : 126 - 133 Measurement Systems : : : : : : : : : : : :134 - 137 Accessoires : : : : : : : : : : : : : : : : : : : : :138 - 141 Advanced Factory Solutions 142 Survey : : : : : : : : : : : : : : : : : : : : : : : : 144 - 145 Planning : : : : : : : : : : : : : : : : : : : : : : : 146 - 153 Cross Functions : : : : : : : : : : : : : : : : : 154 - 157 FAScontract : : : : : : : : : : : : : : : : : : : : 158 - 167 DÜRR Worldwide : : : : : : : : : : 168 3 4 Conveyor Systems Survey : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 6 - 7 System Elements : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 8 - 9 Overhead Conveyors FAStrolley Power & Free : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 10 - 11 Electric Monorail System : : : : : : : : : : : : : : : : : : : : : : : : : : 12 - 13 Twin Trolley System® (TTS) : : : : : : : : : : : : : : : : : : : : : : : : : 14 - 15 Vertical Adjusting Conveyor : : : : : : : : : : : : : : : : : : : : : : : : : 16 - 17 Floor Conveyors FASfloor Skid Conveyor : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 18 - 19 Twin Trolley System® (TTS Inverted) : : : : : : : : : : : : : : : : : : 20 - 21 FASmatic® : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 22 - 23 Skillet Conveyor : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 24 - 25 Belt Conveyor / Modular Chain Conveyor : : : : : : : : : : : : : 26 - 27 Slat Conveyor : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 28 - 29 5 Dürr conveyor systems: Innovative – efficient – and user-oriented „Just in time“ or „just in se- In view of increasing demands quence“ – Dürr conveyor systems for the reliability of a plant verti- from the Factory Assembly cal adjustment conveyors with Systems business unit meet all modern belt technique and requirements for more flexibility water resisting modular chain and cost effectiveness. We set conveyors form an important standards in respect of functio- part of our portfolio. nality and innovations with our extensive range of floor conveyors Against the background of high- and overhead conveyors. We quality demands we conse- offer maximum reliability with quently improve our range of reduced maintenance effort. products. Two examples are our patented innovation Twin Trolley System® The market success of Dürr FAS (TTS) with its modular structure is the result of a continuous and FASmatic®, the automatic systems and the fulfilment of system for non-contact energy specific customer demands. and data supply, can be in-stalled with almost all conveyor technologies. Thus, Dürr FAS continues with setting new standards for higher availability and less maintenance. 6 development of our conveyor guided vehicle. FASmotion, our Conveyor Systems Survey Your Advantage The Conveyor Systems Overhead conveyors FAStrolley Floor conveyors FASfloor High reliability Low maintenance effort Power&Free Skid conveyor Electric Monorail System TTS inverted Twin Trolley System® (TTS) FASmatic® Vertical Adjustment Conveyor Skillet conveyor Future-proof thanks to standardized product range Non-contact energy and data transfer optional Belt conveyor / Modular chain conveyor Slat conveyor 7 Twin Trolley System® (TTS) In this new technology, the drives are not accommodated in the trolleys but in the rail. This means that no on-board control is required. In a further development, TTS is combined with the Skillet technique. Electric Monorail System (EMS) Equally suited to use on pure conveying sections at high speed and on work lines with adjustable speed. Further strength of EMS is its quiet and clean operation. Vertical Adjusting Conveyor Vertical Adjusting Conveyors by Dürr stand for precise adjusting of height and maximum functionality. Its innovative belt technique allows minimized maintenance effort. Power & Free Exceedingly rugged and simple chain conveyors. The scope of application of this conveyor comes to the fore primarily where machining or processing operations do not coincide timewise with materials flow. Slat Conveyors The convincing features of this conveyor are its rugged chain drive and its high resistance to moisture, dirt and high temperatures. 8 Conveyor Systems System Elements FASmatic® FASmatic® is controlled by a high-capacity supervisory system and operates with inductive energy and data transfer. On-board batteries and pits are no more necessary and changes in the layout can be executed with minimized effort. TTS inverted TTS inverted is the floor guided version of the Dürr innovation Twin Trolley System® (TTS). The form-fitting drive system joins very high acceleration and exact positioning with minimized spare parts. Skillet Skillets, optionally with integrated lifting device, allow an optimum working level for each section. In touch with state-of-the-art part logistics, it sets up the backbone of innovative "just in sequence" production. Belt Conveyor / Modular Chain Conveyor As man movers and for vehicle body conveying, belt conveyors are popular in final assembly. The modular chain conveyor is a further development of the belt conveyor. It is insensitive against dirt and requires low maintenance effort. Skid Conveyor Plant layouts in body, paint and final assembly shops are no problem with skid conveyors. Thanks to modular design, all material flow functions can be built in a flexible manner. 9 F A S t r o l l e y 10 Technical Data and Dimensions Overall size 4” Overall size 6” Chain pitch 4” 6” Ultimate load approx. 220 000 N approx. 440 000 N Conveying speed (standard) 0.5 - 18 m/min 0.5 - 18 m/min Horizontal curves 15 - 180° 15 - 180° Vertical curves 10 - 35° 10 - 35° Max. payload capacity, double trolley approx. 2,000 kg approx. 2,400 kg Higher payload capacities with multiple trolley possible Overhead Conveyors FAStrolley Power & Free System Elements Rail system, including suspension, consisting of Power & Free rail in size 4”and 6” Chain, including pusher dogs Horizontal curves Vertical curves Transfers Trolleys Power & Free systems can be Owing to the simple, modular used both as overhead con- design, it is possible to imple- veyor systems and as floor con- ment different functions, such veyor systems (inverted P & F). as buffering, distribution, bran- In the automotive industry, ching or stopping very easily P & F conveyors are used for and at low cost. in-plant transport in all sectors P & F systems are very rugged from the body shop through the and can be used easily even paint shop to final assembly. under aggravated ambient Standardized components of conditions, such as high tem- various sizes are available for peratures or aggressive media various loads. or in welding lines. Drive station Tensioning station Switches Stoppers Lifting stations Control system Mode of Operation A Power & Free system consists of two rails arranged one above the other. A chain runs continuously in the upper rail (power rail) and this chain pulls the trolleys in the lower “free rail” by means of dog pushers. The bogies can be engaged and disengaged as required. 11 F A S t r o l l e y 12 Technical Data and System Elements EMS Light VDI 500 EMS Medium EMS Heavy-duty Aluminum profile (rail) 180 x 60 mm 180 x 60 mm 240 x 80 mm Payload capacity (hanger + load) 500 kg /trolley 750 kg /trolley 1,800 kg /trolley Transport speed up to 120 m/min 80 m/min 40 m/min Curves Switches Track lengh 15°/30°/45°/90° 15°/30°/45°/90° 15°/30°/45°/90° in the case of radius 1,000 and 1,500 mm 45° in the case of radius 750 mm Optional rotary switches unlimited unlimited 45° in the case of radius 1,000 mm unlimited Overhead Conveyors FAStrolley Electric Monorail System System Elements Rail, including energy supply (busbar or FASmotion) Single trolley Double trolley On-board control Horizontal curves Vertical curves Lifting stations The electric monorail system EMS Medium (EMS) is a modular-design over- up to 750 kg payload head conveyor system for trans- capacity per trolley: porting complete vehicles or ve- This version is used to trans- hicle bodies and also all pos- port bodies in white and heavy sible attachments, such as doors, components. The principal di- cockpits or seats. The principal mensions of the aluminum pro- dimensions are standardized in- file are 180 x 60 mm. Switches Hanger (with / without lift) Field of Application Vehicle body transport ternationally. This system offers all capabilities of line routing EMS Heavy-duty through an installation. It is also up to 1,800 kg payload possible to easily implement capacity per trolley: buffer functions, distribution This version is used to trans- functions and branch functions. port vehicle bodies in the area We are able to supply two ver- of vehicle final assembly. sions of electric monorail system. The principal dimensions of Transport of miscellaneous hardware and attachments, such as doors, cockpits and engines etc. the aluminum profile are 240 x EMS Light with 80 mm. 500 kg payload capacity per trolley: This version is used primarily for transporting attachments such as doors and cockpit and for powertrain components such as axles and engines. The dimensions of the aluminum profile are based on the VDI 3643 Regulation. 13 F A S t r o l l e y 14 TTS - Light TTS - Heavy TTS - Skillet Field of Application Field of Application Field of Application Transport of components, Transport of vehicle bodies, Combination of TTS with such as cockpits, doors and e.g. in final assembly skillet system. Used, for powertrain components instance, on work lines in final assembly Transportation is performed using TTS Heavy outside of the work lines Technical Data and Dimensions Type TTS - Light TTS - Heavy TTS - Skillet Payload capacity (hanger + load) 600 kg/2 trolleys 2,500 kg/2 trolleys 5,000 kg/4 trolleys 2,500 kg/2 trolleys 5,000 kg/4 trolleys Conveying speed on straight sections up to 150 m/min max. 40 m/min 3 - 7.5 m/min Conveying speed in curves max. 30 m/min max. 24 m/min – Overhead Conveyors FAStrolley Twin Trolley System® Basic elements Straight section Horizontal curve The innovative Twin Trolley appreciable wear. Provided System® with flexible hanger, the vehicle (TTS) with its modular drive concept overcomes bodies can be lowered to any upgrade sections without the working height. It is also pos- need for additional installations. sible to operate with an over- We can thus implement high head skillet line in the further speeds with no slip and no development, the Skillet TTS. Vertical curve System Elements Type TTS - Light TTS - Heavy TTS - Skillet Straight rail section 4/5/6/7/8 meters 4/5/6/7/8 meters 4/5/6/7/8 meters Curves 15°/30°/45°/90° at radius of 600 mm 15°/30°/45°/90° at radius of 1,500 mm –– Upgrade/downgrade section max. 30° max. 20° –– Switches 30°/45°/90° at radius of 1,500 mm –– 30°/45°/90° at radius of 600 mm Rail profile material (straight Aluminum section / curve / switch) extruded profile Aluminum extruded profile Aluminum extruded profile Track lengths unlimited with 1 push drive 36-84 m, longer lengths on request unlimited Switch Options Lifters Hanger (with / without lift) Preferred values in bold 15 F A S t r o l l e y 16 Technical Data Type Single scissors Double scissors Stroke up to 2,500 mm up to 4,500 mm Payload (car body) 3,000 kg 3,000 kg Lifting velocity max. 10 m/min max. 10 m/min Overhead Conveyors FAStrolley Vertical Adjusting Conveyor System Elements Overhead conveyors (EMS or TTS) Energy- and data transfer (non-contact with FASmotion or with bus bar) Upper frame with drive and safety equipment Lifting belts with integrated steel cables Lift scissors Subframe Load carrying equipment (C, T or 4-arm-hangers) Field of Application Overhead conveyor with vertical adjustment in BIW paint and final assembly With monorail and twin trolley Both continuous and intermit- systems, vertically adjustable tent ope-rations are possible. conveyor hangers can be used The application of belt techni- from the body shop right through que reduces the maintenance to the final assembly shop. Their requirements substantially. standardized modular design allows adjusting the height to the desired position and also meets high ergonomic requirements. The goods to be transported are loaded and unloaded by adjacent conveyors. 17 F A S f l o o r 18 Technical Data and Dimensions Standard Options Payload (skid+car body) 700/1,400/2,000 kg Skid length 4,800 mm 3,400 – 7,000 mm Transfer rate 60 units/h on request till max. 100 units/h Track 900 mm 650 – 1,150 mm Conveying height 500 mm on request Roller pitch 1,064 mm 864 / 1,264 mm Conveying velocity 24 m/min on request till max. 100 m/min – Floor Conveyors FASfloor Skid Conveyor System Elements Roller bed Excenter lift table Turn- / pivot table Transfer car Lifter for normal- und high temperature area Scissors lifting table (hydraulics, belt, spindle) Skid stacker Skid locking unit Transversal belt / chain Buffer belt / chain Suspension belt / chain Process conveyor through spray booth Process conveyor through oven (up to 220° C) RoDip Pendulum conveyor Skid conveyors are modular con- Dürr offers pre-mounted, pre- veyors customized to meet indi- installed and tested mechatronic vidual needs in body, paint and systems fitted with belts in the final assembly shops. Standar- normal temperature range (no dized mechanical and electrical lubrication, thus low mainten- systems using identical compo- ance requirements), and fitted nents permit keeping a reduced with chains in the high tempera- number of spare parts in stock ture range (up to 220° C). Thanks at maximum reliability (≥ 99.5 %). to modular design, all material Continuous and intermittent flow functions such as buffers operations are possible. and distribution systems can be built in a flexible manner. UBS-Shuttle Field of Application Skid conveyors for bodyshop, paint and final assembly Application in high temperature area Application in wet area Application in ex-area 19 F A S f l o o r 20 Technical Data Payload (tooling plate + work piece) 700 kg Conveying velocity on straight sections till 100 m/min Conveying velocity in curves max. 30 m/min Horizontal curve Radius = 1,000 mm Vertical curve Radius = 2,000 mm Floor Conveyors FASfloor Twin Trolley System® TTS Inverted Basic elements Straight section Horizontal curve The compact design of the Inver- the range and number of spare ted TTS conveyor system offers parts that have to be kept in good body accessibility and the stock. In addition, the skillet ver- incorporation of a toothed belt sion of this system has the advan- drive ensures exact positioning. tage of needing fewer drive units. Vertical curve The high acceleration that is possible with an Inverted TTS makes it an ideal system for shuttle Switch applications. Using identical technology for both overhead and floor conveyors reduces the number of different conveyor systems required and this in turn reduces Field of Application Floor conveyor in body shop, paint shop and final assembly Continuous and intermittent operations are possible For operation in demanding environmental conditions (dirt, temperature), the toothed belt can be replaced by chain 21 F A S f l o o r 22 Technical Data Chassis- and steering concept Payload (incl. tooling plate) Running velocity Energy transfer Line guidance Vehicle communication Superstructure Track length References 4-wheel-concept Single wheel-steering front + back 4-wheel-concept Center pivote platesteering front + back till 3,500 kg till 60 m / min FASmotion (non-contact) inductive (non-contact) via funk (WLAN) scissors lifting table, lifting device, tooling fixture unlimited VW Mosel (Golf A5) VW Mosel (Passat B6) BMW Leipzig, S-GM Shanghai MBUSI Tuscaloosa, KIA Zilina Floor Conveyors FASfloor FASmatic® System Elements Floor installation Stationary control Vehicle underframe with steering concept Lifting unit Tooling fixture (swimming function optional) Energy transfer FASmotion Line guidance Data transfer Safety equipment Onboard control Field of Application Floor conveying in discrete manufacturing – Dress-up area – Unit assembly / fitting – Sub-assembly conveying FASmatic® is a new floor con- designed freely, pits are no more veyor system which is mainly necessary. In energy supply, non- used in discrete manufacturing contact energy transfer FAS- for dress-up stations and the motion does replace batteries. marriage process in general This ensures trouble-free conti- assembly. It is applicable in con- nuous operation with high availa- tinuous flow as well as in stop bility and low maintenance effort. and go-operation and offers free access from all sides. Its modular control system is an open concept composed of standardized components. The layout of plant and path can be 23 F A S f l o o r 24 Technical Data and Dimensions Payload capacity 2,500 kg (vehicle body) Conveying speed 0.5 – 7.5 m/min. (adjustable) Useful stroke of lifting table approx. 1,000 mm Dimensions Length approx. 6,000 mm Width approx. 3,000 mm Other dimensions on request Floor Conveyors FASfloor Skillet Conveyor System Elements Skillets with/ without lifting table Lifting tables hydraulic/ with spindle/with belt Track Power supply busbar/ non-contact energy and data transfer FASmotion Main drive based on friction wheel Docking and undocking drives Roller beds Cross conveyors Lifters This system is used in the sec- an optimum working position. The skillets may also be moved tors of vehicle final assembly The skillet can be powered via on roller beds, lifters and cross and body shop. conventional busbars or also conveyors outside of the actual The skillets are suitable for foot using non-contact energy and skillet lines. traffic and may be equipped data transfer FASmotion. with various superstructures Besides the actual skillets, a for accommodating the vehicle skillet line contains the following bodies. If eccentric lifting tables chief components: docking are used, the working height drive, main drive, braking drive, of the vehicle body can be ad- undocking drive and roller strips justed variably so as to ensure on which the skillets lie. 25 F A S f l o o r 26 Technical Data Skid cross conveying Man mover Vehicle conveying Vehicle conveying special applications Case of operation Cross conveying for Skid in bodyshell work, paint and final assembly Conveying of men Conveying of vehicles on wheels Conveying of vehicles on wheels through leak test Distance between axles Standard till 15m Standard till 100m Standard till 100m Standard till 100m Payload 700/1,400/2,000 kg skid + workpiece 400 kg on 6m length 3,000 kg on 6m length 3,000 kg on 6m length Transportvelocity 4 till 20m/min 0.5 till 10m/min 0.5 till 10m/min 0.5 till 10m/min Width 1,400kg 2x100mm 2,000kg 2x200mm maximal 4m maximal 4m maximal 4m Floor Conveyors FASfloor Belt Conveyor / Modular Chain Conveyor System Elements Base frame with track Modular chain conveyor Drive unit Deflection unit, if applicable with braking drive Drive unit A distinction is made in the Basically, there are two types: Deflection unit Drive Base frame with track case of belt conveyors and modular chain conveyors in the Type 1: sector of vehicle transport bet- Wide belt with a width of ween man movers and con- approx. 1 to 4 m for transporting veyor belts for vehicle body vehicle body and, if applicable, transport. worker. Man movers: Type 2: These are normally 1 to 4 m- Twin-strand belt with a width wide belts on which the wor- of approx. 300 – 500 mm. Field of Application Skid conveying Man mover kers “ride” at the same process speed as the main line. The Modular chain conveyors are a vehicle body is transported low cost alternate to slat and in an overhead conveyor for belt conveyors as it is possible instance while the worker rides to replace single modules, and on a man mover below the their low structure calls for far vehicle body at the same speed smaller pit dimensions. In con- as the vehicle body itself. trast to belt conveyors, these Overhead operations can be conveyors are driven by form-fit configured ergonomically with connection and not by friction. this arrangement. Since it is not necessary to Vehicle body conveying Vehicle body conveying through leak test weld belts on site, maintenance Vehicle body transport: requirements, wear and tear The vehicle bodies are normally are notably lower than with transported with their wheels conventional belt conveyors. on the belt or the modular chain. 27 F A S f l o o r 28 Technical Data and Dimensions Distance between axles up to 200 m Payload capacity approx. 3,000 kg over 6 m length Transport speed 1 – 7.5 m/min. Width Double-strand version approx. 300 – 500 mm Single-strand version approx. 3,000 mm Floor Conveyors FASfloor Slat Conveyor System Elements Chain with slats Base frame Drive unit Deflection and tensioning unit Field of Application Transporting vehicle bodies Transporting vehicle bodies in the wet area (leak test) On slat conveyors, vehicle bodies are transported through the body shop or vehicles are transported through final assembly. Owing to the rugged chain drive and the high resistance to moisture and dirt, this system is ideally suited to welding areas in the body shop, the car final area and leak test in vehicle final assembly. 29