Chassis Marriage Systems

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When Innovation & Performance Count
3rd Quarter 2005
Fori Automation News
Volume 2, Number 1
Page 1
Chassis Marriage Systems
Fori is in the process of designing a low cost and flexible chassis marriage system for supporting critical decking operations at
the Ford Oakville Assembly Plant. The process includes critical cart - carrier synchronizing for body to chassis secure. All
carts and tooling are Fori common with individual position-speed programmability of
cart travel and lift heights. Cart travel is designed for a “high speed” 12" /sec maximum
speed with a lift capacity of 4000 lbs. (1814 kg.), top tooling is designed to float +/- 5"
fore/aft and +/- 3" cross car for any sync-build variation potential. Fori patented electric
lifts will provide manual or automatic lift positioning up to a 38" (965 mm) lift height.
Pre-drilled holes on the front and
rear tooling plates provide for easy
and low cost modifications as future
product requires. This chassis
marriage system will include several
assembly stations followed by a
decking system that incorporates
both bottom and topside securing.
All operations are error proofed and
monitored by torque feedback and
component type select. Fori is near
completion of the Belvidere
installation and is testing a new
system for Sterling
Heights Assembly
Plant (SHAP).
Ergonomic
Open
Architecture
Chassis
Marriage
Cart
Ergonomic Electric Lift Cart
50955 Wing Drive, Shelby Township, Michigan 48315 Phone: 586-247-2336 Fax: 586-566-6773 www.foriauto.com
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Fori Korea
Wheel Alignment & Headlamp Aiming Systems
Fori Korea is installing it’s
first Digital Camera NonContact Wheel Alignment
system with integrated
Headlamp Aimer in
Namyang’s Research &
Development Center at
Hyundai Motors. The
system is designed to
accommodate all Kia
Motors and Hyundai
Motors vehicles.
Non-Contact Wheel Alignment
System with Digital Cameras &
In-Foor Headlamp Aiming System
Arvin Meritor Shanghai
UN Chassis Marriage
Line for KMC GwangJu #1
Fori Korea has delivered a low cost and
flexible chassis marriage system for
supporting critical decking operations at the
KIA Kwang-ju Plant in Korea. The process
includes 12 carts and a carrier
synchronizing for body to chassis secure.
The carts are supplied by aan electrified
busbar. Cart travel is designed for a “high
speed” 12" /sec maximum speed with a lift
capacity of 4000 lbs. (1814 kg.), top tooling
is designed to float +/- 5" fore/aft and +/- 3"
cross car for any sync-build variation
potential. Fori patented electric lifts will
provide manual or automatic lift
positioning up to a 38" (965 mm) lift height.
Pre-drilled holes on the front and rear
tooling plates provide for easy and low cost
modifications as future product requires.
This chassis marriage system will include
several assembly stations followed by a
decking system that incorporates both
bottom and topside securing. Decking line
to assemble the front engine/suspension
assembly& the rear suspension assembly of
UN vehicle body. It was delivered on July,
2005 by Fori Korea. And it can be applied to
RV vehicle such like Carens, KM, UN with
production volume of 50 jobs per hour or
200,000 units per year.
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Fori Korea has installed a
Sunroof Module Assembly
System for Shanghai Arvin
Meritor Automotive in China.
The system assembles the
sunroof’s for the Volkswagen
Polo and Passat. The system
consists of 8 main work
stations including a
functional tester for the
sunroof system. Fori Korea is
prepared and ready to support
the customer with quick and
reliable service from Korea as
well as China.
ArvinMeritor Shanghai China
Sunroof Assembly System
Low Profile Electric Lift Cart
INC.
Page 2
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When Innovation & Performance Count
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Fori Brasil
Production Line Fluid Fill Systems
The fluid fill system is designed with to be adapted to an existing structure or line. As a self contained unit, the system does
not rely on other controls or components. The open architecture of the unit allows it to be placed independent of other
systems. The small footprint allows more open floor space. An optional backup fluid fill system is designed to keep the
line moving if the line side system fails. The quick coupling adaptors ensure the filling of fluids at all production line rates.
The system is capable of supplying two (2)
different types of fluids at any one time. The
gearbox supplies 2 types of fluid; mineral and
synthetic. The gear box fluid
fill has been installed at Fiat as
a backup to the production
lines. The power steering
supplies 1 type of fluid and has
been installed at Volkswagen
do Brasil and a second system
at Audi do Brasil. Each system
is set to fill 45 jobs per hour.
All systems perform a leak
test, fill the reservoirs while
controlling pressure and level
the fluid level in the reservoir
at the end of the cycle.
Fluid Filling Station
Quick Coupling Adaptor
Parking Brake Setter / Tester
The parking brake setter / tester system is in used to set the correct tension of the parking brake cables.
One new system with a primary tester and a backup has been installed in Fiat do Brasil with a 50 job
per hour line rate. The 22 lb./10 kg.
unit is installed using a lift assist
into the vehicle prior to the
installation of the seats. Once
installed the tester begins to
move the lever up and down.
The system measures the
brake cable tension and
then uses an electric
wrench to adjust the
tension to within the
plants specification. The
wrench then tightens a
jam nut and returns the
lever to the home
position. All actions are
controlled by PLC with a
small user interface.
Page 3
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Fori Automation GMBH
Cockpit Installation
Semi-Automatic
Cockpit Manipulator
Fori Automation
GMBH designed and
installed a new semi-automatic cockpit manipulator for
integration of the Audi Q7 into the existing Volkswagen Polo seat
lines. The manipulator has an addition handling assembly to
secure the mounting brackets on the “A” pillar. The cockpit
manipulator is a free balancing system in the “Z” axis and is
manually moved in the “X” and “Y” direction via the operator.
The system is controlled pneumatically and has a 120 second
Assembly & Body Chassis Marriage
Fori Automation GMBH is finalizing the installation of several systems for Volkswagen / Audi Bratislava Assembly
Plant. Systems designed and installed for the Volkswagen Polo / Audi Q7 include; a friction roller conveyor, a pallet
sequencer, 17 pallets for the complete engine and drive units. Systems designed and installed for the Volkswagen
Touareg / Audi Q7 include; a conveyor system for 75 chassis pallets, a fastening system containing the complete
overhead structure and controls for each system at a line rate of
40 jobs per hour.
The Volkswagen Polo chassis marriage line included several
semi-automatic and automatic nutrunner stations. A complete
semi-automatic and automatic nutrunner stations were
developed and installed for theAudi Q7.
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Page 4
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Welding Systems
Magna Formex GMT 900 Frame Project
Fori Automation is nearing completion of
the first of 3 Systems for the GMT-900 SUV
Frame project at Magna Structural Systems'
- Formex Automotive Industries Plant in
RamosArizpe Coahuila, Mexico.
The plant produces Frames for General
Motors' Tahoe, Suburban, Yukon and
Yukon XL - 1500 series SUV's.
Fori's project scope includes six Sub
Assembly Cells per line, a Rear Sub Frame
Cell for each line, and Retro-Fit Kits to
convert each of the 3 the existing GMT-800
Final Frame Lines to produce the GMT-900
Frames.
When completed, the project will include
the integration of 92 material handling and
mig welding robots, and complete delivery
and integration of the equipment in the
customer's plant.
The three systems will have a total annual
capacity of more than 700,000 frames.
Magna / Formex
Robotic Frame Welding Station
Shiloh Industries Dickson Manufacturing
Division Nissan TK Program
Fori Automation has received a contract from Shiloh
Industries for Robotic Welding Systems for the
production of Multiple Welded Assemblies for Nissan's
TK vehicle program, at Shiloh's Dickson TN Plant.
Fori will Design, Build, Integrate, Deliver and Install 12
Robotic cells, with a total 23 Material Handling and
Welding Robots to produce 15 Under Body Sub
Assemblies for Nissan. The systems provide, Projection
Welding, Spot Welding, Mig Welding and Arc Stud
Welding operations, with individual assemblies requiring
up to 58 structural welds and up to 15 welded fasteners.
The systems will be capable of producing the assemblies
at a rate of just over 100 per hour, for a total annual
capacity of more than 300,000 vehicle sets.
Robotic Load / Unload Frame Welding Station
Page 5
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Lear Seat Installation System
Lear Seat Installation a Success
LEAR plants Bridgeton , St-Louis Missouri Ram quad cab truck Saltillo, Mexico Chrysler Mega can Ram truck 05/06
Janesville, WI---GMT-900 /800 seats for the suburban, Tahoe, escalade, 2nd and 3rd row seats for both the 800/900
program. Bing/Lear-custom pallets over/under accumulating conveyors ---controls-data collection/special positioning.
Lear Seat Systems
Synchronous, non synchronous, indexing, manual, and automatic are
modes of automated operation for assemblies Fori has provided systems
for custom engineered pallets, cushioned stops with 1mm of accuracy,
elevators and lowerators are all features that encourage increased
production and product flow.
The documentation, controls and part tracking systems are just a view of
the added custom features Fori offers, coupled with data collection as a
complete turn key solution. The part in place, part out of place, spatial
positioning systems, test and vision systems, inspection, lift assists,
automated gantry transfers and robots are optional features on the
assembly lines. Quick and responsive service, replacement parts,
and preventative maintenance have been all key pieces of Fori's
complete integrated automation solutions.
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Fori Automation Inc, recently introduced a new
automated seat assembly line for Daimler
Chrysler's Ram and Dakota heavy duty truck
lines through the Lear Corporation seat
assembly division. Fori Automation Inc has
specialized in modular conveyor systems for a
number of sub assembly component builders.
The synergistic integration of various
automation solutions and controls has been
proven to be a world class modular assembly
system. Fori Has adapted automated assembly
systems to be customized for different tooling
and optimum versatility therefore allowing the
lines to be assembled and disassembled for
reconfiguration during model or product
changes. The synchronized sequencer allows
for front and rear seats to be married up as a
final JIT requested module allowing Fori to
provide the vehicle with a matched lot set of
professionally assembled seats. The assembly
lines consisting of closed loop conveyor
systems, over and under, parallel, in-line,
rectangular, accumulating slat, belt, indexing
slat, palletized and non palletized conveyor
systems are just a few options offered as
configured assembly lines.
Lear Seat Station
INC.
Page 6
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Module Assembly Systems
Arvin Meritor System Delivered
Fori Automation is in the process of delivering a front module assembly line, rear module assembly line (with trailing arm,
rear differential line, sub-assemblies) andcoil-shock assembly fixtures to the ArvinMeritor Belvidere, Illinois facility
which feeds the DaimlerChrysler BelvidereAssembly Plant.
The front module line contains a 9 pallet operation on a low profile conveyor system. The rear module line is also a low
profile conveyor system and contains 14 pallets for operation. Sub assemblies to the rear module line include an automated
bushing press assembly; rear differential assembly with robotic tip applicator, half-shaft auto grease, combined differential
leak test & fluid fill system; and trailing arm assembly on an over/under conveyor system with brake line leak test. Net
cycle time is 43.0 seconds for
each module system. The dual
coil shock assembly fixtures
(four provided) can
accomplish a total combined
assembly of 8 coil-shock
units every 86 seconds.
Fori module assembly
s ystems are designed to
accommodate any level of
automation and volume.
Assembly fixtures are
designed for ease of assembly
& poke-yoke. The modular
assembly systems can contain
any or all of the following:
manual assembly, semi-auto
a s s e m b l y, f u l l y a u t o
assembly, manual transfer,
automatic transfer, manual
fastening, semi-auto
fastening, fully automatic
fastening, fully automatic
alignment, and full birth
certificate.
Rear Module Assembly System
Bushing Press
Page 7
Front Module Assembly System
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Mission Statement
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”.
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50955 Wing Drive, Shelby Township, Michigan 48315 Phone: 586-247-2336 Fax: 586-566-6773 www.foriauto.com