FORI AUTOMATION NEWSLETTER

Transcription

1 FORI AUTOMATION NEWSLETTER Issue 9 Privately held, U.S. Owned and Operated Since 1984 FORI AUTOMATION NEWSLETTER Mile Road Shelby Twp., MI USA Issue 9 NEW WELDING HEADQUARTERS IN THIS ISSUE Fori Opens New Welding Headquarters Fori Automation recently expanded its Global Headquarters with the addition of a new 50,000 square foot facility. The new building is conveniently located across the street from Fori s main building. The facility includes manufacturing and office space to support the continued growth of the company. The new facility was built to support the Welding Business Unit and its customers. Over the past three years Fori has experienced substantial growth within the Welding Business Unit. The Welding Business Unit focuses on Automated MIG, Projection and Spot Welding for the Automotive Industry. Fori Global Headquarters Expansion for Welding Business Unit Fori Automation recently expanded its Global Headquarters with the addition of a new 50,000 square foot facility. Welding Business Unit The dedicated Welding facility and business unit will continue to ensure that our Robotic Welding customers are provided with the highest level of service. The investment is a prime example of the continued support of growing the Robotic Welding business unit and its customer base. The facility was designed to accommodate the requirements of large weld lines, from the column width to power drops, Robotic Welding was the primary focus during the design and build of the new facility. Thanks to the addition of (55) new employees during 2017 and the added manufacturing space Fori will be able to better support our global customers. Fori USA now has over (260) employees at its Global Headquarters and over (650) globally. Fori is continuing to actively add members to the team in order to support the growth of the organization.

2 FORI AUTOMATION NEWSLETTER Issue 9 2 Fori China Celebrates 10 Year Anniversary We are proud to announce the 10 year anniversary of Fori China located in Beijing, China. Fori China s turnkey design and build capabilities have been instrumental in supporting Fori s customers in Asia and around the world. With over (250) employees, Fori China has proven themselves to be a prominent turnkey design and build system integrator. Fori China specializes in End of Line Test Equipment, Chassis Marriage Systems and Assembly Systems for the Automotive Industry. The Fori China team members pictured are the original six employees who started Fori China over ten years ago. It is the hard work and dedication of these key Fori China members that has helped grow the business and customer base in Asia and ensure our customers are supported around the globe The Fori China, offices founded provide open in late access 2007 recently and low celebrated wall cubicles their improve ten year inter-office reunion. communication and collaboration Fori New Product Development Powered Drive Wheel Systems: Powered Drive Wheels are modular drive wheels that can be mounted to tooling or work platforms for mobilization. The Drive Wheel systems utilize a standard control architecture that is expandable to support a variety of wheel configurations as required for added capacity.

3 FORI AUTOMATION NEWSLETTER Issue 9 3 Aerospace Assembly Systems Automated Guided Vehicles (AGVs) for Composite Wing Assembly Fori recently provided seven high capacity Aerospace AGVs for the automated transport of tooling for composite spar and panel assembly. The AGVs were designed around a specific tooling footprint and capacity, the system is capable of auto-leveling and synchronized transport of tooling up to 120,000 lbs. Where traditional aerospace assembly systems rely heavily on overhead crane utilization, The Fori AGVs will be the method for transporting the tooling and product through the plant and assembly process. The main goal of the project was to automate the material handling process for the assembly of the spar and panels. The vehicle is utilized for the load and unload of the autoclaves used for curing the composite wing components. The loading of the autoclave is completed utilizing a natural feature guidance system. The AGVs use the walls of the autoclave for guidance during load and unload, while still maintaining +/- 5mm accuracy. The system is required to transport a variety of tools with different lengths and weights. The AGV system is required to accommodate synchronization of up to three AGVs during the lift and transport between the various assembly stations. Each of the AGVs is outfitted with four servo lifters and a laser alignment system which provides measurement feedback to the onboard Safety PLC for the dynamic leveling of the tooling during transport. The system must maintain levelness of the tool within +/- 1/8 over the length of the 110 long tool. Aerospace Assembly Automated Guided Vehicles (AGVs) for Composite Wing Assembly

4 FORI AUTOMATION NEWSLETTER Issue 9 4 Automotive Module Assembly System Automated Suspension Assembly System for Front Vertical Automatic Hub Bearing and Rotor lateral runout test and assembly Knuckle and Splash Shield assembly Caliper installation and assembly Vision system inspection and verification of caliper selection and installation Vision verification of brake pad presence Automatic Front Coil over Shock assembly Automatic setting of Camber angle and marriage of Front Coil over Shock to Brake Corner Utilizing experienced resources, Fori developed a viable process, engineered the system, manufactured the equipment and integrated the assembly line at the end user. The Module assembly system has resulted in positive results for the customer and OEM. Caster Camber Pre-Set Fixture Fori recently supplied a system for setting the front suspension caster and camber alignment prior to the End of Line assembly equipment. The Caster Camber fixtures were built to fit within the existing assembly plant. The system proved to be a challenge to package in the already congested twin strand pedestal conveyor. The fixture hangs from an overhead rail system and is capable of locating and tracking with the vehicle frame as it passes beneath. The system lowers itself onto the vehicle frame, then pins and clamps to the frame establishing the control datum points to locate to. The machines two pivot arms swing in and clamp the upper and lower control arm ball joints. DC Nutrunners loosen the lower control arm fasteners. Servo motors position the X and Y location of the lower control arm. DC nutrunners secure the lower control arm into the correct location. The fixture unclamps and lifts off the frame then drives itself back to its home position ready to accept the next unit. The system consists of a fully integrated Safety PLC. The PLC has the ability to track and store faults, monitor and record positional and setting information as well as monitor all safety devices.

5 FORI AUTOMATION NEWSLETTER Issue 9 5 Automated Guided Vehicles (AGVs) Tunnel AGVs In order to increase flexibility the Tunnel AGVs are capable of docking to various companion carts, each serving a unique purpose. Applications include pallet transfer, lift tables and powered trunnions. Docking to the companion carts is completed with two docking pins. The docking pins ensure proper alignment to the companion cart for repeatable pick and drop. The Tunnel AGV was designed to minimize the total footprint. With a height of 14 the vehicle provides a high capacity material handling solution in a small footprint. The vehicle is comprised of two fixed drive wheels allowing for bi-directional travel and zero turn capability. Tuggers - Automated Guided Vehicles (AGVs) for Product Delivery Fori has further improved on its standard Tugger AGV design by doubling the overall towing capacity. Fori Tugger AGVs have been used for a variety of material handling applications within the automotive industry. Most recently Fori was tasked to supply a derivative of the standard Tugger product line that is capable of nearly double the capacity of the original vehicle, up to 35,000 lbs. The increase was for the transport of three carts, carrying axle assemblies for a large automotive OEM. Due to the capacity more product was transferred during each move, improving the return on investment for the end user and decreasing the required vehicles. The Tugger AGVs were commissioned to replace non-value added material handling tasks within the assembly process. The most important process considerations were safety and reliable delivery of product. Further improvement of the safety and reliability of the material handling system was the integration of a Fori Vehicle Management System (VMS). Vehicle scheduling for moves, tracking and traffic control is coordinated through the Fori VMS. The system also reports vehicle status, including safety, battery capacity, current moves, etc. The Fori Tugger is a proven and robust product that can be applied to a variety of material handling applications.

6 FORI AUTOMATION NEWSLETTER Issue 9 6 Automated Guided Vehicles (AGVs) for Chassis Marriage Fori recently designed and built a Chassis Marriage AGV utilizing induction power and magnetic guidance. Chassis Marriage has traditionally been completed with a Rail Guided Vehicle (RGV) and in floor track. The system has long been a robust and reliable solution, however some customers require additional flexibility to support the Chassis Marriage process. The Chassis Marriage AGV looks to improve on the RGV technique by utilizing induction power which provides a limitless power source and magnetic guidance which is a proven guidance technology for AGVs providing a high level of reliability and accuracy. Automotive Safety Systems Robot Safety System Robot Safety Systems are stand alone and can be integrated within existing Wheel Alignment systems. 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 Integration of collaborative robots has reduced to complexity of equipment required for calibrating Driver Assist Safety devices, and headlamp aiming, and provides flexibility for integrating new Driver Assist devices for future vehicle platforms. It also provides for an open architecture, allowing more space for walk through areas, and provides for a safe working environment increasing the return on investment to the plant.

7 FORI AUTOMATION NEWSLETTER Issue 9 7 Automotive Welding System Automated MIG Welding Assembly System for Front Suspension Cradles The Robotic MIG Welding system contains resistance spot welding, projection welding, drawn arc welding and a sealer application. The Robotic Weld system provided accommodated multiple structural end item assemblies that consisted of resistance spot welding, projection welding, drawn arc welding, as well as a sealer application. The system contained multiple welding cells with a total of (50) robots. The end item assemblies within this program were Load Beam R/L, Rear Quarter Inner R/L, Rear Closure Inner Assembly, Dash Assembly and Cowl Side R/L. Some welding cells utilized dial indexers to improve the efficiency of the robots. Some robots carried weld guns while others were material handling robots that moved the assemblies through pedestal welders (Spot, Projection and Drawn Arc) or pedestal sealers. Fori North America was responsible for Project Management, Engineering, Assembly and Integration. All cells were run off at Fori's global headquarters in Shelby Township, MI. Fori Mexico was responsible for installation and run off at the customer facility in Toluca, Mexico. Non- Manual Vertical Conveyor System for Rear Fender Assemblies Fori supplied manual push pallets on a vertical conveyor system consisting of a main build line and two vertical lift support stands for a rear fender line. Fori took a powered vertical conveyor system and redesigned it to a manual push pallet system based on cycle times and cost requirements. The redesign provided the customer increased flexibility for their process. The line was designed in modular sections for future expansion and increased production or added processes. Overhead support for tooling was a jib boom that bolted to the floor to remove the assembly to dunnage. The vertical conveyor system was integrated during the 1st quarter of The project was a great success for the customer and Fori Automation. The ability to be flexible with the pallet provided the potential to use the vertical conveyor for more than Rear Fenders or model changes.

8 FORI AUTOMATION NEWSLETTER Issue 9 8 Automated Assembly Line for Rear Suspension Modules Fori recently supplied a rear module suspension assembly line utilizing Fori Rail Guided Carts (RGCs) as a conveyance and assembly method alongside two fully automatic drive through alignment systems. The assembly line consisted of (22) RGCs, two drive-thru aligners, (16) operators & various torque tools. The product for the rear suspension module varied between AWD and RWD variations. The build pallet on top of each RGC accommodated those variants and manipulated the ride height setting of the five link suspension by manually setting the ride height wheel in the correct position verified by a switch on the pallet. A drive-thru aligner was also utilized within the system to streamline the process, a lift and locate was provided in each drive-thru aligner that would pick the pallet from the RGC and accurately present the suspension assembly for alignment. Utilizing Fori RGCs allowed for a timelier changeover. The RGC system also provided long term flexibility by accommodating future product changes, production increases that can affect station to station cycle times and production line shape if required. The assembly system was installed during the 4th quarter of 2016 and started production during the 1st quarter of Automated Assembly Line for Suspension Modules Fori recently retrofitted an existing assembly line to accommodate the integration of a new vehicle platform. The required changes to the existing front corner, rear corner, rear main line and front main line were accompanied by many challenges, including: JPH increase Minimal downtime during retrofit Increased product complexity Rework of two existing module aligners During extensive layout and process reviews all areas that required rework were identified, so a plan could be developed to add field kits which consisted of new portions of assembly line. In order to be flexible and to accommodate the heavy variation in product a number of robotic torque applications were added, each with a common trombone torque tool to be utilized on all module complexity types. In order to accommodate the new product two additional aligners were reworked from another plant and installed on a new conveyor section of the assembly line. The kitted portions of the assembly lines & aligners were installed during the 3rd quarter of 2017 and launched during the 4th quarter of 2017.

9 FORI AUTOMATION NEWSLETTER Issue 9 9 Automated Assembly Line for Axle Modules Fori recently supplied an assembly line for Axle Modules. The system consisted of a Fori twin strand conveyor with manual assembly stations, automatic Lateral Run Out (LRO) and End of Line robotic vision system. The required equipment was met with a few challenges and unique aspects: Inverted assembly and unload vehicle side up Unique LRO testing and retry methodology Inverted robotic vision verification Minimal area for assembly line Prior to testing the LRO, hub and rotor must be assembled on a test fixture complete with constant velocity and joint and hub fasteners tightened according to production standard and able to guarantee an axial load of 100 kn. Assembly Line for Rear Suspension Modules Fori recently supplied a Module Assembly System that included the Fori Flex Rail conveyance system utilizing Rail Guided Carts (RGCs) and a drive-thru Module Aligner for the assembly and alignment of a rear suspension module. The Module Assembly system had a unique set of design constraints, the floor space available for the required rear suspension module within the customer plant was limited and required a common unload area with an existing assembly line. Due to the oddly shaped footprint available for assembly and the mandated unload area the end user utilized Fori RGCs to accommodate their needs for a flexible material handling and assembly system. The system utilized a standardized Siemens control architecture, including the RGC, Traffic Control and Aligners. The standardization of Siemens controls was customer requested in order to match their existing controls architecture at the facility. In matching the controls architecture between all the equipment Fori was able to offer seamless integration into the customer's assembly plant. The rear main assembly line was composed of (15) RGCs, seven operators, one automatic drive through alignment machine and one manual backup alignment system. The assembly line was installed in February of 2017 and was production ready in March of 2017.

10 FORI AUTOMATION NEWSLETTER Issue 9 10 Aerospace Assembly Automated Guided Vehicles (AGVs) for Drill & Fill Mobile Robot Fori recently provided two high capacity Aerospace AGVs for the automated transport of a mobile robotic drill & fill system for a center fuselage section. The AGVs are capable of transporting mobile robotic platforms with weights up to 40,000 lbs. The Fori AGVs will be utilized for transporting the mobile robots between each of the necessary drilling stations. The AGVs were developed to increase system automation, flexibility and remove the traditional monuments that are generally required for automated drilling applications. The design intent was to build a vehicle that was modular and interchangeable. The AGVs were designed to accommodate multiple mobile robots. The Fori AGV is required to locate within +/- 5mm to an existing fuselage transporter. The Fori system utilizes a natural feature and camera based guidance system, which accommodates unexpected location of the transporter. The Fori system overcomes the variability of the fuselage transporters accuracy by measuring the surface of the transporter for final location of the robot. Once positioned, the mobile robot automatically docks to the transporter for power, communication and pneumatics. Automated movement is handled through the tethered Siemens Mobil Panel. The Fori AGV is responsible for safely and accurately lifting and transporting the two mobile robots between (16) different drill positions. Aerospace Assembly Automated Guided Vehicles (AGVs) for Composite Wing Assembly Fori recently provided six high capacity Aerospace Tugger AGVs for the automated transport of tooling, supporting the horizontal build line for a composite wing. The AGVs are capable of automated docking and transport of tooling up to 120,000 lbs. The Fori Tugger AGVs will be the primary method of transporting the tooling and product through the assembly process. The AGVs were developed to support the customers lean, automated manufacturing methodology. The design intent was to build a vehicle that was modular and interchangeable. The AGV system is required to transport nine different tools,all with different weights and footprints.

11 FORI AUTOMATION NEWSLETTER Issue 9 11 Automotive Chassis Marriage System Chassis Marriage Line with Rail Guided Vehicles (RGVs) Fori China recently designed, built and integrated a Chassis Marriage system utilizing Rail Guided Vehicles. Fori China was responsible for supplying the Rail Guided Vehicles (RGVs), associated track, overhead loader and PLC control system that controls the loop. The system has been a robust solution for many years, pushing Fori to become a leader in Chassis Marriage systems globally. The integrated system was a great success for the end user. Installation was completed during the 3rd quarter of 2017, which initial production beginning in August of The RGVs are based on Fori's long standing design and architecture. Each RGV includes two Fori patented servo controlled chain lifts for the synchronized lift and locate of the front and rear pallet. The RGV is focused on maintainability and simplicity for the end user. Automotive End of Line Wheel Alignment, Headlamp Aiming, Roll & Brake Testing An integrated headlamp aimer measures the vehicle headlight intensity and position automatically and guide the operator to adjust the lamp position semi-automated. The Fori Vision aiming unit utilizes a camera based system to measure the intensity and position of the headlight. Roll and brake testing is also completed on the End of Line system, which includes testing for the vehicle acceleration, cruise control, transmission, rear gear, dynamic braking and engine. The End of Line system was installed during the 1st quarter of 2017, with initial production beginning in March of 2017.

12 FORI AUTOMATION NEWSLETTER Issue 9 12 Automotive Chassis Marriage System Automotive Chassis Marriage Line Fori China recently designed, built and integrated a conveyor based Chassis Marriage system. The Marriage line is a sub-set of the trim and chassis final assembly system and delivers the completed front and rear modules to the Marriage line after being assembled. The project uses conveyance of the completed sub-assembly to the marriage line automatically where the complete chassis assembly will be automatically married and secured to the car chassis. The body carrier and frame are powered into the stations via asynchronous conveyors. The spindles index and begin securing the front module, differential cradle and rear module. All (14) fasteners must be torqued at the same time. There are three wheel base variations that have a common front module and center cradle position. An inspection station was supplied with the system. The station will provide positive verification that the details match the corresponding configuration of the vehicle sequencing through the assembly process. The vision inspection is completed at a stop station. The Marriage station includes an electro mechanical hook style body clamping device for models that require holding the body during the marriage process. An external actuator in the station is used to clamp the body to the pallet. Once married the overhead carrier drive is disengaged allowing the pallet conveyor to the move pallet/carrier assembly down the line. Automotive End of Line Wheel Alignment, Headlamp Aiming, Roll & Brake Testing Fori China recently installed a complete turnkey assembly line, including a Chassis Marriage system. The End of Line system included noncontact wheel alignment, automatic headlamp aiming and roll and brake testing. The Wheel Alignment machine is designed for automatic measuring and manual adjustment of the vehicle parameters. The system was designed to measure toe and camber. The system is designed for a wide range of wheel bases and wheel tread width and tire sizes. An integrated headlamp aimer measures the vehicle headlight intensity and position automatically and guide the operator to adjust the lamp position semi-automated. The Fori Vision aiming unit utilizes a camera based system to measure the intensity and position of the headlight. Roll and brake testing is also completed on the End of Line system, which includes testing for vehicle acceleration, cruise control, transmission, rear gear, dynamic braking and engine.

13 FORI AUTOMATION NEWSLETTER Issue 9 13 Automotive End of Line Systems Wheel Alignment, Headlamp Aiming, Roll & Brake Testing Fori China recently designed, built and integrated an End of Line system for wheel alignment, headlamp aiming and roll and brake testing. The End of Line system was integrated for a two vehicle inspection line. Testing completed included: non-contact wheel alignment, automatic headlamp aiming, roll and brake testing and testing for various vehicle sensors. The Wheel Alignment machine is designed for automatic measuring and manual adjustment of the vehicle parameters. The system was designed to measure Toe and Camber. The system is designed for a wide range of wheel bases and wheel tread width and tire sizes. An integrated headlamp aimer measures the vehicle headlight intensity and position automatically and guide the operator to adjust the lamp position semi-automated. The Fori Vision aiming unit utilizes a camera based system to measure the intensity and position of the headlight. Roll and brake testing is also completed on the End of Line system, which includes testing for acceleration, cruise control, transmission, rear gear, dynamic braking and engine. The End of Line system was installed during the 2nd quarter of 2017, with initial production beginning in May of Automotive End of Line Systems Wheel Alignment, Headlamp Aiming, Roll & Brake Testing Fori China recently designed, built and integrated an End of Line system. The End of Line system was included: non-contact wheel alignment, automatic headlamp aiming and roll and brake testing. The Wheel Alignment machine is designed for automatic measuring and manual adjustment of the vehicle parameters. The system was designed to measure Toe & Camber. The system is designed for a wide range of wheel bases and wheel tread width and tire sizes. An integrated headlamp aimer measures the vehicle headlight intensity and position automatically and guide the operator to adjust the lamp position semiautomated. The Fori Vision aiming unit utilizes a camera based system to measure the intensity and position of the headlight. Roll and brake testing is also completed on the End of Line system, which includes testing for acceleration, cruise control, transmission, rear gear, dynamic braking and engine. The End of Line system was installed during the 4th quarter of 2016, with initial production beginning in December of 2016.

14 FORI AUTOMATION NEWSLETTER Issue 9 14 Automotive Assembly System Assembly Line for Automotive Cockpit Fori China recently designed, built and integrated a Cockpit assembly line. The Fori China project aimed to improve the productivity and ease of assembly for the customers cockpit assembly. The manipulators were attached to a steel structure that is used for assisting the operator while installing the cockpit assembly into the vehicle. After the cockpit is attached to the manipulator it is conveyed to the install location, the goal is to reduce the potential of damage to the workpiece. Once the workpiece is located within the vehicle the manipulator holds the panel until tightening of the bolts is completed. The manipulator has improved production efficiency, reduced product damage, and most importantly improved safety for the operators. The integrated system was a great success for the end user. Installation was completed during the 3rd quarter of 2017, which initial production beginning in October of Module Aligner for Rear Axle Pre-assembly The Automated Dynamic Alignment cell is a drive through system that adjusts Camber and Toe. The unique aligner handles two vehicle models that have different geometry. Providing customized equipment such as this starts with a concept design phase. Fori engineering was first requested to complete a thorough engineering review in order to accommodate the rear axle assembly of the three vehicles. A challenging portion to any project is the ability to debug and tryout the process. This project had limited time for debug and startup. The key to success was analyzing every failure mode with precision in order to correct and provide results that would normally require more debug time. The system was comprised of an axle gripping unit that is used for locating and lifting the axle. An alignment unit is also utilized in order to increase repeatability. The adjustment and torque is completed with SEW drives and a special gear head. The new drive alignment cell was integrated during the 3rd quarter of Initial production started during December of 2017.

15 FORI AUTOMATION NEWSLETTER Issue 9 15 Automotive Assembly Automated Guided Vehicles (AGVs) for Body Shop Fori Germany recently supplied a custom designed AGV for an automotive Body Shop in Germany. Fori Germany supplied (16) AGVs for a body shop project. The vehicles were custom designed around the customer's process. The total capacity required for each AGV was 1,100 lbs. The AGV was responsible for carrying a car chassis between various assembly stations. Each vehicle consisted of two fixed drive wheels, an integrated scissor lift and a 24V lithium ion battery to power the vehicle. The system was based on an open controls architecture, utilizing a Siemens PLC for the vehicle control. The vehicle also included a custom scissor lift and battery. The custom designed scissor lift was built to accommodate the stroke and capacity required for the process. Each vehicle is capable of lifting 1,100 lbs., the scissor lift is capable of 21 of total stroke with a collapsed height of 11. The 24V, 67 Ah lithium ion battery was designed to fit within the available footprint on the vehicle. The system allowed for quick charging at the designated opportunity charge stations. Utilization of a lithium ion battery reduced the required charging infrastructure. Each vehicle utilizes a camera based guidance system that follows colored tape or paint. The optical guidance system provides a flexible, reliable and cost effective solution for guiding the vehicles throughout the assembly plant. The AGV system was installed during the 4th quarter of Workpiece Carriers for Front End Assembly

16 FORI AUTOMATION NEWSLETTER Issue 9 16 Automated Guided Vehicles (AGV) for Front End Assembly Line Automotive Stamping System Automotive Hot Stamping System Fori Mexico recently completed a relocation of an existing hot stamping line during production. Timing for this project was critical because it was going to take place during production. The customer was required to build a bank of stampings for production while the equipment was being relocated. The existing hot stamping line in Detroit was a singular process. The customer requested the new process in Mexico be a parallel process to improve the output of the system. Fori was responsible for engineering the new process. Fori developed the new system layout and completed all the robotic simulations with offline programming to verify the performance of the new parallel process system. The customer requested that Fori use as much existing capital as possible to help control cost, anything that was not available for reuse had to be built by Fori. The control architecture of the new system had to be redesigned by Fori as well. Once the engineering was completed and signed off, Fori Mexico managed the installation, integration, and run off of the new parallel process. Fori North America was responsible for Project Management, Engineering, and quoting.

17 FORI AUTOMATION NEWSLETTER Issue 9 17 Automotive Welding System Front Sub Frame MIG Welding / Projection Welding Systems Fori recently supplied a Robotic MIG & Projection Welding System for a Sub Frame Weld Line located in Mexico. The line consists of MIG welding, projection welding and clinch studs. The assembly line consists of (22) MIG welding robots and (10) Material Handling robots. MIG welding is the main process completed, but the line also has Vitronic post welding pierce station and cameras to scan welds for quality control, post welding pierce stations and machining centers for key attachment points and a Map vision system to verify dimensional accuracy. Fori USA was responsible for Project Management and Engineering for the program. Fori Mexico was responsible for building the line, debug and run off on their floor. The Robotic Welding system proved to be a successful collaboration between Fori USA and Fori Mexico. The front sub-frame line has a total capacity of 292,000 units. The line has a cycle time of (54) seconds. The ability to support the setup, buyoff and installation near the customer plant was of great value to the end user. Automotive End of Line Testing Advanced Driving Assistance Systems (ADAS) Fori Korea recently supplied an Advanced Driving Assistance System (ADAS) to accommodate several vehicle platforms and test a variety of safety features. The ADAS test bench certifies the operation of the vehicle cameras related to Lane Departure Warning (LDW), Automatic Head Lights (AHL), Over speed prevention (OSP), Traffic Signal Recognition (TSR) and Distance Warning (DW). The ADAS system also validates functionality of the vehicles radar system which detects the moving elements in front of the vehicle.

18 FORI AUTOMATION NEWSLETTER Issue 9 18 Automotive Chassis Marriage Automated Guided Vehicle (AGV) for Automotive Chassis Decking Line Fori Korea recently provided one battery powered automotive Chassis Marriage AGV for an electric car manufacturer. The battery powered Chassis Marriage AGV with dual independent lifters is capable of lifting and transporting 4,000 lbs. in order to install the front and rear suspension and drivetrain modules. The AGV was developed to support the end users lean, automated manufacturing methodology. Not only will the AGV enable the end user to reduce their hardware investment, there will be significant flexibility in the assembly process. The guidance system of the AGV and reduced plant infrastructure allow the AGV to easily interact with other systems and processes. The AGV is outfitted with multiple safety measures that ensure collision avoidance. The safety components include pressure bumpers and safety laser scanners. The Chassis Marriage AGV is responsible for accurate and repeatable location of product in station for a reliable chassis marriage process. The AGV will provide increased flexibility, safety and decreased product damage, thus increasing profitability within the project for the end user. Automotive Chassis Marriage Rail Guided Vehicles (AGV) for Automotive Chassis Decking Line The adjustability of the pallet allowed the Chassis Marriage system to meet the various engine decking points within the limited hanger pitch. The Chassis Marriage AGV system consisted of a single Traffic Control Panel for the (14) vehicles. The Main Control Panel ensured proper vehicle pitch and synchronization through the Chassis Marriage process. In order to ensure a smooth installation and buy off at the customer facility, the entire Chassis Marriage was setup, debugged and bought off on Fori Korea's floor before shipment to the end user.

19 FORI AUTOMATION NEWSLETTER Issue 9 19 Automotive Assembly System Automatic Transmission Indexing System Automotive Assembly System Assembly Line & Engine Decking System Fori India designed, built and integrated a Chassis Marriage Rail Guided Vehicle (RGV) system for Front and Rear assemblies. The Rail Guided Vehicle system supplied was comprised of a Fori standard Friction Wheel Drive for the required forward and reverse movement. The vehicle included two separate Electro-Hydraulic Scissor Lifts that are used for decking the front module and rear axle assembly. The system also included Wheel base adjustment that was required to accommodate multiple models for the rear axle assembly. Automotive Assembly System Engine Dress & Decking System Fori India recently designed, built and integrated a conveyor based Engine dress and decking system. The system was supplied to accommodate a new vehicle platform. The system was integrated into an existing assembly shop and was designed for (25) jobs per hour. The decking system supplied runs cross-car to the underbody conveyor line. The decking for the engine assembly is completed in a static position. A scissor lift was provided for vertical movement of the pallet. The decking system also included the engine dress conveyor and pallets, as well as a buffer conveyor with overhead hoist and rail system for loading the product on the pallet.

20 FORI AUTOMATION NEWSLETTER Issue 9 GLOBAL LOCATIONS Fori Automation Inc. Global Headquarters Shelby Twp., MI, USA Phone: Fax: Fori Automation China Beijing, BDA, China Phone: Fax: sales@foriauto.com Fori Korea Ltd. Sihung-Si, Korea Phone: Fax: Fori Automation India Pune, India Phone: /80 Fax: Fori Automation do Brasil São Paulo, Brazil Phone: Fax: Fori Automation GmbH Merzig Germany Phone: + 49 (0) Fax: + 49 (0) Fori Automation de México Saltillo, Coahuila, Mexico Phone: Privately held, U.S. Owned and Operated Since Publish Date: Issue March 1st, 2018 ISO 9001:2008 ISO 14001:2008 Certified / ITAR Certified / Cage Code M20746