Ford Mustang Assembly...

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Reginald Shelton
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Ford Mustang Assembly... The AutoAlliance facility in Flat Rock, Michigan manufactures the Ford Mustang and the Mazda6. More than 3,700 employees work at this 2.7 million square foot operation.

More than 400 robots are used to make over 6,000 body welds on each vehicle. 61 robots and 10 automatic paint machines apply sealants, sound deadening and 19 paint colors.

1 Ford Mustang Assembly... The AutoAlliance facility in Flat Rock, Michigan manufactures the Ford Mustang and the Mazda6. More than 3,700 employees work at this 2.7 million square foot operation. AutoAlliance makes extensive use of CC-Link networking in the manufacture of approximately 1,200 vehicles per day. This application article describes the body assembly and paint operations. More than 400 robots are used to make over 6,000 body welds on each vehicle. 61 robots and 10 automatic paint machines apply sealants, sound deadening and 19 paint colors. The ease of assembly line start-up and excellent reliability of CC-Link has translated into a highly productive manufacturing facility. The speed at which these new lines were installed and comissioned resulted in significant savings in comparison to other networked systems used previously. Control engineers at AutoAlliance have commented that they have had no CC-Link network failures but that they have experienced a number of failures with Ethernet networks and with 2 other commonly used fieldbus networks.... Uses CC-Link

Conveyor System A series of conveyors, controlled via CC-Link, move car bodies through the numerous welding, assembly, and painting stations.

The motors that power the conveyors throughout the facility are controlled by Mitsubishi VFD Drives communicating via CC-Link.

However, the sophistication of the control system has changed greatly.

2 Conveyor System A series of conveyors, controlled via CC-Link, move car bodies through the numerous welding, assembly, and painting stations. Each vehicle travels approximately 13 miles in the course of production. Pictured here is a Power and Free (P&F) conveyor. The motors that power the conveyors throughout the facility are controlled by Mitsubishi VFD Drives communicating via CC-Link. An interesting fact concerning P&F conveyors is that, mechanically, the P&F conveyors are essentially the same as they were on Henry Ford s early assembly lines. However, the sophistication of the control system has changed greatly for example, the load on one particular conveyor line requires 2 motors each having its own networked Mitsubishi VFD drive in order to deliver sufficient power to the line. To do this the Mitsubishi controller must coordinate the drives to accomplish proper load-sharing between the 2 motors so that each motor provides an equal amount of torque to the conveyor line. 2 Typical Control Panel Shown here is one of the control panels for the Mustang sub-assembly within the Body Shop portion of the AutoAlliance facility. It handles the control for the assembly of the driver s side panel of the Mustang auto body. This panel includes a Mitsubishi Q Series Controller with five CC-Link network masters. One of the five networks provides communication between other control panels within the body shop. The other CC-Link networks handle control of the material handling equipment, robots and welding operations described below. There are approximately 125 control panels of this type within the Mustang Body Shop. The Mazda Body Shop in this AutoAlliance facility also uses approximately 125 control panels of this type to provide similar control functions for Mazda assembly.

3 Body Panel Assembly and Welding Operations CC-Link networking is also used to communicate and control the VFD drives that power the motors for moving a

Mounted on the JIG and connected to CC-Link are Mitsubishi IP67-rated I/O modules that control the various clamps and actuators.

A CC-Link network handles communication and coordination of the Kawasaki robots within this specific manufacturing cell.

3 3 Body Panel Assembly and Welding Operations CC-Link networking is also used to communicate and control the VFD drives that power the motors for moving a JIG bed. A JIG is a large fixture with remote pneumatic I/O that can clamp, fold and hold a section of the auto body. Mounted on the JIG and connected to CC-Link are Mitsubishi IP67-rated I/O modules that control the various clamps and actuators. Different JIG beds are used for different functions of the auto body assembly. There are numerous fixed and movable JIG beds. A CC-Link network handles communication and coordination of the Kawasaki robots within this specific manufacturing cell. Some of these robots move parts within the cell and other robots perform welding of the body panel assemblies. The CC-Link network initiates and stops robot movement and also enables the robots to communicate their positions to each other in order to avoid collisions.

connector There are multiple remote JIG beds in this cell, although only one remote JIG bed communicates with the controller at a time.

At this point the remote I/O on the JIG bed receives power and is connected to CC-Link to receive commands from the Q Series Controller.

The tight motor control necessary to plug and unplug each JIG bed from the network is communicated to the VFD drives via CC-Link.

4 connector There are multiple remote JIG beds in this cell, although only one remote JIG bed communicates with the controller at a time. When the time comes for the remote JIG bed to operate and communicate with the controller, the bed is automatically plugged into the network via a large connector. At this point the remote I/O on the JIG bed receives power and is connected to CC-Link to receive commands from the Q Series Controller. After the JIG bed completes its portion of the assembly operation, it is automatically unplugged and removed from the network. The tight motor control necessary to plug and unplug each JIG bed from the network is communicated to the VFD drives via CC-Link. With each JIG bed going on and off the network, this shows the capability of the CC-Link network to handle the removal and replacement of devices while operating under power without faulting the network. After the side panel is complete, another robot moves the panel onto a power & free conveyor. A line of CC-Link connected Kawasaki robots finishes welding the body panels together. There are approximately 400 robots in the Body Assembly portion of the facility. Each robot is connected to a Mitsubishi controller via the CC- Link network. One CC-Link network typically controls between 10 and 12 robots. In addition, Mitsubishi VFD drives control the pumps that provide coolant water to the robot welding guns. 4

5 Typical Operator Interface Panel Numerous Mitsubishi GOT Operator Interface Panels are used to depict production information and status on their LCD screens.

Upwards of 95% of the controls within the Body Assembly portion of the facility are connected via CC-Link.

Five different body types can be run through this line (Mustang Coupe or Convertible and Mazda6 Wagon, Hatchback or Sedan). Each body styles requires a different material application routine.

5 5 Typical Operator Interface Panel Numerous Mitsubishi GOT Operator Interface Panels are used to depict production information and status on their LCD screens. The VFD drives and Operator Interface Panels communicate to the PLC controllers via CC-Link. Upwards of 95% of the controls within the Body Assembly portion of the facility are connected via CC-Link. Application of Sound-Deadening Material CC-Link controlled ABB robots apply the LASD (Liquid Applied Sound Deadening) material and joint sealant within the body of the car prior to painting. Five different body types can be run through this line (Mustang Coupe or Convertible and Mazda6 Wagon, Hatchback or Sedan). Each body styles requires a different material application routine. The LASD replaces the mat insulation that previously was used and which had to be installed manually. Depending on the type of auto frame, the LASD and joint sealant can be applied to 12 different areas of the vehicle. As within the body shop, the CC-Link network tells the robots when and where to apply the material. It also provides a method of communication between the robots in order to prevent collisions while operating.

This LASD Body ID Operator Station is connected to the Q Controller via CC-Link.

then is communicated via CC-Link to the ABB robots to properly apply the LASD and joint sealant.

Paint Line Mitsubishi PLCs control the paint line where state-of-the-art Fanuc P500 robots apply the finish

6 This LASD Body ID Operator Station is connected to the Q Controller via CC-Link. The Operator Station utilizes lasers to scan the incoming vehicle frame to determine the body style, which then is communicated via CC-Link to the ABB robots to properly apply the LASD and joint sealant. The Operator Station can also be used to teach the LASD line to recognize a new body style. Paint Line Mitsubishi PLCs control the paint line where state-of-the-art Fanuc P500 robots apply the finish color. These robots can apply 24 different paint colors. After the finish color has been applied, another line of robots sprays two coats of clear paint over the vehicle body. 6

7 Pollution Abatement The AutoAlliance facility also uses the latest in pollution abatement equipment.

before being vented to the atmosphere. The process is called RCO for Regenerative Catalytic Oxidizer.

7 7 Pollution Abatement The AutoAlliance facility also uses the latest in pollution abatement equipment. The strong fumes generated during the body paint process are incinerated to neutralize harmful compounds before being vented to the atmosphere. The process is called RCO for Regenerative Catalytic Oxidizer. A Mitsubishi PLC controls the RCO process and communicates, via CC-Link, to 5 Mitsubishi VFD drives. Each VFD drive controls a 500 HP fan. The process involves exhausting the fumes from the paint line and passing the fumes through a catalytic oxidizer. There are 6 oxidizer beds (2 incinerators, 2 regeneration, 2 standby).

8 This CC-Link network used in the RCO process also includes a Mitsubishi 800 Series GOT Operator Interface to display current system status and to allow the operator to interact with the control system. 500 Corporate Woods Parkway Vernon Hills, Illinois USA Phone: Fax: info@cclinkamerica.org CC-Link Partner Association North America CLPA-1602

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