Fiat - Argentina - Wheel Aligner / Headlamp Aimer #16435

Transcription

1 2017 Fiat - Argentina - Wheel Aligner / Headlamp Aimer #16435 Wheel Aligner / Headlamp Aimer Operation & Maintenance Manual Overview Fori Automation Version 1.2 4/21/2017

2 TABLE OF CONTENTS Section 1.0 System Overview Control Panels System Units Operator J-Box Aimer Mast Pushbutton Box Stack Lights Section 2.0 Wheel Aligner Theory Section 3.0 Headlamp Aimer Theory Headlamp Aiming Theory Figures System Overview Fori Automation Version 1.2 Page 1

3 SECTION 1.0 SYSTEM OVERVIEW The Fori Automation 3-D Wheel Alignment system measures and adjusts toe, camber and caster. The system uses a multiple laser lines to accurately see the tire and its location. Fori s custom computer software calculates the adjustments that need to be made and they are displayed on one of the several flat panel displays. The front and rear tooling are placed in position by the operators and the adjustments are made automatically. Fori s digital headlamp aiming system aligns the plant supplied headlamps to government specifications. Fori s gantry style headlamp aimer system is designed to fit on the wheel alignment system. The main frame consists of heavy duty support legs and a structural aluminum position system. The mast is constructed of high grade aluminum (extrusion). Automatic vertical and horizontal positioning is accomplished using Emerson servo motors to +/- 1mm The digital aimer box consists of one digital processing camera with automatic shuttering to process a variation of headlamps for American, European, Japanese and all other lamp specifications. All data is processed through the industrial grade PC in the panel. Aiming accuracy +/ meters Optimal focal distance to lamp cm Safety sensors / bumpers are in place for safe travel. Semi-automatic screwdrivers are placed on the headlamp adjuster and automatically adjust the headlamp to within spec using Fori s software system. A verification laser is used to verify the headlamp aimer box returns to the proper home position. System Overview Fori Automation Version 1.2 Page 2

4 1.1 Control Panels Line voltage: 380 VAC 3PH 50Hz Control Voltage: 24VDC Control Voltage: 24 VDC Short circuit rating: 100,000 AMPS Full load amperage: 47.5 AMPS System Overview Fori Automation Version 1.2 Page 3

5 1.2 System Units The Fori Wheel Alignment / Headlamp Aiming System contains the following features: Unit Overview Machine Covers Fori Unit #810. Deck plating and structural steel risers, wheelbase track and measuring head covers with a center plate for crossing the machines. Vehicle Guides: Fori Unit #830 Solid tube guides for the inside of the tires. The guides are consist of a steel shaft and roller assembly to easily guide the vehicle while it enters the machine. Flip Up Wheel Stop: Fori Unit #970 Front of right hand floating plate. Prevents accidental drive off in cycle Wheel Aligner Base Frame: Fori Unit #1010 Main structure that compromises the wheel alignment machine. System Overview Fori Automation Version 1.2 Page 4

6 a. Unit Overview Steering Wheel Leveler: Fori Unit #1061 Aligns the steering wheel. Master Calibration Fixture: Fori Unit #1082 Calibrates the 3-D wheel aligner machine and the headlamp aimer. The laser and sight for calibrating the headlamp aimer is mounted to the fixture. 3-D Corner Assembly: Fori Unit #1178 Contains floating plates, cable centering and 3-D camera module. 3-D Measuring System: Fori Unit #1180 The 3-D measuring camera uses multi-line lasers to read the highest possible accuracy for reading toe, camber and caster. The unit has its own temperature control. Caster Sweep: During caster sweep toe and camber value samples (as measured on the tires) are collected and then used to calculate the caster at the end of the caster sweep cycle. System Overview Fori Automation Version 1.2 Page 5

7 b. Unit Overview Load cells measure the weight of each of the corners. Four sets of load cells under each floating plate, each with a 500 Kg measuring range. Output signals from these 4 cells are summed in the electronic summing circuit and then sent to AD103C amplifier. AD103C amplifier converts the signals to weight values (using info stored during calibration) and sends the weight values on request to PC. with weight measurement enabled, when the audit cycle is complete, the rollers stop and PC reads for about 4 seconds the raw weight values from each of 4 AD103C amplifier Weight transport carts. System Overview Fori Automation Version 1.2 Page 6

8 c. Unit Overview Gantry Style Headlamp Aimer: Fori Unit #1281 In-floor headlamp aimer. Digital Headlamp Aimer Box: Fori Unit #1318 Contains the image camera System Overview Fori Automation Version 1.2 Page 7

9 d. Unit Overview Semi-Automatic Screwdrivers: Fori Unit #1380 Automatically adjusts the headlamps. HLA Verification Laser: Fori Unit #1391 Locates the headlamp aimer box in the home position. System Overview Fori Automation Version 1.2 Page 8

10 1.3 Operator J-Box Start Cycle Push Button / Cycle in Process light. Starts the cycle and turns yellow when cycle is in process. Cycle Complete: Illuminates green when the cycle is complete. Mode Select: Auto Mode - Automatic production mode None No Mode, neither manual or auto Manual Mode: Allows maintenance personnel to manual control features of the system System Overview Fori Automation Version 1.2 Page 9

11 Auto Mode Initiate: When the system is in Auto mode this button initiates the automatic / production sequence. Master Start / E-Stop Reset: Powers up the system and resets an E-Stop. Emergency Stop stops all machine motion. Warning: Power is still supplied to the system when an E-Stop is pressed. Cycle complete light illuminates green when the cycle is complete. Cycle Stop stops the cycle. System Overview Fori Automation Version 1.2 Page 10

12 1.4 Aimer Mast Pushbutton Box Clear to move: press this after a fault or E-Stop has stopped the system motion and the reason for the interruption has been cleared / fixed. Aborts / stops the current cycle. Emergency Stop, stops all system motion. Warning: Power is still supplied to the system when an E-Stop is pressed. System Overview Fori Automation Version 1.2 Page 11

13 1.5 Stack Lights Green = Aimer OK Yellow = Mast moving Red = Fault Audible alarm = Fault / bumper tripped. System Overview Fori Automation Version 1.2 Page 12

14 SECTION 2.0 WHEEL ALIGNER THEORY Proper alignment prevents unreasonable and uneven tire wear and provides safer and easier vehicle handling, thus ensuring customer satisfaction. The FORI WHEEL ALIGNMENT MACHINE is a geometric alignment system that collects data and provides accurate and repeatable toe and camber results for front and rear toe angle adjustments. Data collection of alignment results helps plant personnel judge the quality of the production process and allows engineering to decide if their specifications are accurate or in need of revision. Knowledge of the wheel alignment definitions given below will contribute to a better understanding of alignment procedures. Tire and Wheel Runout Compensation: The calculation of true toe angle, taking the tire s out of roundness conditions into account. Surface irregularities (such as raised letters, bumps, or deformities) and mechanical wobble (induced by dirty drum rollers, loose bearings or lug nuts) must be accounted for if true toe values are to be obtained for use in alignment calculations. To compensate for tire and wheel runout, running averages are calculated over one tire rotation to derive the mean toe value. The geometric centerline of the vehicle is established by connecting a line between the theoretical midpoint of the front spindles and the theoretical midpoint of the rear axle. Geometric Centerline Wheel Aligner Theory Fori Automation Version 1.2 Page 13

15 A method of aligning tires based on angular measurements of tire sidewall surfaces referenced to the geometric centerline). These measurements are taken after the vehicle operator has leveled the steering wheel). Geometric Alignment Note: The different types of alignments offered today are front-end, thrust angle, and fourwheel. During a front-end alignment, only the front axle's angles are measured and adjusted. Front-end alignments are fine for some vehicles featuring a solid rear axle, but confirming that the front tires are positioned directly in front of the rear tires is also important. On a solid rear axle vehicle, this requires a thrust angle alignment that allows the technician to confirm that all four wheels are "square" with each other. Thrust angle alignments also identify vehicles that would "dog track" going down the road with the rear end offset from the front. If the thrust angle isn't zero on many solid rear axle vehicles, a trip to a frame straightening shop is required to return the rear axle to its original location. On all vehicles with four-wheel independent suspensions, or front-wheel drive vehicles with adjustable rear suspensions, the appropriate alignment is a four-wheel alignment. This procedure "squares" the vehicle like a thrust angle alignment, and also includes measuring and adjusting the rear axle angles as well as the front. Wheel Aligner Theory Fori Automation Version 1.2 Page 14

16 Thrust angle is an imaginary line drawn perpendicular to the rear axles centerline. The thrust angle compares the direction that the rear axle is aimed with the centerline of the vehicle. It confirms if the rear axle is parallel to the front axle and the wheelbase on both sides of the vehicle is the same. Thrust angle Thrust Angle Positive Thrust Angle The front tires are adjusted to the thrust angle of the rear tires. The geometric centerline is the reference line for determining the thrust angle. Negative Thrust Angle Two Wheel Alignment Wheel Aligner Theory Fori Automation Version 1.2 Page 15

17 All four toe angles are adjusted parallel to the geometric centerline of the vehicle Four Wheel Alignment Wheel Aligner Theory Fori Automation Version 1.2 Page 16

18 Caster Theory Caster is the angle between the centerline of the wheel and the steering axis when viewed from the side. Positive caster is when the top of the steering axis is tilted toward the rear of the vehicle. Positive caster helps the vehicle track straight when driving down the road; it also helps the wheels straighten out after turning. Cross caster refers to the difference between caster angles for wheels on the same axle. Left Caster minus Right Caster = Cross Caster If caster is not set evenly the vehicle will pull to the side having the smallest caster angle. Positive cross caster will cause the vehicle to pull to the right Negative cross caster will cause the vehicle to pull to the left Wheel Aligner Theory Fori Automation Version 1.2 Page 17

19 Camber Theory Camber is the angle between the centerline of the wheel and the vertical axis when viewed from the front. Positive camber is when the top of the wheel is tilted away from the center of the vehicle. Negative camber is when the top of the wheel is tilted towards the center of the vehicle. Wheel Aligner Theory Fori Automation Version 1.2 Page 18

20 Cross Camber Cross Camber refers to the difference between camber angles for wheels on the same axle. Left camber minus right camber = Cross Camber. If camber is not set evenly the vehicle will pull to the side having the more positive camber angle. Positive cross camber will cause the vehicle to pull to the left. Negative cross camber will cause the vehicle to pull to the right. Cross Camber Theory Wheel Aligner Theory Fori Automation Version 1.2 Page 19

21 Toe Theory Toe is the angle between the centerline of the wheel and the centerline of the vehicle viewed from above. Positive toe is when the front of the wheel is angled in towards the centerline of the vehicle, also referred to as toe in. Negative toe is when the front of the wheel is angled away from the centerline of the vehicle, also referred to as toe out. Sum toe is the left toe angle plus the right toe angle. Wheel Aligner Theory Fori Automation Version 1.2 Page 20

22 Individual Toe Individual toe is the angle drawn by a line drawn through a plane of one wheel referenced to the thrust angle line of the vehicle. Toe-in is when the horizontal lines intersect in front of the wheel. Toe-out is when the lines intersect behind the wheel. Wheel Aligner Theory Fori Automation Version 1.2 Page 21

23 Sum Toe Sum toe is the value obtained by adding the left and right individual toes on a single axle. Positive Sum Toe: Toe-In: Refers to the front of a tire that is pointed toward the centerline of the vehicle. Negative Sum Toe: Toe-Out: Refers to the front of a tire that is pointed away from the centerline of the vehicle. Sum Toe: The angle formed by the thrust line and geometric centerline. The thrust angle determines the direction of travel for the rear axle. An angle as close to 0.00 degrees is optimal. When the rear axle tracks to the right (positive thrust angle) or to the left (negative thrust angle), a condition known as Dog Trot develops, in which the vehicle appears to travel sideways down the road. Sum Toe Dog Trot Wheel Aligner Theory Fori Automation Version 1.2 Page 22

24 Clear Vision Obtained when the steering wheel is level at 0.00 degrees and the left and right toe angle are equal as the vehicle travels a straight-ahead course. Front toe bias or thrust angle will affect clear vision. Steering Axis Inclination The (SAI) Steering Axis Inclination angle is created and measured in degrees. It runs from the lower ball joint through the upper ball joint, or on most front wheel vehicles, through the center of the strut mount. The illustration uses ball joints to represent the angle. This measurement of degrees includes the measurement from lower ball joint to the upper ball joint or the upper strut mount and true vertical (the tire actually sitting straight up and down). The included angle is the fixed SAI with the camber angle included. This is the why it s called the included angle. The larger of the two angles is the included angle and the smaller the SAI angle Wheel Aligner Theory Fori Automation Version 1.2 Page 23

25 SECTION 3.0 HEADLAMP AIMER THEORY No two lamps, lenses or fog lights are completely identical in every way. FORIVISION can detect these changes and decide whether or not the headlamp has the proper intensity and shape. This maximum intensity beam or Fractional Balance (Method) Percentage, is then sensed and moved in the horizontal and vertical directions until it is aimed correctly. Vertical alignment aligns the driving lamps to shine onto the ground at a certain distance. Horizontal alignment converges the two lamps slightly together and positions them slightly right of center or as plant SAE standards specify. (Vehicles which are driven from the left front seat usually have the driving lamps aimed slightly right of center. Vehicles which are driven from the right front seat; as in European cars, usually align the lamps slightly left of center.) High beams or bright lights are aimed higher than regular lights and are much brighter, thus illuminating farther and helping the driver see over obstacles. They are slightly less converged, thus allowing the driver to see more of a panoramic area rather than a specified point. Fog lamps are also aligned horizontally and vertically. Some manufacturers pre-install these fog lamps on a bar before they are put into a vehicle, which pre-aligns the horizontal axis. It may not be adjustable, therefore, only the vertical adjustment may be required. Fog lamp aiming aims the light beam straight or slightly up. This light beam is also less dense, allowing it to shine underneath the fog and behind the fog. Driving lamps reflect off the fog and not through it, creating a reflection. See plant specifications and SAE alignment procedures for proper alignment angles and luminosity for your specific vehicle. FORIVISION can take the defined SAE/EEC lamp styles and align them. The final aim is determined at installation, based on data relative to vehicle and lamp type. Headlamp Aimer Theory Fori Automation Version 1.2 Page 24

26 3.1 Headlamp Aiming Theory Figures SAE Low Beam Light Board Requirements Note: 1. Horizontal center line of low beam headlamp bulb. 2. Vertical center line of low beam headlamp bulb. 3. Center line of vehicle. 4. Floor, from rear wheels to front wheels, must be level within +/ ' 2 B 1 3 A 3 4 Headlamp Aimer Theory Fori Automation Version 1.2 Page 25

27 SAE LOW BEAM VERTICAL C HEADLAMP L HORIZONTAL C HEADLAMP L TOP EDGE OF HOT SPOT 4'' 4'' LEFT EDGE OF HOT SPOT SPECIFICATION WINDOW 4'' 4'' HOT SPOT Distance is 25 feet away from headlamp Aim specification: The hot spot top edge and left edge has to be aimed within the angle window (8 ). Vehicle drives on the right hand side of the road, (steering wheel left or LHD). Headlamp Aimer Theory Fori Automation Version 1.2 Page 26

28 3.1.2 Japanese Low Beam Light Board Requirements Note: 1. Horizontal center line of low beam headlamp bulb. 2. Vertical center line of low beam headlamp bulb. 3. Center line of vehicle. 4. Floor, from rear wheels to front wheels, must be level within +/ ' European Low Beam Light Board Requirements Headlamp Aimer Theory Fori Automation Version 1.2 Page 27

29 Note: 1. Horizontal center line of low beam headlamp bulb. 2. Vertical center line of low beam headlamp bulb. 3. Center line of vehicle. 4. Floor, from rear wheels to front wheels, must be level within +/ ' 2 B " A 3 4 Headlamp Aimer Theory Fori Automation Version 1.2 Page 28

30 ECE - LOW BEAM HIGH BEAM FOG LAMP VERTICAL C HEADLAMP L A A HORIZONTAL C HEADLAMP L HOT SPOT HIGH BEAM D B C BREAK POINT CUT-OFF LINE LOW BEAM FOG LAMP Aim Specification: Low Beam - Break point on vertical center line within A. A is country dependent (guideline A = 5 cm / 10 m) Horizontal part cut off line B below horizontal centerline and (tolerance country dependent) (guideline B = min 10; max 15 cm / m) High Beam - Centered on vertical center line tolerance as low beam. C above cut-off line (C = 10 cm / 10 m) Note: C is fixed by construction to 10 cm / 10 m on combined headlamps Fog Lamp - D below horizontal center line no L/R adjustment D and tolerance country depending (guideline D = min 20 max 25 cm / 10 m) Headlamp Aimer Theory Fori Automation Version 1.2 Page 29

31 3.1.4 SAE Fractional Balance Aiming Method V H Highest intensity zone. 2 80% of the highest intensity zone. 3 70% of the highest intensity zone 4 50% of the highest intensity zone. 5 30% of the highest intensity zone. 6 20% of the highest intensity zone. 10.5" left H,V 5" down from H,V H, V intersection represents center of bulb at 25 feet Headlamp Aimer Theory Fori Automation Version 1.2 Page 30

32 3.1.5 Japan Fractional Balance Aiming Method V H Highest intensity zone. 2 80% of the highest intensity zone. 3 70% of the highest intensity zone 4 50% of the highest intensity zone. 5 30% of the highest intensity zone. 6 20% of the highest intensity zone. 10.5" left H,V 5" down from H,V H, V intersection represents center of bulb at 25 feet Headlamp Aimer Theory Fori Automation Version 1.2 Page 31