WHEEL LUG NUT MACHINES

Transcription

1 1) OVERVIEW This document summarizes the current ITM requirements for new Wheel Lug Nut Torque Machines to be installed in Chrysler Assembly Plants. This document is managed by the ITM Assembly System Launch Management Group (ASLM) of Chrysler. For the latest version of this document, please contact a member of this group. Please refer to the BOIG (Book of Implementation Guidelines) for specific hardware part numbers. Deviations to equipment from this document must be approved through the launch deviation process. 2) SCOPE This document applies to new equipment built from 3/1/2003 forward. It does not imply that any existing equipment shall be modified to meet these requirements. It can be used as a reference for existing equipment that is being refurbished. 3) OPERATION OF EQUIPMENT 1. A standard Wheel Lug Nut Machine is PC Based 2. Chrysler ITM shall specify the make and model of PC to be used in the machine. This shall ensure that the plant will be able to provide hardware support. 3. Chrysler ITM shall need to approve the operating system to be used on the PC. (Typically called the software slam ) 4. The equipment must be capable of detecting the wheel (front vs. rear and left side vs. right side) on which the current torque operation is being performed. 5. Send a unique PFCS machine ID for each wheel 6. The equipment must be capable of operating in plants with or without QAS. 7. In QAS mode: The Quality Alert System (QAS) will be used to sequence the operator terminals. The lug nut machine will send a VIN of to PFCS at the completion of each cycle. The machine must be capable of accepting style download information. 8. In non QAS mode: Owner: F. Moore Page 1 of 8 Revision: 1.8

2 The Lug Nut Machine shall utilize a fixed barcode scanner to identify the vehicle s VIN from the windshield label. This machine shall send the VIN number to PFS. A scanned VIN must be held in a buffer if a torque operation is in process A screen must be provided to allow an operator to enter the correct VIN in the case of a scanner no read. If no valid VIN is scanned or entered, the torque operation will be allowed to continue, and a default VIN of will be sent with the torque data. The vehicle will be flagged in PFS as a fail 9. Monitor, process (set pass and fail), and transmit both torque and angle values. 10. Have a user settable minimum torque threshold value that at least one of the spindles must achieve before data is sent to PFS. (Don't send a package of 0 torque or angle value's) 11. Send a fail for both the Overall data packet, and each individual spindle that is set in bypass mode. 12. PFS shall not set up problem description codes to identify specific spindle numbers, as it is impossible to positively relate a particular lug nut with a spindle number after the vehicle has left the torque station. 13. AME s process requires a repair person to torque all nuts on a failed wheel. 4) GENERAL PROCESS FLOW This is the process flow from the ITM perspective: 1. Vehicle enters station 2. Non-QAS: Limit switch signals the PC to turn barcode scanner on. 3. Non-QAS: Scanner reads VIN into PC 4. Non-QAS: PC turns scanner off 5. Operator torque's the front wheel. 6. Results are sent to PFS with machine ID LUG1 (front left wheel) or LUG2 (front right wheel). The torque controller will send one message for each wheel with all torque values for that wheel included. 7. Pass/Fail Information is sent to the PFS screen 8. AME s process does not allow the operator to repair fails in station 9. Operator torque's the rear wheel. 10. Results are sent to PFS with machine ID LUG3 (rear left wheel) or LUG4 (rear right wheel) and scanned VIN. 11. Vehicle exits station Owner: F. Moore Page 2 of 8 Revision: 1.8

3 5) AVI (AUTOMATIC VEHICLE IDENTIFICATION) If QAS sequencing is used, barcode scanning is not required. If QAS is not used, then AVI standards apply, specifically to hardware model numbers and the requirement of the PC to duplicate PLC functionality, such as beam control and stack lights. Refer to BOIG documents , (PLC-5 implementations) or (CLx implementations), and (PLC-5 implementations) or (CLx implementations), for detailed AVI Reader Implementation information. 6) FIS (FACTORY INFORMATION SYSTEM) Lugnut machines are not required to connect to FIS. 7) PFCS (PLANT FLOOR COMMUNIATIONS SYSTEM) The device shall conform to PFCS Vendor Specifications, BOIG Document : 1. The connection to PFCS shall be made via Ethernet (TCP/IP). (Must be made through a dedicated NIC, not through a switch or router internal to the machine) 2. Have a unique IP address assigned by the plant. 3. Use PFCS group-certified communication software (a combination of the hardware, firmware and software). No device shall be connected to the Chrysler network until this certification process has been completed. 4. Use a machine ID format of LUG1 (front left), LUG2 (front right), LUG3 (rear left), LUG4 (rear right). The next machine would use machine ID s LUG5 - LUG8. 5. Send torque data as one PFCS message for each wheel. 6. All messages sent back and forth to PFCS shall be logged into a file on the Lugnut PC and kept for 96 hours. Documentation must be provided directing maintenance personnel in how to read and access this file. This is useful for debugging communications problems. 7. Utilize the PFCS recommended DLL software module as the basis of your communications driver. The latest version will be specified by your ASLM contact. Owner: F. Moore Page 3 of 8 Revision: 1.8

4 8) PFS (PERFORMANCE FEEDBACK SYSTEM) Every Lug Nut Machine shall be tested at the OEM's facility for its ability to communicate to PFS before delivery to the assembly plant. Contact your ITM ASLM representative for more information. DATA FORMAT Start End Len Description Machine ID, LUG1 - LUG4 or LUG5 - LUG Spaces Message Sequence Number (refer to PFCS Vendor Specs) Data byte count (position 22 to the end, exclude <CR> Spaces Last 6 of the VIN (Zero's) Date and Time (YYMMDDHHMMSS) Overall Pass/Fail (P/F) Pass/Fail of First Measurement Spindle number (01-x) Torque Status (Pass or Fail) Torque High Limit Torque Low Limit Torque Reading Angle Status (Pass or Fail) Angle High Limit Angle Low Limit Angle Reading Results for Spindle Results for spindle 3 Etc. Results for spindle 4-x. Owner: F. Moore Page 4 of 8 Revision: 1.8

5 9) SYSTEM ARCHITECTURE NON QAS B a r c o d e S c a n n e r R Y G B P F C S V e h ic le RS-232 Ethernet V e h ic le S e n s o r ( L S o r P /E ) V e h ic le S e n s o r ( L S o r P /E ) C o n v e y o r M o v e m e n t Owner: F. Moore Page 5 of 8 Revision: 1.8

6 10) ACCEPTANCE CRITERIA This is a summary of the ITM acceptance criteria required of the vendor; please refer to the Chrysler Do s and Don ts for more detail. 1. PFCS certification must be completed before: The device can be attached to the plant network PFS data certification can be conducted 2. PFS certification must be complete before the device ships to the plant. 3. AVI standard point certification must be followed if an AVI barcode reader is used; this includes testing at the OEM prior to equipment shipping. 4. No FIS certification is required. 5. The following line items must be tracked in the OEM timeline: 1. ITM Hardware Design 2. ITM Software Design 3. ITM Communications Testing At Chrysler (PFCS) 4. ITM System Testing At OEM (PFS Functionality) 5. ITM System Testing at Chrysler Assembly Plant Owner: F. Moore Page 6 of 8 Revision: 1.8

7 Document Revisions Doc. Rev. Date Doc. Rev. Number Doc. Rev. Description Section No. Revised 10/29/ Second draft All 12/10/ Add QAS TNG as a requirement (does not support QAS TFG. Add wording requiring a viewable history file for communications. 2/20/ Multiple changes after AME review 1,2,3 3/3/ First official Release, paragraph numbers added. All 5/1/ Remove ambiguity Remove The assumption is made 3.1 Make QAS the preferred sequencing method 3.5 Clarify that there is one PFCS for each wheel 4.6 Add QAS wording that no AVI is required if QAS 5 Remove RS-232 option 7.1 Remove barcode option eliminating section Add BOIG wording to AVI documents 5 Clarify terminal sequencing methods 3.7,3.8 Refer to Do s and Don ts for Acceptance section 10 Add exact wording for OEM timelines 10 10/26/ Clarify QAS vs. non QAS Mode 3 Clarify scanner operation Change 48 hours to 96 hours 7.6 Revise timeline wording /11/ Expand BOIG 1 Acceptance criteria clarified /02/ Add QAS Style download Owner: F. Moore Page 7 of 8 Revision: 1.8

8 Owner: F. Moore Page 8 of 8 Revision: 1.8