Leak Test Machines ICT Requirements

Transcription

1 Manufacturing Engineering General Assembly (MEGA.ICT _A.01) ICT Requirements

2 1) OVERVIEW This document summarizes the current ICT requirements for new to be purchased and installed in Fiat Chrysler Automobiles (FCA) US LLC Assembly Plants. This document is managed by the ICT Assembly System Launch Management Group (ASLM) of FCA US LLC. For the latest version of this document, please contact a member of this group. Please refer to the latest Corporate Controls Standards (previously known as the BOIG; Book of Implementation Guidelines) for specific controls information. Deviations to equipment from this document must be approved through the launch deviation process. 2) SCOPE This document applies to new equipment built from 12/1/2003 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 QAS operation guideline (Refer to ICT documentation for additional requirements) 1) A standard Fill machine is CLx based 2) A single Ethernet connection is required, 2 communications ports will be utilized, and one for solicited PFS data, the second for unsolicited QAS downloads. 3) QAS will be utilized to deliver style information to the processor. 4) Limit switches will be used by the OEM to track the position of their fill heads 5) The operation shall not be performed without a known valid VIN number 6) Pass/Fail fields should default to a Z (bypass) at the start of a cycle. As each test or function is executed, the appropriate Pass or Fail should be entered in the correct field. 7) A Handheld scanner is required for backup; Hand scanned data will override all VIN's currently in the machine. 8) Utilize a Panel view to allow the operator to correct failed read conditions; this Panel view will allow the operator to enter the correct VIN number, hand scanning should be performed prior to going to Panel-view and inputting manually the VIN Owner: ICT Launch Management Page 2 of 14 Revision: 2.2

3 4) GENERAL PROCESS FLOW This is a general process flow from the ICT perspective: 1) Vehicle enters station 2) QAS downloads unsolicited style information to processor 3) Processor acknowledges on same port that it has received the information 4) If no information received: a) Hand Scan VIN b) ALS (See ICT integrator for more information) c) Manual VIN entry 5) Operator performs fill operation 6) Machine send data to PFS 5) AVI (AUTOMATIC VEHICLE IDENTIFICATION) If a scanner is used in the system, then AVI standards apply, specifically to hardware model numbers and the requirement for items 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. If the system is CLx based: 1) A Barcode reader requires an ICT Clx processor in slot 9. AVI and PFCS drivers will be installed in this processor. 2) A QAS download with no barcode reader will require that PFCS drivers are installed in the OEM processor and no ICT CLX is required. 3) A QAS Download will require a handheld scanner as a backup. 6) FIS (FACTORY INFORMATION SYSTEM) This equipment is required to connect to FIS for diagnostic and production information reporting. Use the following bitmap to configure the equipment for FIS reporting. Owner: ICT Launch Management Page 3 of 14 Revision: 2.2

4 LEAK TEST BITMAP Word[Bit Number] DINT state_code TEXT 0[02-15] FAULTED GLx WRONGPROGRAM DOWNLOADED 0[16-31] FAULTED GLx MODULE FAULT 1[00-09] FAULTED Ipxx POWER CB NOT ON 1[10-12] POWER OFF DIAGNOSTIC POWER OFF 1[13-15] POWER OFF CONTROL POWER OFF 1[16-31] POWER OFF E-STOP PUSHED/SAFETY PINS PULLED 2[00-15] FAULTED E-STOP /C-STOP /SAFETY PINS FAULT 2[16-19] PROD STOP CYCLE STOP 2[20-31] SPARES SPARES 3[00-10] FAULTED I/O RACK FAULT 3[11-31] FAULTED MRS SAFETY FAULT 4[00-09] POWER OFF MASTERRESET REQUIRED 4[10-13] OUT OF AUTO CYCLE ENABLERESET REQUIRED 4[14-18] OUT OF AUTO FAULT RESET REQUIRED 4[19-25] OUT OF AUTO NOT READYFOR AUTO 4[26-31] OUT OF AUTO WAITING FORSTARTUP 5[00-01] OUT OF AUTO NO MODE SELECTED 5[02-12] OUT OF AUTO MACHINE MODES "MANUAL/ CALIBRATEMODE/ MAINTENANCE MODE/ NO MODE.etc" 5[13-14] BYPASS BYPASS MODE 5[15-16] BYPASS ADAPTOR REMOVED PHOTO-EYE BYPASSED 5[17-22] IDLE IN IDLE STATE 5[23-27] FAULTED MOTOR OFF 5[28-29] FAULTED AIR OFF 5[30-31] FAULTED FLUID OFF 6[00-09] FAULTED FILL MOTOR OVERLOAD TRIPPED 6[10-31] FAULTED TANK xx OVERFILL FAULT 7[00-09] FAULTED VALVE O/L TRIPPED FAULT 7[10-16] FAULTED VOLUME TRANSDUCER FAULT 7[17-31] FAULTED VOLUME SENSOR FAULT Owner: ICT Launch Management Page 4 of 14 Revision: 2.2

5 8[00-16] FAULTED VACUUM TRANSDRE FAULT 8[17-31] MAINT. ASSIST TANK xx OVERFILL FAULT 9[00-09] FAULTED BOOSTER EXTEND/EXTRACT FAULT 9[10-15] FAULTED ADAPTER CLAMP PRESS LOW 9[16-25] FAULTED ABS CPU FAULTS 9[26-31] SPARES SPARES 10[00-31] MAINT. ASSIST TANK xx LOW FAULT 11[00-15] FAULTED VACUUM SENSOR FAULT 11[16-31] SPARES VACUUM FAULTS/ALARMS 12[00-15] FAULTED PRESSURE SENSOR FAULT 12[16-31] FAULTED FILLOVER-PRESSURE FAULT 13[00-31] SPARES SPARES 14[00-15] FAULTED xxxnxx SHORTED SOLENOID FAULT 14[16-31] FAULTED xxxnxx OPENSOLENOID FAULT 15[00-31] FAULTED DNETNODE xx FAULT 16/17[0-31] FAULTED PFCS FAULTS EX. MAINT. ASSIST PFCS DRIVER'S FAULTS EX. MAINT. ASSIST PFCS SOL.RESPONSE ERROR EX. MAINT. ASSIST PFCS SOL.MESSAGE ERROR EX. MAINT. ASSIST PFCS SOL. MESSAGE RESP. TIMEOUT EX. MAINT. ASSIST PFCS UNSOL. RESPONSE ERROR EX. MAINT. ASSIST PFCS UNSOL. MESSAGE ERROR EX. MAINT. ASSIST PFCS UNSOL. MESSAGE RESP. TIMEOUT EX. MAINT. ASSIST PFCS NOCLIENT COMM DETECTED EX. MAINT. ASSIST PFCS ETHERNET SLOT ERROR EX. MAINT. ASSIST PFCS ETHERNET WCC IP ERROR EX. MAINT. ASSIST PFCS UNDEFINED STYLE RECEIVED 18[00-31] FAULTED E-NET COMMLOST TO CLX(xxx) FAULTS 19[00-10] ALARM STYLE CHANGED MANUALLY 19[11-15] FAULTED HMIxx COMMUNICATION LOST 19[16-19] STARVED BLOCKEDUP STREAM 19[20-23] BLOCKED DOWN BLOCKED DOWNSTREAM 19[24-31] ALARM PROCESSOR's ALARMS/CLx BATTERYLOW,.,etc Owner: ICT Launch Management Page 5 of 14 Revision: 2.2

6 20[00-15] FAULTED MODULES FAULTS 20[16-31] SPARES SPARES 21[00-31] QUALITY ALERT CYCLES FAULTS EX. QUALITY ALERT ADAPTOR VACUUM TEST CYCLE FAULT EX. QUALITY ALERT INITIAL PRES. CHECK CYCLE FAULT EX. QUALITY ALERT LEAKE TEST OVERALL TEST (P)ass/(F)ail EX. QUALITY ALERT VACUUM LARGE LEAK CYCLE FAULT EX. QUALITY ALERT VACUUM SMALL LEAK CYCLE FAULT EX. QUALITY ALERT FINAL VACUUM CYCLE FAULT EX. QUALITY ALERT VACUUM LEAK DECAY CYCLE FAULT EX. QUALITY ALERT FILL ABORT CYCLE FAULT EX. QUALITY ALERT FILL TIME EXCEEDED CYCLE FAULT EX. QUALITY ALERT STABALIZE TEAT (P)ass/(F)ail/(Z)NO TEST EX. QUALITY ALERT AIR TOLERANCE ALARMS EX. QUALITY ALERT AIR PRESSURIZATION TEST(P)ass/(F)ail/(Z)NO TEST EX. QUALITY ALERT FILL OVERPRESSURE CYCLE FAULT EX. QUALITY ALERT FILL VOL.< MINIMUM CYCLE FAULT EX. QUALITY ALERT/FAULTED PREMATURE PRESSURE FAULT EX. QUALITY ALERT/FAULTED HIGH CAR PRESSURE FAULT EX. QUALITY ALERT FILL VOL.> MAXIMUM CYCLE FAULT 22[00-01] MAINT. ASSIST PARAMETER CHANGES ADJUSTMENT/MODIFICATION 22[02-03] MAINT. ASSIST FLUID FILL PASS/FAIL-QUALITY ALERT 22[04-05] MAINT. ASSIST PARAMETER SCREEN NOTIFICATION/CHANGES USED BY PASSxxx 22[06-07] MAINT. ASSIST NOTIFICATION PASS. CHANGED 22[08-09] MAINT. ASSIST TIME COUNTER EXCEEDED LIMIT -MAINT. ACTIVITY 22[10-13] MAINT. ASSIST CALIBRATION CHECK/VERIFICATION VALUES CHANGED 22[14-15] MAINT. ASSIST FLUID PRESSURE SUPPLIES LOW-"UNDER SET POINT" 22[16-17] MAINT. ASSIST PORTABLE PUMPING STATION TOTES LOW 22[18-19] MAINT. ASSIST PORTABLE PUMPING STATION TOTES EMPTY 22[20-31] MAINT. ASSIST SPARES POWER 23[00-31] OFF/FAULTED/ALARM CIRCUIT BREAKERS/FUSES ALARMS 24[00-31] FAULTED SPARES Owner: ICT Launch Management Page 6 of 14 Revision: 2.2

7 25[00-31] FAULTED SPARES 7) PFCS (PLANT FLOOR COMMUNIATIONS SYSTEM) The device shall conform to PFCS Vendor Specifications: 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. Have a unique Machine ID(s) and DCNO Port(s) assigned by the Plant ICT group. 4. Use PFCS group-certified communication software (a combination of the hardware, firmware and software). No device will be connected to the FCA US LLC network until this certification process has been completed. 5. If operation requires unsolicited data downloads from PFCS (QAS), it must receive this download on a separate port. One port sends data to PFS and VIN requests to AVI, the other port receives unsolicited QAS VIN and Style data. 6. Utilize the USD communications driver. Owner: ICT Launch Management Page 7 of 14 Revision: 2.2

8 8) PFS (PERFORMANCE FEEDBACK SYSTEM) Every machine will be tested at the OEM's facility for its ability to communicate to PFS before delivery to the assembly plant. Please contact your ICT ASLM representative for more information. DATA FORMAT Start End Length Description Format Machine ID, PC01, etc Ack/Nak Area (spaces) Message Sequence Number (refer to PFCS vendor specs) Request Type (0002) Data Byte Count (position 22 to the end, exclude <CR>) Number Of Records In Block (0001) Filler Spaces Last 6 Of VIN Last 6 Of Track Number If VIN Is Zero Date and Time (YYMMDDHHMMSS) Leak Test Overall (P)ass/(F)ail (P/F) Fill (Vacuum 1) Test (P)ass/(F)ail/(Z)No Test (P/F/Z) Fill (Vacuum 1) Actual Value (inh2o) (x.xxx) Fill (Vacuum 1) High Tolerance (x.xxx) Fill (Vacuum 1) Low Tolerance (x.xxx) Fill (Vacuum 1) Time (xx.x) Fill with Monitor (Vacuum 2) Test (P)ass/(F)ail/(Z)No Test (P/F/Z) Fill with Monitor (Vacuum 2) Actual Value (inh2o) (x.xxx) Fill with Monitor (Vacuum 2) High Tolerance (x.xxx) Fill with Monitor (Vacuum 2) Low Tolerance (x.xxx) Fill with Monitor (Vacuum 2) Time (xx.x) Isolate Test (P)ass/(F)ail/(Z)No Test (P/F/Z) Isolate Actual Value (inh2o) +/ (x.xxx) Isolate High Tolerance +/ (x.xxx) Isolate Low Tolerance +/ (x.xxx) Owner: ICT Launch Management Page 8 of 14 Revision: 2.2

9 Isolate Time (xx.x) Stabilize Test (P)ass/(F)ail/(Z)No Test (P/F/Z) Stabilize Actual Value (inh2o) +/ (x.xxx) Stablize High Tolerance +/ (x.xxx) Stablize Low Tolerance +/ (x.xxx) Stabilize Time (xx.x) Leak Test (P)ass/(F)ail/(Z)No Test (P/F/Z) Leak Test Actual Value (sccm) +/ (xxx.xx ) Leak Test High Tolerance +/ (xxx.xx ) Leak Test Low Tolerance +/ (xxx.xx ) Leak Test Time (xx.x) Exhaust Time xx.x Exhaust Value +/ (x.xxx) Overall Cycle Time From Cycle Start to Exhaust Complete (Sec) (xx.x) Dealta Pressure Value (inh2o) +/ (x.xxx) Temperature Reading at end of Test Time (F) (xx.x) Temperature Change from Start to End of test (F) (xx.x) Future Test (P)ass/(F)ail/(Z)No Test (P/F/Z) Future Test Actual Value (sccm) +/ (xxx.xx ) Future Test High Tolerance +/ (xxx.xx ) Future Test Low Tolerance +/ (xxx.xx ) Machine Fault During Cycle (Y)es/(N)o (Y/N) Machine Fault Code (xxx) Console Number (1,2,3) or (A,B,C) (x) Leak Test Tool Used (1=non caplesee; 2=caplesss) (x) Operator Abort During Cycle (Y)es/(N)o (Y/N) Owner: ICT Launch Management Page 9 of 14 Revision: 2.2

10 Late Start (Past Start Zone) (Y)es/(N)o (Y/N) End of Travel Actuated During Cycle (Y)es/(N)o (Y/N) (H)and Scanner/(M)anual VIN entry/(q)as (x) Internal Program Style Selected (xx) Broadcast/QAS Download Style Received (xx) 9) QAS DOWNLOAD QAS Downloads will be sent unsolicited on the machine ID ending with a letter (example: DF0A). A handheld scanner shall be used as a backup device should QAS not be functioning. The handheld scanner will make its request, and gets its reply, on the machine ID ending with a number (example: DF01). This is a sample QAS style download for a Leak Test machine: Start End Len Field Name Machine ID s: DF0A, DF0B Spaces Description Message Sequence Number Refer to PFCS vendor specs Data byte count Position 22 to end, exclude <cr> Aa Broadcast Message Type Code Bc Last 6 of the VIN Label Barcode Vehicles status B=Model year C=plant code Owner: ICT Launch Management Page 10 of 14 Revision: 2.2

11 Track Sequence number Style download to device 00 Invalid style plant specific engine type 90 No Op condition Owner: ICT Launch Management Page 11 of 14 Revision: 2.2

12 10) ACCEPTANCE CRITERIA This is a summary of the ICT acceptance criteria required of the vendor; please refer to the FCA US LLC 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. FIS certification is required. 5. The following line items are examples of what must be tracked in the OEM timeline: 1. ICT Hardware Design 2. ICT Software Design 3. ICT Communications Testing At FCA US LLC (PFCS) 4. ICT System Testing At OEM (PFS Functionality) 5. ICT System Testing at FCA US LLC Assembly Plant Owner: ICT Launch Management Page 12 of 14 Revision: 2.2

13 DOCUMENT REVISIONS Doc. Rev. Date Doc. Rev. Number Doc. Rev. Description Section No. Revised 5/4/ Change Chrysler to FCA US LLC All Added step 3 in section 7. 7 Updated PFS Data String 8 6/26/ Added FIS bit map 6 Owner: ICT Launch Management Page 13 of 14 Revision: 2.2

14 Owner: ICT Launch Management Page 14 of 14 Revision: 2.2