BRAKE Fill Machines ICT Requirements

Transcription

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

2 1) OVERVIEW This document summarizes the current ICT requirements for new machines 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, 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 15 Revision: 3.4

3 Fixed Scanner Operation (Refer to ICT documentation for additional requirements) 1) A standard Fill machine is CLx based 2) A fixed barcode scanner shall be used to identify the Vehicle Identification Number (VIN). 3) Fixed scanner operations will request Style information from AVI utilizing the PFCS Ethernet network (DCM network connection not required). 4) Utilize a limit switch, beyond which the incoming VIN number scanned by the fixed reader is buffered until the current operation is complete. 5) Have a handheld scanner for backup purposes. 6) 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 be performed prior to going to Panel-view and inputting manually the VIN 7) Hand scanning operations will request Style information through PFCS to AVI. 8) Hand scanned data will override all VIN's currently in the machine. 9) Send the VIN number to PFS along with the process data in the format specified below. 10) The operation shall not be performed without a known valid VIN number. 11) 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 4) GENERAL PROCESS FLOW This is a general process flow from the ICT perspective: QAS Operation 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 Fixed Scanner Operation Owner: ICT Launch Management Page 3 of 15 Revision: 3.4

4 1) Vehicle enters station 2) Limit switch signals the PLC to turn barcode scanner on 3) Scanner reads VIN into PLC 4) PLC turns scanner off 5) PLC Requests style information from AVI 6) Equipment signals to operator if valid style information has been read. 7) If no information received, a. Operator scans using handheld barcode reader. b. Equipment requests style information from AVI through PFCS. 8) Operator connects equipment to vehicle. 9) If a valid VIN is identified, and style information is received, the Operator performs the machine function. 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 4 of 15 Revision: 3.4

5 BRAKE FILL 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 Owner: ICT Launch Management Page 5 of 15 Revision: 3.4

6 7[17-31] FAULTED VOLUME SENSOR FAULT 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 Owner: ICT Launch Management Page 6 of 15 Revision: 3.4

7 19[24-31] ALARM PROCESSOR's ALARMS/CLx BATTERYLOW,.,etc 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 BRAKE EVAC & FILL OVERALL (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 BRAKE ADAPTER SEAL CHECK (P)ass/(F)ail/(Z)NO TEST EX. QUALITY ALERT BRAKE TOLERANCE ALARMS EX. QUALITY ALERT FILL TIME EXCEEDED CYCLE FAULT 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 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 PARAMETER SCREEN NOTIFICATION/CHANGES USED BY 22[04-05] MAINT. ASSIST 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 7 of 15 Revision: 3.4

8 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. Simply put, 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 8 of 15 Revision: 3.4

9 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. Ideally this test will consist of running the equipment, filling bottles, and creating Pass/Fail conditions to verify every field below. 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) Brake Evac & Fill Overall (P)ass/(F)ail (P/F) Vacuum 3 Seconds (mmhg) (xxx) Vacuum 6 Seconds (mmhg) (xxx) Vacuum 9 Seconds (mmhg) (xxx) Vacuum 12 Seconds (mmhg) (xxx) Vacuum 15 Seconds (mmhg) (xxx) Vacuum 18 Seconds (mmhg) (xxx) Vacuum 21 Seconds (mmhg) (xxx) Vacuum 24 Seconds (mmhg) (xxx) Vacuum 27 Seconds (mmhg) (xxx) Vacuum Time To 50 mbar (Sec) (xx.x) Large Leak Test (P)ass/(F)ail/(Z)No Test (P/F/Z) Large Leak Value (mmhg) (xxx) Large Leak High Tolerance (mmhg) (xxx) Owner: ICT Launch Management Page 9 of 15 Revision: 3.4

10 Large Leak Low Tolerance (mmhg) (xxx) Final Vacuum 1 Test (P)ass/(F)ail/(Z)No Test (P/F/Z) Final Vacuum 1 Value (mmhg) (xx.x) Final Vacuum 1 High Tolerance (xx.x) Final Vacuum 1 Low Tolerance (xx.x) Vacuum Decay Test (P)ass/(F)ail/(Z)No Test (P/F/Z) Vacuum Decay Value (mmhg) (xx.x) Vacuum Decay High Tolerance (xx.x) Vacuum Decay Low Tolerance (xx.x) Vacuum 2 Time Set Point (Sec) (xx.x) Vacuum 2 level (mmhg) (actual vacuum end of V2) (xx.x) Clamp Pressure (psi) (xxxx) Initial Fill Pressure Test (P)ass/(F)ail/(Z)No Test (P/F/Z) Initial Fill Pressure Value (PSI) (xxx) Initial Fill Pressure High Tolerance (xxx) Initial Fill Pressure Low Tolerance (xxx) Final Fill Pressure Test (P)ass/(F)ail/(Z)No Test (P/F/Z) Final Fill Pressure Value (PSI) (xxx) Final Fill Pressure High Tolerance (xxx) Final Fill Pressure Low Tolerance (xxx) Brake Fill Volume Test (P)ass/(F)ail/(Z)No Test (P/F/Z) Brake Fill Volume Value (ml) (xxxx) Brake Fill Volume High Tolerance (xxxx) Brake Fill Volume Low Tolerance (xxxx) Brake Fill Time Test (P)ass/(F)ail/(Z)No Test (P/F/Z) Actual Brake Fliud Fill Time (Sec) (xx.x) Brake Fill Time High Tolerance (xx.x) Brake Fill Time Low Tolerance (xx.x) Overall Cycle Time From Cycle Start to Unclamp (Sec) (xxx.x) Machine Fault During Cycle (Y)es/(N)o (Y/N) Machine Fault Code (xxx) Owner: ICT Launch Management Page 10 of 15 Revision: 3.4

11 Constant P (for ICT use) (x) Fill Type (V) Volume Fill, (P) Pressure Fill (x) Console Number (1,2,3) or (A,B,C) (x) Operator Abort During Cycle (Y)es /(N)o (Y/N) 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) Constant P (for ICT use) (x) Internal Program Style Selected (xx) Broadcast/QAS Download Style Received (xx) 9) ACCEPTANCE CRITERIA QAS Downloads will be sent unsolicited on the machine ID ending with a letter (example:bf0a). A handheld scanner shall be used as a backup device should QAS not be Owner: ICT Launch Management Page 11 of 15 Revision: 3.4

12 functioning. The handheld scanner will make its request, and gets its reply, on the machine ID ending with a number (example: BF01). This is a sample QAS style download for a Brake fill machine: Start End Len Field Name Description Machine ID s: BF0A, BF0B Spaces Message Sequence Number Refer to PFCS vendor specs Data byte count Position 22 to end, exclude <cr> Broadcast Message Type Code Aa Bc Last 6 of the VIN Label Barcode Vehicles status Track Sequence number Style download to device B=Model year C=plant code 00 Invalid style plant specific engine type 90 No Op condition Owner: ICT Launch Management Page 12 of 15 Revision: 3.4

13 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 13 of 15 Revision: 3.4

14 Document Revisions Doc. Rev. Date Doc. Rev. Number Doc. Rev. Description Section No. Revised 10/26/ Initial Draft N/A 12/09/ BOIG expanded 1 Remove reference to Broadcast 3.7 Add statement about default PFS string values 3.11 Remove reference to Broadcast 4.9 Add Operator Abort field 8 Add End of Travel Abort field 8 Remove extra Cycle Time field 8 Acceptance criteria clarified /2/ Update to 2.0 format All 2/27/ Note that hand scanner is required for backup to QAS 3.6 Add Clx details to hardware 5.1 4/6/ Delete diagram 9 Add QAS download information 9 Add direction for PFS values in the volume fill field when this is a pressure fill 1/27/ Remove Daimler references All 5/28/ Change ITM to ICT All 8 02/01/ Converted to New MEGA form All Added FCA Logo Header Reorganize PFS Data, group Pass/Fail Fields 8 04/12/ Added PFS Data String. 8 Owner: ICT Launch Management Page 14 of 15 Revision: 3.4

15 Doc. Rev. Date Doc. Rev. Number Doc. Rev. Description Change Chrysler to FCA US LLC Section No. Revised Added Step 3 in section 7 7 6/26/ Added FIS bit map 6 10/10/ Updated PFS Data String 8 10/30/ Change units from mbar to mmhg 8 All Owner: ICT Launch Management Page 15 of 15 Revision: 3.4