INDUSTRY FOCUS AUTOMOTIVE SUPPLY CHAIN
AUTOMATING PARTS DELIVERY WITH HELP FROM AGVS AND WIRELESS RADIOS
network whose speed can keep up with the constantly moving machines. Mirage needed to come up with a communication solution that would link the AGVs to a master control panel. An alternative solution – wireless RS232 communications over a radio link – did not work out: Mirage noted the Modbus communications were slow and time-consuming to implement. “The need for simplified configuration
led them to ProSoft Technology,” says Adam Tatton, director at Mirage. “ProSoft’s Industrial Hotspot radios
A
s anyone who has ever tried to narrow down an unclear issue with a
vehicle knows, automotive parts are many and varied – and that’s after they’ve been fully put together. In the manufacturing process, many smaller parts go into the finished product. And in any industry – automotive especially – speed on the assembly line is economically crucial. The movement of those parts on the
plant floor is closely watched and handled given their value. One major automotive manufacturer was looking to make a more efficient change. It had a worker manually pushing a dolly containing parts and was hoping to automate that task.
AUTONOMOUSLY GUIDED VEHICLES The end user reached out to Mirage, based in Stoke-on-Trent, England. Mirage designs and builds bespoke machinery and automated solutions. Its solutions include Autonomously Guided Vehicles (AGVs), jigs and fixtures, control panels and software solutions, conveyors, and mechanical handling equipment, with poka-yoke mechanisms built-in. Poka-yoke is a Japanese phrase that means ‘mistake-proofing.’ In a lean manufacturing process, this feature essentially helps operators avoid lasting errors. It is an integrated part of many of Mirage’s solutions. For more than a decade, Mirage has
specialised in lean manufacturing and factory automation solutions for several industries, including automotive. The firm’s knowledge of the automotive industry and materials handling was especially key for this application. AGVs are a cost- and time-effective
alternative to manual transportation throughout a location, but key to their successful implementation is a wireless
12 JUNE 2018 | AUTOMATION
Mirage Services designs and builds bespoke machinery and automated solutions including AGVs used in the automotive industry
allowed the end user to use their own PLC,” says Tatton. “This meant the end user was now able to use a corresponding specialist HMI screen, which allowed them to improve production. Meanwhile, the use of Ethernet radios saved Mirage configuration time by eliminating the need for Modbus commands. “ProSoft’s support throughout the application was also a plus, says Tatton.
TECHNICAL SUPPORT “Mirage had to lower the AGV to accommodate the dollies and space was at a premium,” says ProSoft regional sales manager, Myles Heinekey. “To help support this AGV modification, we selected a lower-profile OMNI antenna with MIMO and loaned the antenna to
them to see if that would help.” “That type of local technical and sales support and demonstration of the solution was a key factor in opting to use ProSoft’s solutions in the application,” says Tatton. “With this setup, the AGV starts by
driving under the dolly with parts for vehicle assembly. The parts are dropped off at the assembly line before the AGV returns in a loop to the collection point to drop off the empty dolly and pick up a new one. The radios, meanwhile, are constantly sending diagnostic and location data to the main control panel. That live program monitoring has improved commissioning and speeded up system integration on site.”
LOWER COSTS In addition, the software complexity for this solution has been reduced from the alternative setup, making it easier to use and program. Data volume has also been reduced, and the reduced engineering time has helped decrease manufacturing costs.
To learn more about services provided by Mirage Services, please visit:
www.mirageservices.co.uk . Additional information about ProSoft Technology’s Industrial Wireless solutions is available at:
http://psft.com/CHT
Fully programmed hybrid ECUs can be customised M
anufacturers of hybrid vehicles now have access to a powerful new tool in the form of fully
programmed engine control units (ECUs) customised for their application. Ford has appointed Essex-based Revolve Technologies as its sole European Quality Calibration Modifier (QCM), giving it unique access to its engine technical information. As engine designs become ever more complex,
optimising for new applications is an increasing challenge that requires access to complex data sets. Engines produced for hybrid vehicles using specially calibrated ECUs can offer improved reliability and fuel economy. Complying with Euro6 emissions regulations in particular requires highly precise designs to meet the stringent emission requirements. Revolve has been granted access to the complete
engine data, and is one of only five companies in the world to partner with Ford in this way. Hybrid vehicle OEMs can now use Ford engines with optimised engine management parameters, based on full technical information obtained through the authorised and supported QCM route. Previously, they had to purchase their ECUs for each engine design from third parties with no access to the important Ford parameters that are essential to maximising performance from hybrid engines.
Revolve’s
engineering manager, Bryn Slaney says: “There are many new opportunities to take advantage of this new development, as we now have infinitely variable control over what can be offered. Niche OEMs and volume producers of hybrid and conventional vehicles will benefit.” Paul McDermott, sales director of Ford
L to R: Paul McDermott, Ford; Stephen Message; Alec Pell-Johnson; and John Willis, Revolve
component sales, says: “By giving Revolve access to an ‘open/development’ ECU, it can start work with the base calibration of a current Ford vehicle, and then work with customers, adjusting calibration settings to suit the customer’s application or vehicle.” The Revolve formal QCM partnership is already in
place for conventional engines. The latest move reflects Revolve’s role as a leading automotive design consultancy.
Revolve Technologies
www.revolve.co.uk /AUTOMATION
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