Vehicle Manufacturing Automation System

IntroductionPart 4 - EPS

Tallrain / Oct 2016

1 – What’s…EPS?

EPS = Error Proofing System, or Fail Safe System. EPS is designed for Manual/Machine/Material

operations. EPS integrates with PLC. EPS integrates with ANDON/AVI systems.

2 – EPS Business

Part Scanning: 1. Operator scans VIN Label.2. MES client requests to

refresh page.3. MES returns part list and

verification rules.4. Operator scans Part Labels.5. MES verifies labels, and

alerts if wrong part labels are scanned.

Part ScanningMES Server

23

RequestPart List

1

VIN

4 Part S/N

5

Verify

ID P/N S/N Length S/N Rule1 BT12345 9 0-92 LT12346 9 0-93 CT12347 12 0-9,A-Z4 QT12348 12 0-9,A-Z

Part Picking: Mainly used in Engine assembly:1. When engine arrives, PLC reads

Engine S/N via RFID Tag.2. PLC sends VIN to MES.3. MES downloads Part List and

Rack ID list into PLC.4. PLC turns on light for each Part.5. Each time Operator picks a part,

its light turns off by PLC. 6. After all parts are picked up, PLC

uploads result into MES.

Part Picking

OPC

MES Server

ME PLC

IT Layer

Control Layer

1

5

RFID Reader

2

3

4

6

P/N Station Rack IDA0001 1001 1

A0002 1002 2

A0003 1001 2

Vehicle Torque Gun:1. When vehicle passes through PBS Out

station, MES broadcasts it to whole shop.2. MES sends VIN and Torque Gun

Command into Torque Gun Server.3. When vehicle comes to Torque Gun

station, Torque Gun Server sends Command into Torque Controller, which controls Torque Gun to operation accordingly.

4. Controller uploads Torque results into Torque Gun Server.

5. Torque Gun Server sends result into MES.

Vehicle Torque Gun

RFID Reader

OPC

MES ServerTorque Gun Server

Controller

Torque Gun

Command

Result

1

Prepare

2

4

Command

3

Result5

PBS OUT PLC

Engine Torque Gun

OPC

MES Server

ME PLC

IT Layer

Control Layer

1

5

RFID Reader

2

3

4

6

Controller

P/N Station Gun IDA0001 1001 1

A0002 1002 2

A0003 1001 2

Engine Torque Gun:1. When engine comes to station, PLC

reads Engine S/N via RFID Tag.2. PLC sends Engine S/N into MES.3. MES downloads Torque Command,

including: Torque Gun ID, Torque Count, etc.

4. PLC sends Torque Command into Controller, which controls Torque Gun to operate accordingly.

5. Controller sends actual Click Number and Value into PLC.

6. PLC uploads actual Click Number and Value into MES.

VIN Marking

Marking

5RFID Reader

OPC

MES Server

Mark PC

taskfile

Request

Result

1

Prepare

2

3

6

taskfile

4

Feedback7

PBS OUT PLCPLC

VIN Marking:1. When vehicle passes through PBS Out

station, MES broadcasts it to whole shop.2. MES sends Marking Command into VIN

Marking PC.3. When vehicle comes to VIN Marking

station, operator scans VIN Label.4. Marking PC sends Command into PLC.5. PLC controls machine to mark

accordingly.6. PLC sends Marking result into Mark PC.7. Mark PC sends Marking result into MES.

Filling/Gluing

Filling/Gluing:1. When vehicle comes to station, PLC

reads VIN via RFID Tag, and sends it to MES.

2. MES downloads command into PLC.3. PLC controls machine to operate

accordingly.4. PLC uploads result into MES.

OPC

MES Server

PLC

IT Layer

Control Layer

1

2

3

4

RFID Reader

3 – EPS& AVI

RFID Tags are used in most vehicle plants for vehicle identification.

But in General Assembly Shop, Plain-Chain Conveyors are used for most lines, which is always moving continuously, so it’s low efficient to read RFID in middle stations.

EPS PLC integrates Encoder to calculate line speed and position, together with AVI reading in Line Head/End stations, to output each vehicle’s real time position.

EPS PLC integrates position sensors, to output pulse signal of 0%/70%/100% position of station, which will be used for Alarm and Stop.

RFID Reader

OPC Server

MES Server

EPS PLCComing Vehicle

Encoder

Line Position

Vehicle Sequence

COUPLER

Conveyor PLC

EncoderPosition Sensor

Vehicle Position

Line Position

4 – EPS & ANDON

In General Assembly Shop, EPS result sends to Conveyor PLC via ANDON PLC:1. When operation is completed,

operation data will be sent to MES.2. Control PLC/PC sends

result(OK/NOK) into ANDON PLC.3. ANDON PLC sends OK/NOK and

70%/100% position signals to Conveyor PLC, which stops line when condition matches.

OPC

MES Server

Control PCResult

Data

2

3

1

PLCANDON PLC

PLC

Stop

Thank you!

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