Fori Automation recently provided a turn-key automated assembly line for the build of utility trailers for a customer. Fori provided (4) duplicate assembly lines to support their facilities in GA, VA, TX & IA.
The utility trailer assembly line included a variety of improvements over the customer's traditional assembly lines, including overhead lift assists, automated transfer utilizing rail guided carts (RGCs) and DC electric tools for fastening and traceability. Fori was responsible for supplying (4) systems, each system comprised of (6) RGCs, (5) overheads with custom lift assists and (11) DC Electric Tools.
The customer wanted to ensure a flexible assembly system that can be leveraged across all their plants. The RGCs provided were able to be used at their four facilities by modifying the track layout based on floor space, building columns and ceiling heights.
Tooling pallets were designed with quick change features to accommodate (16) trailer variations ranging from 4’ x 5’ up to 6’ x 12’. To lift the various components such as frames, axles, gates and tongues, custom overheads with lift assists were provided to improve ergonomics for the operator.
Another design consideration was traceability for fastening, this was completed with the implementation of DC electric tools and ToolsNet from Atlas Copco. With the integration of barcode scanners, the trailers fastener torque data is saved on a database linked to the trailer serial number.
The lines were installed during the first quarters of 2021.
Fori Mexico recently provided an automated bushing press system for a Martinrea production plant in Queretaro, Mexico.
The bushing press system includes two tooling modules, one to produce left hand modules and one to produce right hand modules. The system includes a single press in the center of the equipment to product either configuration of product. The press system supplied utilizes a Fori servo controlled press system that is capable of 50 kN of force.
An operator loads the busing into a product fixture, which is automatically loaded into the press system via automatic indexing slides. The press moves to the work position via servo controlled slide and performs the insertion of the bushings.
Start of production for the equipment was during the 1st quarters of 2019. The system provided improved production rate versus more manual methods of bushing insertion.
Fori recently supplied (2) automated Tugger AGVs for Aerospace composite tooling cart transport.
The Fori Tugger AGVs were supplied to transport a variety of composite tooling parts with total transfer weight up to 30,000 lbs. The Tugger AGV system included auto docking to the product carts. The purpose of the auto docking is to eliminate the need for operator intervention to couple to the carts and transfer them through the assembly plant.
The Fori Tugger AGV is utilized in two configurations, first as a Tugger pulling tooling carts in a single direction. The Tugger AGV is also used as a Dock N’ Lock. In the Dock N’ Lock configuration, the AGV automatically connects to the tooling cart and pulls it against the bumpers (shown in bottom picture). The attachment allows the tooling cart to rotate with the Tugger AGV and back it into work stations as required by the process.
The Tugger AGVs were commissioned to ensure safe and reliable product transfer. Previously, this transfer was completed with fork lifts or manned tow vehicles. The AGVs eliminated non-value added material handling and provided a hands off system for transporting product through the assembly process.
Complex assemblies matched with high production requirements mean reduced ability to provide repeatable operator output. In an industry with constant pressure to boost efficiency and improve quality, automation becomes the solution most look for.
The suspension module assembly consisted of a heavily automated system. The equipment included a rear suspension module line, front suspension module line, front and rear combo module line and a front coil over shock assembly (FCOS).
Rail guided carts (RGCs) were provided for conveyance of the product down the assembly line. The front and rear corner assembly consisted of (13) RGCs, robotic hub assembly & caliper torque cell.
The front suspension assembly line consisted of (16) RGCs, a semi-automatic ride height and trending set machine that positioned the links within a slot. The equipment could be adjusted based on the tolerances provided by the OEM.
The rear suspension assembly line consisted of (37) RGCs, (2) automatic alignment systems, ride height set automatic torque cell and a robotic flip station.
The new RGC assembly line was installed during the first quarter of 2019.
The Fori Tugger AGVs were supplied to transport a variety of composite tooling parts with total transfer weight up to 30,000 lbs. The Tugger AGV system included auto docking to the product carts. The purpose of the auto docking is to eliminate the need for operator intervention to couple to the carts and transfer them through the assembly plant.
The Fori Tugger AGV is utilized in two configurations, first as a Tugger pulling tooling carts in a single direction. The Tugger AGV is also used as a Dock N’ Lock. In the Dock N’ Lock configuration, the AGV automatically connects to the tooling cart and pulls it against the bumpers (shown in bottom picture). The attachment allows the tooling cart to rotate with the Tugger AGV and back it into work stations as required by the process.
The Tugger AGVs were commissioned to ensure safe and reliable product transfer. Previously this transfer was completed with fork lifts or manned tow vehicles. The AGVs eliminated non-value added material handling and provided a hands off system for transporting product through the assembly process.
Fori Automation recently supplied a number of powered drive wheel systems for an automotive Tier 1 supplier. The drive wheels were integrated into a customer supplied tooling cart providing automated movement of product through the automotive assembly process.
Automotive Assembly with Powered Drive Wheel System on Assembly Cart
The Fori powered drive wheel systems include modular drive wheel units that are mounted to new or existing assembly carts. Once mounted the drive wheels automate the transfer of materials through the manufacturing facility. The drive wheel systems provide the same capability as an off the shelf Automated Guided Carts (AGCs). The powered drive wheel systems can be manually moved by the operator or can be supplied with an integrated vehicle management system (VMS) or traffic control to automatically control movement from station to station.
The key benefits of a powered drive wheel system include:
Reduced reliance on fork lifts or manned Tuggers.
Improve ergonomics, reduction in injuries in relation to pushing or pulling assembly or kit carts.
Repeatable, reliable delivery of goods and consistent line pulse for assembly operations.
Ability to integrate into manufacturing execution system (MES) for data analysis and production streamlining.
Safe transfer of goods through the use of onboard Safety PLC and associated safety devices.
Accurate positioning of carts and goods, standard station positioning is +/- 10 mm when utilizing a Fori provided vehicle management system (VMS).
Drive wheel systems include their own self-contained power supply, control panel, collision avoidance devices, guidance hardware and tethered (or wireless) pendant for manual control. Power supplies include sealed lead acid batteries and lithium ion product offerings. The controls architecture is safety PLC based and available in Siemens or Rockwell. Guidance or navigation options available include optical, magnetic or natural feature utilizing the onboard safety scanners.
Powered Drive Wheel System with Safety Scanner, Alarm & Lights, E-Stops & HMI
Total carrying capacity of the powered drive wheel systems is accommodated by a variety of standard drive wheel sizes. Capacities can be increased by up-sizing the drive wheel and motor combination or adding more of the smaller drive wheel units. Drive wheel systems can also be configured to allow for different levels of maneuverability. The maneuverability ranges from uni-directional, loop based systems, up to omni-directional systems for complex material handling or assembly systems with the integration of two or more drive wheels.
The drive wheel systems are structured for current or future automation with the ability to retrofit the assembly cart later in the production cycle. The assembly cart can be designed to accommodate mounting of the drive wheels and required equipment at a later date. For existing carts, our design team will work with the production team to define the required changes for addition of the powered drive wheel system. The ability to add automation as production increases, decreases the initial capital expenditures, allowing production rates to increase before adding the automation required for automated or manual transport through the assembly process.
Powered Drive Wheel System with Single Powered Drive Wheel & Support Casters for Assembly Cart & Product Transport through Automotive Assembly Process
Overall the powered drive wheel system provides a flexible, safe and reliable material handling and assembly solution for the a wide range of industries and processes.
To learn more about Fori's available products please visit our website or contact us at sales@foriauto.com.
Fori Automation recently supplied a number of powered drive wheel systems for an automotive Tier 1 supplier. The drive wheels were integrated into a customer supplied tooling cart providing automated movement of product through the automotive assembly process.
Automotive Assembly with Powered Drive Wheel System on Assembly Cart
The Fori powered drive wheel systems include modular drive wheel units that are mounted to new or existing assembly carts. Once mounted the drive wheels automate the transfer of materials through the manufacturing facility. The drive wheel systems provide the same capability as an off the shelf Automated Guided Carts (AGCs). The powered drive wheel systems can be manually moved by the operator or can be supplied with an integrated vehicle management system (VMS) or traffic control to automatically control movement from station to station.
The key benefits of a powered drive wheel system include:
Reduced reliance on fork lifts or manned Tuggers.
Improve ergonomics, reduction in injuries in relation to pushing or pulling assembly or kit carts.
Repeatable, reliable delivery of goods and consistent line pulse for assembly operations.
Ability to integrate into manufacturing execution system (MES) for data analysis and production streamlining.
Safe transfer of goods through the use of onboard Safety PLC and associated safety devices.
Accurate positioning of carts and goods, standard station positioning is +/- 10 mm when utilizing a Fori provided vehicle management system (VMS).
Drive wheel systems include their own self-contained power supply, control panel, collision avoidance devices, guidance hardware and tethered (or wireless) pendant for manual control. Power supplies include sealed lead acid batteries and lithium ion product offerings. The controls architecture is safety PLC based and available in Siemens or Rockwell. Guidance or navigation options available include optical, magnetic or natural feature utilizing the onboard safety scanners.
Powered Drive Wheel System with Safety Scanner, Alarm & Lights, E-Stops & HMI
Total carrying capacity of the powered drive wheel systems is accommodated by a variety of standard drive wheel sizes. Capacities can be increased by up-sizing the drive wheel and motor combination or adding more of the smaller drive wheel units. Drive wheel systems can also be configured to allow for different levels of maneuverability. The maneuverability ranges from uni-directional, loop based systems, up to omni-directional systems for complex material handling or assembly systems with the integration of two or more drive wheels.
The drive wheel systems are structured for current or future automation with the ability to retrofit the assembly cart later in the production cycle. The assembly cart can be designed to accommodate mounting of the drive wheels and required equipment at a later date. For existing carts, our design team will work with the production team to define the required changes for addition of the powered drive wheel system. The ability to add automation as production increases, decreases the initial capital expenditures, allowing production rates to increase before adding the automation required for automated or manual transport through the assembly process.
Powered Drive Wheel System with Single Powered Drive Wheel & Support Casters for Assembly Cart & Product Transport through Automotive Assembly Process
Overall the powered drive wheel system provides a flexible, safe and reliable material handling and assembly solution for the a wide range of industries and processes.
To learn more about Fori's available products please visit our website or contact us at sales@foriauto.com.
The battery powered chassis marriage AGV with dual independent lifters is capable of lifting and transporting up to 4,000 pounds (1,818 kilograms) in order to install the front and rear suspension and drivetrain modules.
This AGV was developed to support the end users lean, automated, manufacturing methodology. Not only will the AGV enable the end user to reduce their hardware investment, there will be significant flexibility in the assembly process. The guidance system and reduced plant infrastructure allows the AGV to easily interact with other systems and processes. The AGV is also outfitted with multiple safety measures that ensure collision avoidance.
The chassis marriage AGV is responsible for accurate and repeatable location of a part within the station for a reliable chassis marriage process. The AGV will provide increased flexibility, safety, and decreased product damage, thus increasing profitability within the manufacturing process for the end user.
Fori China recently designed, built and integrated a cockpit assembly line in Shanghai.
Features:
Jobs Per Hour: 60 jobs
Results: Increased production rate, reduced labor, decreased injury concerns
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The Fori China project aimed to improve the productivity and ease of assembly for a cockpit. The manipulators were attached to a steel structure that is used for assisting the operator while installing the cockpit assembly into the vehicle. After the cockpit is attached to the manipulator, it is conveyed to the install location, the goal is to reduce potential of damage to the workpiece. Once the workpiece is located within the vehicle, the manipulator holds the panel until tightening of the bolts is completed.
The manipulator has improved production efficiency, reduced product damage, and most importantly improve safety for the operators. For more information about Fori's aerospace tooling, please visit our website.
https://www.youtube.com/watch?v=lehMe10Vx9g&t=
Fori Germany supplied 16 AGVs for a body shop project that were custom designed around the customer’s process. The total capacity required for each AGV was 1,100 pounds (500 kilograms). The AGV was responsible for carrying a car chassis between various assembly stations.
Each vehicle consisted of two fixed drive wheels, an integrated scissor lift, and a 24 volt lithium ion battery to power the vehicle. The system was based on an open controls architecture, utilizing a Siemens PLC for the vehicle control. In addition, each vehicle is equipped with a camera based guidance system that follows colored tape or paint. The optical guidance system provides a flexible, reliable and cost effective solution for guiding the vehicles throughout the assembly plant.
The vehicle included a custom scissor lift to accommodate the vertical lift stroke and capacity required for the process. Each vehicle is capable of lifting 1,100 pounds (500 kilograms), and the scissor lift is capable of 21 inches of total stroke with a collapsed height of 11 inches. The custom 24 volt 67 ampere hour lithium ion battery was designed to fit within the available footprint on the vehicle. The system allowed for quick charging at the designated opportunity charge stations. Utilization of a lithium ion battery reduced the required charging infrastructure.
For more information about Fori Automation's AGVs, please visit our website.
Fori China designed, built and integrated a chassis marriage system for a automotive manufacturer located in Slovenia.
Features:
Jobs Per Hour: 45 jobs
Results: Increased production rate, reduced labor, decreased injury concerns
https://www.youtube.com/watch?time_continue=29&v=3_u1UGkP928
The marriage line is a sub-set of the trim and chassis final assembly system that delivers the completed front and rear modules to the marriage line after being assembled. The overall project is based on the green field sit to provide the delivery conveyance of the completed sub-assembly from the tunnels to the marriage line automatically where the complete chassis assembly will be automatically married and secured to the car chassis.
The body carrier and frame are powered into the stations via asynchronous conveyors. The spindles index and begin securing the front module, differential cradle, and rear module. All 14 fasteners must be torqued at the same time. There will be three wheel base variations that have a common front module and center cradle positions.
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An inspection station was supplied with the system. The station will provide positive verification that the details match the corresponding configuration of the vehicle sequencing through the assembly process. The vision inspection is completed at a stop station.
The marriage station includes an electro-mechanical hook style body clamping device for models that require holding the body during the marriage process. An external actuator in the station is used to clamp the body to the pallet. Once married the overhead carrier drive is disengaged allowing the pallet conveyor to the move pallet/carrier assembly down the line. Future non-related products may be introduced by either pallet redesign or through additional pallets and a future pallet storage system.
For more information about Fori Automation's body and chassis marriage systems, please visit our website.
The Fori module assembly system sequences and processes multiple product variants utilizing Fori’s Rail Guided Cart (RGC) assembly solution.
Features:
Assembly Cycle Time: 32 jobs per hour
Keys to Success: Automatic camber set, automated front coil over shock assembly, automatic lateral runout, flexible product transport from dunnage to line
Results: System capable of sequencing multiple variants, increased quality
https://www.youtube.com/watch?v=zzAw5dgQn9U
Fori’s integration of manufacturing execution systems with the RGC system allows the value added assembler the means to create multiple variants of brake systems. The sequenced brake systems are then assembled as requested by the original equipment manufacturer (OEM) and ready for installation into the vehicle.
The single loop style conveyor system consists of 13 RGCs to transport front brake corner and strut components (front vertical assembly) from incoming material dunnage through the various assembly processes including:
Vision system inspection and verification of caliper selection and installation
Vision verification of brake pad presence
Automatic front coil over shock assembly
Automatic setting of camber angle and marriage of front coil over shock to brake corner
Utilizing experienced resources, Fori developed a viable process, engineered the system, manufactured the equipment and integrated the assembly line at the end user. The module assembly system has resulted in positive results for the customer and OEM.
For more information about Fori's modular assembly systems, please visit our website.
https://www.youtube.com/watch?v=lehMe10Vx9g&t=
Fori Germany supplied 31 AGVs for a front end assembly line. The AGVS are used to transport the workpiece carriers that are mounted on the carrier plate of the AGV.
The total capacity required for each AGV was 1,100 pounds in order to support the pallet and associated product. The carrier plate used for locating the product was mounted onto a trunnion to provide better ergonomics and accessibility for the operator completing the assembly.
Each vehicle consisted of two fixed drive wheels, an integrated trunnion, and a 24 volt lithium ion battery to power the vehicle. The system was based on an open controls architecture, utilizing a Siemens PLC for the vehicle control.
Each vehicle utilizes a camera based guidance system that follows colored tape or paint. The optical guidance system provides a flexible, reliable and cost effective solution for guiding the vehicles throughout the assembly plant.
The system was supplied with a Siemens based Vehicle Management System (VMS) to schedule and coordinate vehicle moves, communicate with the plant and for monitoring of the vehicles.
For more information about Fori Automations' AGVs, please visit our website.
Fori supplied a cost effective solution for setting the front suspension caster and camber alignment prior to the end of line equipment.
https://www.youtube.com/watch?v=WcFVxdwJ4BA
Features:
Safety: Safety scanners, system interlocks
Controls: Allen Bradley
Keys to Success: Highly accurate and repeatable, fully automatic with manual override functionality.
Results: Increased production rate, reduced personnel injuries
The Caster Camber fixtures (primary and back up) were built to fit within the existing assembly plant. The system proved to be a challenge in the already congested twin strand pedestal conveyor. The fixture itself hangs from an overhead rail system and is capable of locating and tracking with the vehicle frame as it passes beneath.
The fixture lowers itself onto the vehicle frame, and then pins and clamps to the frame which establishes the control datum points to locate to. The machine's two pivot arms swing in and clamp the upper and lower control arm ball joints. DC Nutrunners loosen the lower control arm fasteners. Servo motors position the X and Y location of the lower control arm. DC nutrunners secure the lower control arm into the correct location. The fixture then un-clamps and lifts off of the frame. At that point the fixture drives itself back to it's home position ready to accept the next unit.
The system consists of a fully integrated Safety PLC. The PLC has the ability to track and store faults, monitor and record positional and setting information as well as monitor all safety devices.
For more information about Fori Automation's automotive assembly capabilities, please visit our website.
Fori Germany supplied 21 work piece carriers for a front end assembly line. The work piece carriers were integrated with an existing automated guided vehicle (AGV) system, and are mounted directly to the AGVs.
The purpose of the work piece carriers is to provide a repeatable solution for locating the parts to the pallet for assembly. The work piece carrier also provides a process to the operator for adjusting the part location and orientation. Adjustment is completed through a powered trunnion.
The carrier trunnion has an integrated motor in order to tilt (the system has four automatic tilt angles) the fixture both automatically and manually. The carrier utilizes the power available on the AGV and communicates with the it to provide confirmation of the correct position. Upon completion of the front end module, the carrier returns to the home position and the module is unloaded via a lift assist.
The system supplied provided a simple technique for locating the front end module for the operator. The design considerations were based on a high level of reliability and minimal maintenance.
To learn more about Fori Automation's AGVs and assembly capabilities, please visit our website.
Fori recently supplied a module assembly system that included the Fori Flex Rail conveyance system which utilized Rail Guided Carts (RGCs) and a drive-thru module aligner for the assembly and alignment of a rear suspension module.
Features:
Assembly Jobs Per Hour: 25 jobs per hour
Keys to Success: RGC conveyance, manual alignment backup
Results: Jobs per hour fulfillment, flexible assembly
The module assembly system had a unique set of design constraints. One example was that the floor space available within the plant for the required rear suspension module was limited, requiring a common unload area with an existing assembly line. Due to the oddly shaped footprint available for assembly and the mandated unload area, the end user utilized Fori’s RGC to accommodate their needs for a flexible material handling and assembly system.
The system utilized a standardized Siemens control architecture, including the RGC, traffic control, and aligners. The standardization of Siemens controls was customer requested in order to match their existing controls architecture. In matching the controls architecture between all of the equipment, Fori was able to offer seamless integration into the customer’s assembly plant.
The rear main assembly line was composed of 15 RGCs, seven operators, one automatic drive through alignment machine, and one manual backup alignment system.
https://www.youtube.com/watch?v=_vAiYKMojDU
For more information about Fori Automation's RGCs, assembly systems, and aligners, please visit our website.
Fori Automation specializes in module assembly & alignment systems. Modules include suspensions, corners, axle, instrument panels, coil over shock and many others.
Fori supplied a rear module suspension assembly line utilizing Fori Rail Guided Carts (RGC) as a conveyance and assembly method alongside two fully automatic drive-thru module alignment systems.
Drive-thru Suspension Module Aligner for Automotive Assembly
The assembly line consisted of (22) RGCs, two drive-thru aligners, (16) operators and various torque tools. The product for the rear suspension module varied between all-wheel drive and rear wheel drive vehicle variations. The build pallet on top of each RGC accommodated those variants and manipulated the ride height setting of the five link suspension by manually setting the ride height wheel in the correct position verified by a switch on the pallet.
https://www.youtube.com/watch?v=XX0VgCh6d9Y
A drive-thru aligner was also utilized within the system to help streamline the process. A lift and locate unit was located in each drive-thru aligner that would pick the pallet from the RGC and accurately present the suspension assembly for alignment.
https://www.youtube.com/watch?v=hximcPC65jE
Utilizing Fori’s RGCs allowed for a timelier changeover. The RGC system also provided long term flexibility supporting:
Accommodating future product changes that could add new stations.
Production increases that can affect station to station cycle times.
Production line shape if required.
Fori Rail Guided Carts (RGC) with Custom Tooling Pallet
For more information about Fori Automation's RGCs and assembly systems, please visit our website.
During extensive layout and process reviews, all areas that required rework were identified so a plan could be developed to add field kits which consisted of new portions of assembly line. In order to be flexible and to accommodate the heavy variation in product, a number of robotic torque applications were added each with a common trombone torque tool to be utilized on all module complexity types.
In order to accommodate the new product, two additional aligners were reworked from another customer plant and installed on a new conveyor section of the assembly line.
https://www.youtube.com/watch?v=usiSOJZkGnA&t=3s
For more information about Fori Automation's assembly products, please visit our website.
Fori recently supplied a module assembly line for axle assembly. The production line consisted of a Fori twin strand conveyance system with manual assembly stations, automatic Lateral Run Out (LRO) and automatic end of line robotic vision system for inspection.
Features:
Assembly Jobs Per Hour: 81 jobs
Keys to Success: Inverted assembly process, integrated robots for vision inspection, lateral run out with WSS testing
Results: High build efficiency, reduction in rejected parts
https://www.youtube.com/watch?v=MySCkX35R6I
The required equipment was met with a few unique challenges and aspects:
Inverted assembly and unloading of the vehicle side up
Unique LRO testing and retry methodology
Inverted robotic vision verification
Minimal area available for assembly line
Robotic vision verification
Prior to testing the LRO, the hub and rotor must be assembled on a test fixture complete with constant velocity. The joint and hub fasteners are then tightened according to production standard and are able to withstand an axial load of 100 kN. In order to accomplish these items the equipment had to lift the axle from the pallet prior to being secured.
https://youtu.be/fZ15gTgPO60
Due to the rotors being unable to be retained flat against the hub, the equipment could not guarantee "non-contamination" that could potentially produce a fault during LRO. In order to correct this the “retry method” of the equipment was to remove the rotor, index to the next rotary present pattern and reinstall the rotor to the hub prior to LRO testing.
For more information regarding Fori Automation's assembly or end of line systems, please visit our website.
Fori recently designed and built a Tunnel AGV to support its global customers. The Tunnel AGVs are utilized for transporting product and dunnage throughout the production process.
The Tunnel AGV pictures includes a Roller Conveyor companion cart for Pallet Transfer.
Features:
Guidance Technology: Magnetic bar, inertial with pencil magnets
Capacity: Up to 10,000 lbs./4,545 kg. (can be increased upon request)
Safety: Safety scanners and bumpers, Siemens safety PLC, system interlocks
Controls: Siemens open architecture, vehicle management system
Keys to Success: Custom designed chassis, highly accurate and repeatable
Results: Improved flexibility
The Fori Tunnel AGVs are capable of automated docking and transport of companion carts carrying up to 10,000 pounds. The design intent was to build a vehicle that was modular and interchangeable. In order to increase process flexibility the Tunnel AGVs are capable of docking to various companion carts, each serving a unique purpose.
Applications include pallet transfer via roller conveyors, lift tables and powered trunnions. Automated docking to the companion carts is completed with two docking or hitch pins. The docking pins ensure proper alignment to the companion cart for repeatable pick and drop.
The Tunnel AGV was designed to provide a high capacity material handling solution in the smallest footprint possible. The vehicle is comprised of two fixed drive wheels allowing for bi-directional travel and zero turn capability.
A Fori Vehicle Management System (VMS) is utilized for scheduling of vehicles and traffic management of the system. The vehicle controls are based on an open architecture utilizing a Siemens safety PLC, eliminating the black box technology that is commonly used across the industry. The Tunnel AGV has proven to be a cost effective and reliable material handling system for a variety of applications.
For more information on Fori's automated material handling products, please visit our website.
Fori recently supplied an assembly system for an american motorcycle manufacturer. The system comprised of manual push pallets on a vertical conveyor system consisting of a main build line and two vertical lift support stands.
Features:
Assembly Units Per Day: 500 units / 2 shifts
Keys to Success: Operator ergonomics, flexible tooling, loop configuration, modular sections for line expansion
Results: Quality built assemblies, on time turnkey install
Not all projects require high levels of automated equipment in order to meet the end users production requirements. This project is a great example of how Fori took a powered vertical conveyor system and redesigned it to a manual push pallet system based on cycle times and customer budget requirements. The updated design provided the customer increased flexibility for their long term build process. The line was designed in modular sections for future expansion of increased production as required based on customer demand.
The ability to be flexible with the pallet provided the ability to use the vertical conveyor for more than current parts or model changes. Overhead support for tooling was a jib boom that bolted to the floor to remove the assembly to dunnage.
For more information about Fori's assembly solutions, please visit our website.
The Robotic MIG Welding system contains resistance spot welding, projection welding, drawn arc welding and a sealer application.
https://www.youtube.com/watch?v=yKQiLvi-SyU
Features:
Assembly Cycle Time: 54 seconds
Keys to Success: Integrated robots, custom designed turn tables, custom precision welding
Results: Decreased cycle time and increased quality
The robotic weld system provided accommodates for multiple structural end item assemblies that consisted of resistance spot welding, projection welding, drawn arc welding, as well as a sealer application. The system contained multiple welding cells with a total of (50) robots.
The end item assemblies within this program were Load Beams, Rear Quarter Inner, Rear Closure Inner Assembly, Dash Assembly, Cowl Side, Center Floor Pan Assembly and Sill Outer.
Dial indexers where integrated into a number of the weld cells to improve the efficiency of the robots. Within the process some robots carried weld guns while others were material handling robots that moved the assemblies through pedestal welders (spot, projection and drawn arc) or pedestal sealers.
Fori USA was responsible for Project Management, Engineering, Assembly and Integration. All cells were setup and run off at Fori's global headquarters in Shelby Township, MI. Fori Mexico was responsible for installation and buy off at the end user's production facility.
For more information on Fori Automation's weld lines, please visit our website.
Guidance Technology: Magnetic bar, natural feature/laser contour
Capacity: 40,000 lbs./18,181 kg.
Safety: Safety scanners and bumpers, Siemens safety PLC, system interlocks
Controls: Siemens open architecture
Keys to Success: Custom designed chassis, highly accurate and repeatable
Results: Improved flexibility
The two high capacity AGVs (transporting mobile robotic platforms with weights up to 40,000 pounds) have been designed to accommodate projected production. The Fori AGVs will be the primary method of transporting the mobile robots between each of the necessary drilling stations.
The AGVs were developed to increase system automation, flexibility, and remove the traditional monuments that are generally required for automated drilling applications. The design intent was to build a vehicle that was modular and interchangeable. The AGVs were designed to accommodate multiple mobile robots, the software is modular, and simplifies the communication between the Fori AGV and mobile robot.
The Fori AGV is required to locate within +/- 5mm to an existing fuselage transporter. The Fori system utilizes a natural feature and camera based guidance system, which accommodates unexpected location of the transporter. The Fori system overcomes the variability of the fuselage transporters accuracy by measuring the surface of the transporter to generate angular offsets and utilizes a SICK camera and reflector based system for final location. Once positioned, the mobile robot automatically docks to the transporter for power, communication, and pneumatics.
Automated movement is handled through the tethered Siemens Mobil Panel. The operators are able to select drill positions on either the Fori HMI or robot HMI. Once selected the Fori AGV is responsible for safely and accurately lifting and transporting the two mobile robots between 16 different drill positions.
For more information about our drilling platform AGVs, please visit our website.
Automated Guided Vehicles (AGVs) for Aerospace Wing Assembly Systems
Fori recently provided seven high capacity Aerospace AGVs for the automated transport of tooling for spar assembly, supporting the production of composite wing assemblies.
Features:
Guidance Technology: Magnetic bar, inertial with pencil magnets, natural feature/laser contour
Capacity: 120,000 lbs./54,545 kg.
Safety: Safety scanners and bumpers, Siemens safety PLC, system interlocks
Controls: Siemens open architecture, vehicle management system
Keys to Success: Vehicle synchronization, custom designed chassis, and highly accurate and repeatable.
Results: Improved flexibility and decreased crane usage
The seven high capacity AGVs, capable of auto-leveling and synchronized transport of tooling up to 120,000 pounds have been designed to accommodate projected wing production. The Fori AGVs will be the primary method of transporting the tooling and product through the assembly process. Traditional assembly systems rely heavily on overhead crane utilization, the AGV based solution eliminates the reliance on cranes.
https://www.youtube.com/watch?v=lehMe10Vx9g
The AGVs were developed to support a lean, automated manufacturing methodology. The goal of the project was to automate the entire material handling process for the assembly of the spars. Notably, the load and unload of the autoclaves used for curing the composite wing spars. The loading of the autoclave is completed utilizing a natural feature guidance system, the AGV uses the walls of the autoclave for the guidance in and out, while still maintaining +/- five mm accuracy.
The design intent was to build a vehicle that was modular and interchangeable. The AGV system is required to transport many tools of different lengths and weights. The AGV system needs to be able to accommodate synchronization of up to three AGVs during the lift and transport from assembly stations.
Each of the AGVs is outfitted with four servo based lifters and a laser alignment system which provides measurement feedback to the on-board PLC for the dynamic leveling of the tooling during transport. The system must maintain levelness within +/- 1/8” from each end of the tool.
A Fori Vehicle Management System has been provided to monitor system I/O, communication between the AGVs, tooling and automated assembly stations. Scheduling of moves also occurs at the Fori VMS.
For more information about Fori Automation's aerospace assembly products, please visit our website.
Fori Automation Flex Floor Product Line for Flexible Assembly and Material Handling Systems.
Fori Automation, a global leader in the design, build and integration of material handling, assembly, testing and welding systems has further expanded its assembly and material handling product lines. Fori has added a new material handling platform to its ever growing product line to help facilitate material flow through today's manufacturing facilities.
The Fori Flex Floor product line is a flexible material handling and assembly system that is designed to fit around the customer process and product, whereas many of the other material handling products on the market require the customer process and product to fit around the material handling system. The Flex Floor platform includes a variety of vehicles based on the same architecture that have varying levels of capability depending on the end users specific needs.
The Fori Flex Floor utilizes a heavy duty extrusion style frame that enables the footprint of each style vehicle to be modified to fit the product being assembled or the materials being moved. The Flex Floor platform utilizes commercially available drive wheels, casters, batteries, controls components and guidance. The Flex Floor platform is based on a Siemens Safety PLC based architecture, providing the end user an open architecture. Many of the other products on the market include a “black box”, requiring the user to enlist support from the equipment supplier. Each assembly and material handling system can be supplied with a Fori Vehicle Management System (VMS), enabling the system to be fully autonomous, only requiring input for scheduling of moves either from the user or from the plant production system, the Fori VMS takes care of the rest. The Flex Floor vehicles are outfitted with the latest safety components available on the market. At a minimum the vehicles are supplied with perimeter Safety Scanners, Indicator Lights, Alarms and E-stops. The Safety Scanners provide collision avoidance for the end user to ensure safety for the operator and that no damage occurs to the product or part. Additionally, each vehicle is designed to be user friendly and virtually maintenance free for the end user.
Example of Fori Flex Floor - Rail Guided Cart (RGC) utilized for a Corner Module Assembly LineFlex Floor – RGC: Flex Floor Rail Guided Carts (RGCs) are a direct replacement for traditional, monument based conveyor systems that are typically utilized in assembly processes. Fori RGCs utilize a low profile, floor mounted rail for tracking and a single, suspended drive wheel to propel the vehicle through the assembly process.
Flex Floor 1.0: Flex Floor 1.0 is a cost effective, scalable Automated Guided Cart (AGC) that is used for a variety of applications, including assembly and material transport. The vehicle includes a single drive wheel, perfect for loop style assembly and material handling systems.
Flex Floor 2.0: Flex Floor 2.0 is based on the same platform as the Flex Floor 1.0, but provides more capability by utilizing dual drive wheels. The results are a vehicle with double the capacity and Omni-directional capability. The vehicle is capable of spinning on its center and moving laterally, resulting improved layout flexibility and the capability to transport larger assemblies, such as large truck frames.
Flex Floor 2.0T: Flex Floor 2.0T is a Tunnel style AGC that utilizes the same architecture as the Flex Floor 2.0, but also includes (2) electric hitch pins that are utilized for transportation of companion carts. These companion carts are utilized for material transport and can include a variety of attachments, including roller conveyor, lift tables and powered trunnions.
Fori Automation, Inc. privately held and U.S. owned and operated since 1984, specializes in the custom design, build and integration of automated material handling, assembly, testing and welding systems for the automotive and non-automotive industries. With over 30 years of experience and seven locations across four continents, we are positioned to support our customers around the globe.
Fori Automation specializes in the design, build and integration of automated assembly systems for the automotive & non-automotive industries. Fori has supplied systems for axle, battery pack, cockpit, engine dress, headliner, seat, motorcycle and recreational vehicles.
Fori Automation specializes in the custom design, build and integration of automated assembly lines for a variety of industries and products. Fori has supplied assembly lines for the automotive, construction and recreational vehicle industries.
Our dedicated assembly and automation group has the experience to process a wide range of assembly systems across nearly any industry. Our assembly systems include: Axle, battery pack, bullet manufacturing, cockpit, door, electric stator, engine dress, glass roof, headliner, seat, motorcycle front end & saddle pack, electric scooter and many others.
https://www.youtube.com/watch?v=zzAw5dgQn9U
Fori's main system verticals which include, automated assembly, material handling, robotic welding and testing, enable us to be a one stop equipment supplier for the entire assembly system. Within the main system verticals, include vast experience with error proofing, data collection, MES integration, lift assists, auto-torquing and robotic handling.
Our latest material handling systems, such as our Rail Guided Carts (RGCs) or Automated Guided Carts (AGCs) have been a differentiator for our Tier 1 and OEM customers from a flexibility and scalability perspective versus a traditional conveyor system.
RGCs and AGCs improve tear down and setup times and also allow the end user to scale their material handling system based on projected production rates. The ability to re-utilize their capital expenditure on future programs through a simple tooling change is another long term benefit. Below is a success story where one of automotive Tier 1 customers utilized a fully automated assembly line with RGCs for their assembly system.
https://www.youtube.com/watch?v=Bd3bIlIrjfk
For more information on Fori Automation's available products and automated systems, please visit our website.
Fori Automation has added a variety of automated material handling options to its product portfolio, including automated tuggers, powered drive wheels, high capacity AGVs and multiple AGV synchronization for tooling transport.
We are proud to announce that we have added (4) automated material handling platforms to help facilitate material flow through today's manufacturing facilities.
These developments include Automated Tuggers, Powered Drive Wheel Systems, High Capacity AGVs and Synchronization of automated vehicles for the transport of large tooling.
The systems are designed to increase safety, throughput and accuracy and are supplied to replace traditional material handling methods such as fork lifts, manned Tuggers and overhead cranes. The systems are fully configurable to vary the level of automation depending on the requirements of the end user. The AGV control can be as simple as utilizing a control pendant to manually move the vehicle, all the way up to the highest level of automation which includes a Fori Vehicle Management System (VMS) or Traffic Control. A VMS allows the system to be fully autonomous, only requiring input for scheduling of moves, the VMS takes care of the rest.
Fori’s software is based on a Siemens Safety PLC for the vehicle control, providing an open architecture for the end user. Utilization of the Safety PLC based system eliminates the “black box” supplied by many of the AGV companies in the industry. All Fori AGVs are outfitted with the latest safety components available on the market. At a minimum the vehicles are supplied with perimeter Safety Scanners, Indicator Lights, Alarms and E-stops. The Safety Scanners provide collision avoidance for the end user to ensure safety for the operator and that no damage occurs to the product. Additionally, each vehicle is designed to be user friendly and virtually maintenance free for the end user.
Automated Tuggers:Tuggers are a direct replacement for Fork Lifts. The vehicles are utilized for transporting carts, kits and various product throughout the manufacturing process.
https://www.youtube.com/watch?v=TdX5-JNfPsw&t=28s
Powered Drive Wheels: Powered Drive Wheels are modular drive wheel sets that are mounted to mobile tooling or operator platforms for automated mobilization. The systems utilize a standard control architecture that is expandable to support added powered drive wheels in order to increase capacities.
Fori offers a variety of Powered Drive Wheels with a wide range of capacities that can be mounted to tooling or operator platforms for automated guidance.High Capacity AGV: AGVs are used for a variety of applications that are traditionally completed with an overhead crane. Fori AGV capacities are upwards of 250,000 lbs.
https://youtu.be/FTCMlcp9AEQ
Synchronized AGVs: When required multiple vehicles can be synchronized to move large tooling, this methodology allows a single, modular vehicle design to be provided to the end user, but multiples of two or three vehicles can be used for lift and carry of various tools.
https://www.youtube.com/watch?v=MnJJ5vnQ6NM
Fori Automation, Inc. privately held and U.S. owned and operated since 1984, specializes in the custom design, build and integration of automated material handling, assembly, testing and welding systems for the automotive and non-automotive industries. With over 30 years of experience and seven locations across four continents, we are positioned to support our customers around the globe.
For more information of Fori Automation's products and capabilities, please visit our website.
Fori recently integrated a flexible assembly system for a scooter assembly line. The line currently utilizes a scalable manufacturing methodology, enabling the end user to increase automation as production requirements increase.
The assembly system is made up of a single assembly loop and two offline stations. The two offline stations consist of a battery assembly area, along with a tire & wheel assembly area.
A unique characteristic about this assembly loop is the manual carts are tied into a track that resides on the floor similar to the Fori Flex Rail system that utilizes Rail Guided Carts (RGCs).
The unique equipment provided includes:
Flexible production tooling pallets
Bushing press
Heavy duty torque tube for front fork attachment
Robotic sealant dispensing cell
Automotive Assembly System - Automated Sealant Apply
Implementation of these types of scalable assembly systems allow the end user to minimize upfront expenditure and utilize a cash flow structure which supports increased automation as throughput requirements increase.
For more information on Fori's available equipment, please visit our website.
A Fori Flex Rail system, utilizing Rail Guided Carts (RGCs) was recently supplied for a rear suspension module build. The system consisted of a main build line, two module alignment machines and a final assembly build line.
The utilization of a Flex Rail System and Rail Guided Carts provides the utmost flexibility for those customers who need to be able to accommodate change easily. The ability to be flexible in the automotive world means less downtime, cost and reduced infrastructure during installation.
Rail Guided Cart based assembly systems are becoming the norm on Fori's Automotive Assembly Systems. The systems can be modified easily, whether it be adding a station or even accommodating fluctuations in throughput requirements.
Fori Flex Rail System - Rail Guided Cart Assembly System with Integrated Robots
Each Rail Guided Cart is a stand along unit with an integrated Siemens Safety PLC and Wireless Client. Utilization of the PLC based system, results in an open architecture to the end user. Each of the carts are outfitted with safety bumpers and collision avoidance laser scanners to ensure the safety of the operators. A video of the Fori Rail Guided Cart can be found here.
Overhead support to the operators for tooling in most cases are simple jib booms and inverted "L" posts that are bolted to the floor to promote flexibility of the system. In instances where sequence and repeatability are critical, a robot is integrated for final torquing and the load and unload of assemblies.
Benefits of the Fori Flex Rail Systems utilizing Rail Guided Carts include:
Increased safety
Improved part and assembly access
Decreased plant infrastructure
Reusable for future programs
Scalable solution - add or remove carts for production fluctuations
For more information on Fori Rail Guided Carts please visit our website or contact us at sales@foriauto.com.
Fori Automation, Inc. designs, builds and integrates custom assembly and material handling systems for the Aerospace industry. Fori recently provided a turnkey Automated Guided Vehicle (AGV) system for a large Aerospace OEM. The assembly system utilized a moving line methodology.
Fori Automation Automated Guided Vehicle (AGV) for Aircraft Assembly and Material Handling
There were a number of design considerations for the AGVs provided. The AGVs were built with an emphasis on operator access and ease of use. The AGVs included integrated scissor lifts for cockpit assembly, as well as other operator platforms that aided in the assembly of the aircraft. The vehicles were required to move at very slow speeds, sometimes as slow as 20″ per hour. The system utilized a high voltage servo based controls architecture in order to meet the accuracy and speed requirements for the project.
A total of (18) Fori Aerospace AGVs were supplied for the system. A video outlining the manufacturing and assembly methods used for the aircraft assembly can be viewed here.
For more information please visit Fori Automation’s website.
The bushing press system includes two tooling modules, one to produce left hand modules and one to produce right hand modules. The system includes a single press in the center of the equipment to product either configuration of product. The press system supplied utilizes a 
bushings.
Start of production for the equipment was during the 1st quarters of 2019. The system provided improved production rate versus more manual methods of bushing insertion.
pace composite tooling cart transport.
The 
hment allows the tooling cart to rotate with the Tugger AGV and back it into work stations as required by the process.
The Tugger AGVs were commissioned to ensure safe and reliable product transfer. Previously, this transfer was completed with fork lifts or manned tow vehicles. The AGVs eliminated non-value added material handling and provided a hands off system for transporting product through the assembly process.
ean reduced ability to provide repeatable operator output. In an industry with constant pressure to boost efficiency and improve quality, automation becomes the solution most look for.
The suspension module assembly consisted of a heavily automated system. The equipment included a rear suspension module line, front suspension module line, front and rear combo module line and a front coil over shock assembly (FCOS).
spension assembly line consisted of (16) RGCs, a semi-automatic ride height and trending set machine that positioned the links within a slot. The equipment could be adjusted based on the tolerances provided by the OEM.
The rear suspension assembly line consisted of (37) RGCs, (2) automatic alignment systems, ride height set automatic torque cell and a robotic flip station.
The new RGC assembly line was installed during the first quarter of 2019.
The Fori Tugger AGV is utilized in two configurations, first as a Tugger pulling tooling carts in a single direction. The Tugger AGV is also used as a Dock N’ Lock. In the Dock N’ Lock configuration, the AGV automatically connects to the tooling cart and pulls it against the bumpers (shown in bottom picture). The attachment allows the tooling cart to rotate with the Tugger AGV and back it into work stations as required by the process.
The Tugger AGVs were commissioned to ensure safe and reliable product transfer. Previously this transfer was completed with fork lifts or manned tow vehicles. The AGVs eliminated non-value added material handling and provided a hands off system for transporting product through the assembly process.
The vehicle included a custom scissor lift to accommodate the vertical lift stroke and capacity required for the process. Each vehicle is capable of lifting 1,100 pounds (500 kilograms), and the scissor lift is capable of 21 inches of total stroke with a collapsed height of 11 inches. The custom 24 volt 67 ampere hour lithium ion battery was designed to fit within the available footprint on the vehicle. The system allowed for quick charging at the designated opportunity charge stations. Utilization of a lithium ion battery reduced the required charging infrastructure.
For more information about Fori Automation's AGVs, please visit our 
The single loop style conveyor system consists of 13 RGCs to transport front brake corner and strut components (front 
For more information about Fori's 
Each vehicle consisted of two fixed drive wheels, an integrated trunnion, and a 24 volt lithium ion battery to power the vehicle. The system was based on an open controls architecture, utilizing a Siemens PLC for the vehicle control.
Each vehicle utilizes a camera based guidance system that follows colored tape or paint. The optical guidance system provides a flexible, reliable and cost effective solution for guiding the vehicles throughout the assembly plant.
The system was supplied with a Siemens based Vehicle Management System (VMS) to schedule and coordinate vehicle moves, communicate with the plant and for monitoring of the vehicles.
For more information about Fori Automations' AGVs, please visit our 
The fixture lowers itself onto the vehicle frame, and then pins and clamps to the frame which establishes the control datum points to locate to. The machine's two pivot arms swing in and clamp the upper and lower control arm ball joints. DC Nutrunners loosen the lower control arm fasteners. Servo motors position the X and Y location of the lower control arm. DC nutrunners secure the lower control arm into the correct location. The fixture then un-clamps and lifts off of the frame. At that point the fixture drives itself back to it's home position ready to accept the next unit.
The system consists of a fully integrated Safety PLC. The PLC has the ability to track and store faults, monitor and record positional and setting information as well as monitor all safety devices.
For more information about Fori Automation's automotive assembly capabilities, please visit our 
Fori Germany supplied 21 work piece carriers for a front end assembly line. The work piece carriers were integrated with an existing 
The purpose of the work piece carriers is to provide a repeatable solution for locating the parts to the pallet for assembly. The work piece carrier also provides a process to the operator for adjusting the part location and orientation. Adjustment is completed through a powered trunnion.
The carrier trunnion has an integrated motor in order to tilt (the system has four automatic tilt angles) the fixture both automatically and manually. The carrier utilizes the power available on the AGV and communicates with the it to provide confirmation of the correct position. Upon completion of the front end module, the carrier returns to the home position and the module is unloaded via a 
The system supplied provided a simple technique for locating the front end module for the operator. The design considerations were based on a high level of reliability and minimal maintenance.
To learn more about Fori Automation's AGVs and assembly capabilities, please visit our website.
The rear main assembly line was composed of 15 RGCs, seven operators, one automatic drive through alignment machine, and one manual backup alignment system.
https://www.youtube.com/watch?v=_vAiYKMojDU
For more information about Fori Automation's RGCs, assembly systems, and aligners, please visit our 
The required changes to the existing front 
A Fori Vehicle Management System (VMS) is utilized for scheduling of vehicles and traffic management of the system. The vehicle controls are based on an open architecture utilizing a Siemens safety PLC, eliminating the black box technology that is commonly used across the industry. The Tunnel AGV has proven to be a cost effective and reliable material handling system for a variety of applications.
For more information on Fori's automated material handling products, please visit our 
The ability to be flexible with the pallet provided the ability to use the vertical conveyor for more than current parts or model changes. Overhead support for tooling was a jib boom that bolted to the floor to remove the assembly to dunnage.
For more information about Fori's assembly solutions, please visit our 
Fori USA was responsible for Project Management, Engineering, Assembly and Integration. All cells were setup and run off at Fori's global headquarters in Shelby Township, MI. Fori Mexico was responsible for installation and buy off at the end user's production facility.
For more information on Fori Automation's weld lines, please visit our 
The Fori AGV is required to locate within +/- 5mm to an existing fuselage transporter. The Fori system utilizes a natural feature and camera based guidance system, which accommodates unexpected location of the transporter. The Fori system overcomes the variability of the fuselage transporters accuracy by measuring the surface of the transporter to generate angular offsets and utilizes a SICK camera and reflector based system for final location. Once positioned, the mobile robot automatically docks to the transporter for power, communication, and pneumatics.
Automated movement is handled through the tethered Siemens Mobil Panel. The operators are able to select drill positions on either the Fori HMI or robot HMI. Once selected the Fori AGV is responsible for safely and accurately lifting and transporting the two mobile robots between 16 different drill positions.
For more information about our drilling platform AGVs, please visit our 
For more information about Fori Automation's aerospace assembly products, please visit 
The Fori Flex Floor utilizes a heavy duty extrusion style frame that enables the footprint of each style vehicle to be modified to fit the product being assembled or the materials being moved. The Flex Floor platform utilizes commercially available drive wheels, casters, batteries, controls components and guidance. The Flex Floor platform is based on a Siemens Safety PLC based architecture, providing the end user an open architecture. Many of the other products on the market include a “black box”, requiring the user to enlist support from the equipment supplier. Each assembly and material handling system can be supplied with a Fori Vehicle Management System (VMS), enabling the system to be fully autonomous, only requiring input for scheduling of moves either from the user or from the plant production system, the Fori VMS takes care of the rest. The Flex Floor vehicles are outfitted with the latest safety components available on the market. At a minimum the vehicles are supplied with perimeter Safety Scanners, Indicator Lights, Alarms and E-stops. The Safety Scanners provide collision avoidance for the end user to ensure safety for the operator and that no damage occurs to the product or part. Additionally, each vehicle is designed to be user friendly and virtually maintenance free for the end user.
Flex Floor 1.0: Flex Floor 1.0 is a cost effective, scalable Automated Guided Cart (AGC) that is used for a variety of applications, including assembly and material transport. The vehicle includes a single drive wheel, perfect for loop style assembly and material handling systems.
Flex Floor 2.0: Flex Floor 2.0 is based on the same platform as the Flex Floor 1.0, but provides more capability by utilizing dual drive wheels. The results are a vehicle with double the capacity and Omni-directional capability. The vehicle is capable of spinning on its center and moving laterally, resulting improved layout flexibility and the capability to transport larger assemblies, such as large truck frames.
Flex Floor 2.0T: Flex Floor 2.0T is a Tunnel style AGC that utilizes the same architecture as the Flex Floor 2.0, but also includes (2) electric hitch pins that are utilized for transportation of companion carts. These companion carts are utilized for material transport and can include a variety of attachments, including roller conveyor, lift tables and powered trunnions.
