With eight global locations Fori Automation, Inc. is no stranger to meeting customer needs on an international level. A great example of this is shown through our Fori Korea team. In 2021, Fori Korea supplied a stable AGV system to an automotive manufacturer located in Andizon, Uzbekistan.
Fori Korea successfully installed a Body to Chassis Marriage system or BCM AGV system, as we like to call it, for an automotive manufacturer that made a major facility investment after converting another Uzbekistan automotive plant to a state-owned company. Fori Korea's BCM AGV System was selected because of our longstanding experience with body to chassis marriage systems. Fori Korea stabilized the facility in a short period of time and started mass production in September 2021.
The results consisted of four processes of sub-line and four processes of marriage line. The sub process is a go and stop method, and the marriage process is composed of a reflector and a smart camera, so that the vehicle body and AGV are synchronized to execute marriage. Annual production for line one is 180,000 units and line two is 150,000 units. Fori is a global leader in automotive chassis marriage systems and turnkey integration. Contact us to learn more about our offerings or head over to our website.
A high production capital welding system for large truck frames require efficient transfer and handling systems to maintain production thru-put. Close-coupled direct feed systems for major sub components (rails), and AGV’s integrated into end of line processes, help provide flexible facility configuration and efficient production flow.
Fori Automation recently supplied a high production robotic welding line with 150 robots (114 MIG welding and 36 transfer), inline inspect and repair stations, inline buffers, over aisle transfer conveyors, 8 AGV’s with frame positioner trunnions, 3 inspect/repair platform stations, and final frame stacking cell.
The weld system provided flexible tooling and welding processes for 35+ models of pickup and SUV frames with multiple wheelbase variations, and multiple drivetrain, body and box configurations. The AGV’s were built by Fori Automation, USA.
The complete welding system was built, runoff and delivered from Fori Automation de Mexico—Arteaga, Coahuila.
Fori Automation recently provided (2) High Capacity AGVs for the assembly of rockets for a large aerospace OEM.
The High Capacity AGVs can lift and transport up to 330,000 lbs. when used as a pair. Each AGV is capable of 165,000 lbs. when used in a single tool configuration. The system is designed to carry several different tools with varying lengths, widths, and total weights. The AGV system utilizes an optical coupler to communicate between the AGVs to coordinate motion and safety.
Each AGV includes (4) servo lift arbors, (6) suspended drive wheel assemblies and (8) suspended caster assemblies. The AGV chassis was custom designed to accommodate all of the different use cases. Each system included (3) different guidance methods for the various use cases within the plant. Currently, the system utilizes semi-automated control, with the ability to be upgraded to fully automated in the future.
The system can repeatedly locate within +/- 1.5mm at pick and drop stations. While driving the vehicle must maintain +/- 10 mm at slower speed. Improved accuracy and repeatability are accomplished through the use of Siemens servo motors and drives. The system is based on a high voltage DC Architecture, with a DC-DC converter to run the high voltage servo motors and drives.
The AGV solution reduced reliance on overhead cranes and other manual material handling methods for moving tooling and product through the plant. The AGVs will improve production flow and improve safety and repeatability for the assembly processes moving forward.
Fori has further improved on its standard Tugger AGV design by doubling the overall towing capacity.Fori Tugger AGVs have been used for a variety of material handling applications within the automotive industry. Most recently Fori was enlisted to supply a derivative of the standard Tugger product line that is capable of nearly double the capacity of the original vehicle. The driver of this increase was the transport of (3) carts, carrying axle assemblies for a large automotive OEM.
The Fori Tugger capacity allowed more product to be transferred during each move, further increasing the return on investment to the end user and decreasing the number of required vehicles. The Tugger AGVs were commissioned to replace non-value added material handling tasks within the assembly process. The most important process consideration was safety and reliable delivery of product.
Further improvement of the safety and reliability of the material handling system was the integration of a Fori Vehicle Management System (VMS). Vehicle scheduling of moves, tracking and traffic control is coordinated through the Fori VMS. The Fori Tugger is a proven and robust product that can be applied to a variety of material handling applications.
Fori Automation has further improved on its standard Tugger AGV design by incorporating a Fori chain lift and pallet tooling for lithium ion battery decking.
Fori AGVs have been used for a variety of material handling applications within the automotive industry. Most recently Fori was enlisted to supply a derivative of the standard Tugger product line that has a built in electric lift and pallet tooling to be used for marrying the electric vehicle battery to the chassis.
The AGV was required to synchronize with the vehicle chassis in the overhead carrier. The synchronization was a challenge in itself as there was no physical tracking arm. All of the vehicle synchronization for battery decking was completed utilizing tracking cameras and encoder positioning. The most important process consideration was the safe and reliable positioning of the product for the operators.
Further improvement was the integration of a Fori Vehicle Management System (VMS). The Fori VMS allows for vehicle scheduling, charging, vehicle status information and traffic control. The Fori battery decking AGV platform partnered with the Fori VMS is a proven and robust product that can be applied to a variety of material handling applications.
Cost effective, flexible AGV solutions have allowed automotive companies to implement a safe, reliable and repeatable material handling solution within their build processes.
The Dock N’ Lock AGVs were built to fit within existing plants and each plants respective material handling strategy. The AGVs were commissioned to replace non-value added material handling tasks. Specifically as a direct replacement for all of the fork lifts, creating a “fork free” environment. The Dock N’ Lock AGVs are responsible for auto-docking to the pictured companion carts. Previous methodology utilizing fork lifts was not a safe or reliable option, the Dock N’ Lock AGVs solved this problem.
The automated locking feature is what differentiates the Dock N’ Lock AGVs from standard Tuggers. The AGVs were required to auto-couple to newly developed racks, doing so removed the need for operator interface and allowed the end user to relocate operators to value added activities. The vehicles were required to repeatedly locate within +/- 10mm and travel at speeds up to 200 feet per minute.
A fully integrated, automated Vehicle Management System (VMS) was also provided. The VMS handles the traffic routing between the 19+ vehicles that are currently operating within the system. The VMS has the ability to track and store faults, monitor battery consumption and ensure safe operation by monitoring all safety devices.
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.
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.
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 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.
Solutions: Vehicle synchronization, auto-leveling, vehicle management system
The six high capacity AGVs, capable of auto-leveling and synchronized transport of tooling up to 40,000 pounds have been designed to accommodate projected wing production. The AGV system is required to be synchronized during the lift of the tooling and product, as well as synchronization of the three AGVs during transport. The system includes an auto-leveling feature that dynamically levels the tooling during travel to ensure a level plane is maintained during transport between stations. 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, whereas the AGV based solution eliminates the reliance on cranes.
The AGVs were developed to support the customer's lean automated manufacturing methodology. The goal of the project was to automate the entire material handling process for the assembly of the stringers (specifically the load and unload of the autoclaves used for curing the composite wing stringers). The loading of the autoclave is completed utilizing a natural feature guidance system. Then the AGV uses the walls of the loaded autoclave for the guidance in and out, while still maintaining +/- 5mm 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 two servo based lifters and a laser alignment system which provides measurement feedback to the onboard 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 (VMS) 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 AGV products, please visit our website.
Controls: Rockwell open architecture, vehicle management system (VMS)
Keys to Success: Vehicle synchronization, custom designed chassis, high capacity lifts
Results: Improved flexibility, decreased infrastructure, elimination of batteries and chargers
Chassis marriage has traditionally been completed with a Rail Guided Vehicle (RGV) and in floor track. The system has been a longstanding robust and reliable solution; however some customers require additional flexibility to support their process.
The chassis marriage AGV looks to improve on the RGV technique by utilizing induction power. Using induction provides a limitless power source and magnetic guidance which is a proven guidance technique for AGVs providing a high level of reliability and accuracy.
One of the main design considerations for the chassis marriage AGV development was flexibility and infrastructure reduction. Utilization of an in floor induction wire and magnetic bar will decrease the cost and time associated with the installation of Chassis Marriage systems. The ease of layout changes supports the added flexibility requested by the end users of these systems.
In floor induction wire.
A Vehicle Management System (VMS) is supplied with the vehicles to manage communication with the overhead conveyor, synchronization of vehicles and system diagnostics required by the end user. This inductive chassis marriage AGV can be designed to use the proven and reliable patented Fori electric chain lift or other suitable lift devices.
For more information about Fori's AGVs or Chassis Marriage systems, please visit our website.
Fori has further improved on its standard Tugger AGV design by doubling the overall towing capacity.
https://www.youtube.com/watch?v=TdX5-JNfPsw
Features:
Guidance Technology: Inertial with pencil magnets, bi-directional, capable of 0 degree turn
Capacity: 35,000 lbs./15,909 kg.
Safety: Scanners and bumpers
Controls: Siemens Open Architecture
Keys to Success: Highly accurate and repeatable
Results: Increased production rate, reduced personnel injuries, decreased infrastructure
Fori was enlisted to supply a derivative of the standard Tugger AGV product line that is capable of nearly double the capacity of the original design. The driver of this increase was the goal of being able to transport three carts carrying axle assemblies for a large automotive OEM.
Due to the capacity, more product was transferred during each move which further increased the return on investment while decreasing the total number of required vehicles. The Tugger AGVs were commissioned to replace non-value added material handling tasks within the assembly process. The most important process consideration was safety and reliable delivery of product.
Integration of a Fori Vehicle Management System (VMS) introduced further improvements to safety and reliability. Vehicle scheduling of moves, tracking and traffic control is coordinated through the Fori VMS. The Fori Tugger is a proven and robust product that can be applied to a variety of material handling applications.
For more information about Fori's Tuggers and other material handling systems, please visit our website.
Fori has traditionally supplied Rail Guided Vehicles (RGVs) for automotive Chassis Marriage, but over the past five years Fori has leveraged its AGV experience to transfer existing automated vehicle technologies to its Chassis Marriage systems. The automated vehicle technology provides a Chassis Marriage system that decreases the required plant infrastructure. Whereas the traditional RGV based system requires an in floor track and power transfer system. The AGV system removes this requirement by utilizing an on board, battery based power supply and magnetic tape or bar guidance for vehicle tracking and positioning. Overall these improvements decrease facility work and associated cost, and allow for decreased installation times and provide long term flexibility for changing production needs.
The battery powered Chassis Marriage AGV includes dual independent Fori patented chain lifts capable of lifting and transporting 4,000 pounds in order to install the front and rear suspension and drive train modules to the vehicle Chassis. The battery based Chassis Marriage AGV was developed to support the end users lean automated manufacturing methodology, decreasing the total in plant infrastructure required for the system. Not only will the AGV enable the end user to reduce their plant hardware investment, there will be significant long term flexibility in the assembly process. The guidance system of the AGV and reduced plant infrastructure allow the AGV to easily interact with other systems and processes.
The AGV is outfitted with multiple safety measures that ensure collision avoidance. Safety scanners are included on the front and rear of the vehicle that will slow down and stop the vehicle as objects enter the scanning field. The Chassis Marriage AGV also includes indicator lights in each corner, (4) e-stops, safety pressure bumpers on the perimeter of the AGV and an on board HMI for vehicle status and diagnostics.
Automated Guided Vehicle (AGV) for Chassis Marriage utilizing Magnetic Tape Guidance
The Chassis Marriage AGV is responsible for accurate and repeatable location of product in station for a reliable chassis marriage process. The AGV will provide increased flexibility, safety and decreased product damage, thus increasing profitability within the project for the end user.
For more information on Fori's Chassis Marriage AGVs, 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 provided six high capacity Aerospace Tugger AGVs for the automated transport of tooling, supporting the horizontal build line for wing assembly.
https://www.youtube.com/watch?v=XMOAJ_BuOEQ
Features:
Guidance Technology: Magnetic bar, inertial with pencil magnets, natural feature and 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 (VMS)
Keys to Success: Vehicle synchronization, custom designed chassis, highly accurate and repeatable.
The six high capacity Tugger AGVs (capable of automated docking and transport of tooling up to 120,000 pounds) have been designed to accommodate projected production. The AGVs will be the primary method of transporting the tooling and product through the assembly process.
The AGVs were developed to support a lean automated manufacturing methodology. The design intent was to build a vehicle that was modular and interchangeable. The AGV system is required to transport nine different tools, all with different weights and footprints. Due to tools exceeding lengths of 100 feet, the AGVs are required to dock at each end of the tool and move in tandem.
The automated docking utilizes a natural feature and camera based guidance system, which accommodates unexpected movement of the tooling. The system measures the surface of the tooling to generate angular offsets and utilizes a SICK camera and reflector based system for final location. Once positioned, servo driven couplers automatically pin spring loaded receivers mounted to the tooling. The tooling is also outfitted with safety scanners powered and controlled by the AGV.
Responsibilities of the AGVs include: automated docking, tooling identification and transport throughout the facility. A Fori Vehicle Management System (VMS) has been provided to monitor system I/O, communication between the AGVs, tooling, and automated assembly stations. Scheduling of moves also occurs between the vehicle Siemens Mobile Panel and the Fori VMS.
For more information about Fori Automation's aerospace products, please visit our website.
The (3) high capacity automated guided vehicles (AGVs) were supplied to replace a legacy system that was over 20 years old. The Fori AGVs will be the primary method of transporting the aluminum ingots through the finishing process. Traditional handling systems rely heavily on overhead crane utilization, but the AGV based solution reduces reliance on cranes.
https://www.youtube.com/watch?v=lehMe10Vx9g
The AGVs were designed to fit within the existing plant and process. One of the biggest challenges on the project was packaging eight drive wheels and (2) 100 ton capacity lifts within the existing vehicle footprint. Each drive wheel was outfitted with a suspension system to ensure proper radial loading and equal load distribution between the (8) drive wheels. Another improvement on the Fori system was ball screw based lift jacks that included integrated load cells for measuring fore/aft and side to side loading of the ingot. If the ingot is loaded outside of an acceptable range, the AGV stops immediately and sets down the ingot.
The Fori AGV utilizes a 72VDC sealed lead acid battery as a power supply. The vehicles utilize PMAC motors that provide improved control and efficiency over the previous system which utilized DC brushed motors. Each vehicle had a safety bumper front and rear, as well as six safety scanners around the perimeter of the vehicle to provide added safety coverage.
A Fori Vehicle Management System has been provided to monitor system I/O, manage communication between the AGVs and scheduling of moves for production.
For more information about Fori Automation's high capacity AGV capabilities, 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 Germany recently hosted a customer open house exhibition. The visitors were able to see Fori Germany latest and greatest products which were highlighted by two new styles of automated guided carts for the automotive industry.
Fori Automation's German Headquarters recently hosted an in-house exhibition to feature some of their latest and greatest products.
Products and projects presented included Automated Guided Carts (AGCs) for Automotive applications such as body shops and front end pre-assembly, as well as rear axle adjustment stations for axle alignment.
Fori AGCs for Automotive Module Assembly Systems
Pictured above is an example of an AGC utilized for module assembly within the automotive industry. The vehicle will transport the work piece carriers in the front end pre-assembly line. The assembly system was comprised of over (30) vehicles.
Low Profile AGC for Automotive Body Shop Applications
Fori Germany also developed a low profile AGC that is capable of lifting over 500 kg. and providing a total lift stroke of 350 mm for transport of car frames through a body shop. The system utilized the latest lithium ion battery technology and an optical guidance system which increased flexibility for the end user.
Fori Germany Headquarters in Merzig, Germany
The open house exhibition was a great success for Fori Germany. Over the last year Fori Germany has supplied a number of innovative products. For more information on Fori Automation's global locations and our products, please visit our website.
Fori recently supplied a custom designed Chassis Marriage Automated Guided Vehicle (AGV) for an electric vehicle manufacturer.
Over the past twenty years, Fori automation has been a leader in Automotive Chassis Marriage. Chassis Marriage, the process of bringing the car body and chassis together, has been primarily completed with the use of Rail Guided Vehicles (RGVs).
The Chassis Marriage process is completed utilizing integrated lifts and custom tooling pallets to support various chassis depending on the model of vehicle being manufactured. The Chassis Marriage process is completed once the operator does a final torque of fasteners, bringing the car body and chassis together.
Fori Automated Guided Vehicles (AGVs) provide increased flexibility and reduced infrastructure versus traditional Chassis Marriage methods.
The utilization of Automated Guided Vehicles (AGVs) for Chassis Marriage has increased flexibility for the end user by removing the monuments that are required on RGV based Chassis Marriage systems. The Chassis Marriage AGVs utilize a number of different power sources and guidance methods. Power sources include both lead acid and lithium ion batteries, induction and some cases a combination of both battery and induction power. Guidance can be completed in a number of ways, the guidance systems utilized most frequently are magnetic guidance, induction or optical.
Each Chassis Marriage AGV includes (2) integrated Fori electric lifts that are used for raising the drive train of the vehicle to the body. Each lift is capable of lifting up 2,500 kg. and upon request can reach lift strokes of up to 52" depending on the project requirements.
Utilization of AGVs within Chassis Marriage has resulted in increased system flexibility, decreased plant infrastructure for the end user and has provided a scalable solution allowing for addition of vehicles based on expected production rates.
For more information on Fori Chassis Marriage AGVs, please visit our website.
The central pillar of the partnership is the continued integration of Siemens Factory Automation hardware and software within Fori's Material Handling and Automation Equipment. Fori Automation will have one of their Automated Guided Vehicles (AGVs) for automated material handling on display.
Fori Automated Guided Vehicles (AGVs) with Siemens Controls for Flexible, Safe and Reliable Assembly and Material Handling Automation
Fori Material Handling equipment is utilized within the Aerospace, Automotive and Defense industries. Fori equipment has capacities as low as 500 lbs. to over 250,000 lbs.
The AeroDef takes place on March 7th and 8th at the Fort Worth Convention Center in Fort Worth, Texas.
Please visit us at booth #526 or contact us at sales@foriauto.com for more information!
Fori recently provided two custom designed, high capacity Automated Guided Vehicles (AGVs) for a large Aerospace OEM. The AGVs were utilized for component material handling and assembly.
Over the past decade, there has been a strong push in the Aerospace industry to increase Automation. Main drivers for this initiative include decreased crane utilization, process control, improved safety and reduction in product damage and waste.
The AGVs supplied required a customized frame design in order to mimic the footprint of the transported tooling. The project team had specific requirements on the length, width and height of the vehicle, as well as deflection requirements for the AGV frame while transporting the part and tooling. These requirements required a substantial engineering effort through the utilization of Finite Element Analysis (FEA) to ensure the final design would meet all the design requirements.
Fori Aerospace Automated Guided Vehicle (AGV) for Aircraft Component Assembly
Fori AGVs are Siemens safety PLC based, providing an open controls architecture, eliminating the "black box" provided by many material handling suppliers. The AGV system is outfitted with the latest and greatest safety devices available. The AGVs provided include perimeter safety bumpers and 360º SICK safety scanner coverage to ensure collision avoidance.
Responsibilities of the AGVs include:
Lift & Transport up to 90,000 lbs.
Minimize tooling & part deflection
Accurate and repeatable tool placement
Fully automated order scheduling & completion
Utilization of AGVs has resulted in decreased reliance on overhead cranes, providing a reduction in product damage and an increase in system efficiency and most importantly safety.
For more information on Fori AGVs, please visit our website.
Manual drill & fill has been a topic of conversation within the Aerospace industry due to the health and safety concerns. Utilization of automated drill & fill systems with a mobile platform has helped alleviate these concerns.
Fori recently supplied a custom Automated Guided Vehicle (AGV) for automated drill & fill. The automated drill & fill system is used for the side panel of a large commercial aircraft.
The AGV is required to auto-lift and level the platform upon arrival in each production station. The AGV must be positioned within +/- .005" and level within +/- .16 degrees. This is accomplished through the utilization of inclinometer feedback and precision servo motion control.
Fori Aerospace Automated Guided Vehicle (AGV) for Automated Drill & Fill Tooling Transport
Strict requirements were placed on the actual AGV frame design and the allowable deflection while traveling. The frame was designed to deflect less than .03" during transport of the drill & fill system from station to station.
AGVs within the Aerospace industry will enable the automated tooling to move to the part versus traditional systems where the part has always moved to the tool or machine station. The results will include minimized part handling and a substantial reduction in crane utilization.
Long term, the automated drill & fill system will minimize safety and health concerns, while increasing throughput.
For more information on Fori Aerospace AGVs, please visit our website or contact us at sales@foriauto.com.
Fori recently supplied two high capacity, halogen free Automated Guided Vehicles (AGVs) for a nuclear power plant refurbishment project. The AGVs will result in decreased total infrastructure and long term flexibility for the project team.
Two different high capacity Fori AGVs were designed and built to meet a number of different design requirements. The requirements included specific accuracy, repeatability, dimensions and total load capacities.
The AGV system was designed to support a refurbishment project that runs 24 hours a day, 7 days a week, 365 days a year.
Each of the vehicles had unique requirements, supporting different dimensional and capacity requirements for safe and reliable operation within the work area.
The first vehicle included strict height, width and length requirements, while still providing the capability of transporting up to 18,000 lbs.
Fori Automated Guided Vehicle for Nuclear Power Plant Refurbishment - 18,000 lbs. Capacity
A larger vehicle was also required for the project that was rated to carry up to 70,000 lbs.
Fori Automated Guided Vehicle for Nuclear Power Plant Refurbishment - 70,000 lbs. Capacity
The Fori AGVs were required to locate within +/- 5mm and allow for finite manual adjustment while handling equipment for the project. A Siemens MP277 Wireless Mobile Panel was provided to the operators for manual adjustment and control.
Due to the 24/7/365 project requirement a lithium ion battery system was utilized, the lithium ion system provided a more reliable power source, that will result in an increased total life of the battery pack and less overall charge time. The system is designed to facilitate charging during load and unload of equipment, minimizing production downtime.
The vehicles have reduced total plant infrastructure for the project, improved safety and increased long term flexibility.
Fori has supplied over 1,000 automated vehicles over the last twenty years, for more information please visit our website.
Cost effective, flexible Automated Guided Vehicle (AGV) solutions have allowed automotive companies to implement a flexible, safe, reliable and repeatable material handling solution within their assembly processes.
The Fori Dock' N Lock AGVs were built to fit within existing plants and each plants respective material handling strategy. The AGVs were commissioned to replace non-value added material handling tasks. Specifically as a direct replacement for majority of fork lift traffic, creating a "fork free" environment.
Fori Automation - Dock N' Lock AGV for Automated Material Handling
The Dock N' Lock AGVs are responsible for auto-docking to the companion carts pictured above. The previous methodology utilizing fork lifts and pallets resulted in injury and product damage concerns. Utilization of the repeatable and accurate guidance, along with integrated safety has solved this problem.
The automated locking feature and cart interface design is what differentiates the Dock N' Lock AGV from standard Tuggers. The ability to automatically connect to the carts removes the need for operator interface and cart staging. The cart and Dock N' Lock design also allows the AGVs to be bi-directional, which results in greater long term layout flexibility. An overview video of the Fori Dock N' Lock and Tugger AGV can be found here.
A fully integrated Fori Vehicle Management System (VMS) is also provided with the system. The Fori VMS acts a traffic cop for the AGVs and manages the routing of 20+ AGVs in some cases. The VMS has the ability to track and store faults, monitor battery status and communication with automated work cells.
Fori more information on Fori's Automated Material Handling equipment please visit our website.
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.
andling applications within the automotive industry. Most recently Fori was enlisted to supply a derivative of the standard Tugger product line that is capable of nearly double the capacity of the original vehicle. The driver of this increase was the transport of (3) carts, carrying axle assemblies for a large automotive OEM.
The Fori Tugger capacity allowed more product to be transferred during each move, further increasing the return on investment to the end user and decreasing the number of required vehicles. The Tugger AGVs were commissioned to replace non-value added material handling tasks within the assembly process. The most important process consideration was safety and reliable
delivery of product.
Further improvement of the safety and reliability of the material handling system was the integration of a Fori Vehicle Management System (VMS). Vehicle scheduling of moves, tracking and traffic control is coordinated through the Fori VMS. The Fori Tugger is a proven and robust product that can be applied to a variety of material handling applications.
hassis.
The AGV was required to synchronize with the vehicle chassis in the overhead carrier. The synchronization was a challenge in itself as there was no physical tracking arm. All of the vehicle synchronization for battery decking was completed utilizing tracking cameras and encoder positioning. The most important process consideration was the safe and reliable positioning of the product for the operators.
Further improvement was the integration of a Fori Vehicle Management System (VMS). The Fori VMS allows for vehicle scheduling, charging, vehicle status information and traffic control. The Fori battery decking AGV platform partnered with the Fori VMS is a proven and robust product that can be applied to a variety of material handling applications.
methodology utilizing fork lifts was not a safe or reliable option, the Dock N’ Lock AGVs solved this problem.
The automated locking feature is what differentiates the Dock N’ Lock AGVs from standard Tuggers. The AGVs were required to auto-couple to newly developed racks, doing so removed the need for operator interface and allowed the end user to relocate operators to value added activities. The vehicles were required to repeatedly locate within +/- 10mm and travel at speeds up to 200 feet per minute.
A fully integrated, automated Vehicle Management System (VMS) was also provided. The VMS handles the traffic routing between the 19+ vehicles that are currently operating within the system. The VMS has the ability to track and store faults, monitor battery consumption and ensure safe operation by monitoring all safety devices.
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 
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 
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 AGVs were developed to support the customer's lean automated manufacturing methodology. The goal of the project was to automate the entire material handling process for the assembly of the stringers (specifically the load and unload of the autoclaves used for curing the composite wing stringers). The loading of the autoclave is completed utilizing a natural feature guidance system. Then the AGV uses the walls of the loaded autoclave for the guidance in and out, while still maintaining +/- 5mm 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 two servo based lifters and a laser alignment system which provides measurement feedback to the onboard 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 (VMS) 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 AGV products, please visit our 
For more information about Fori's AGVs or 
Fori was enlisted to supply a derivative of the standard Tugger AGV product line that is capable of nearly double the capacity of the original design. The driver of this increase was the goal of being able to transport three carts carrying axle assemblies for a large automotive OEM.
Due to the capacity, more product was transferred during each move which further increased the return on investment while decreasing the total number of required vehicles. The Tugger AGVs were commissioned to replace non-value added material handling tasks within the assembly process. The most important process consideration was safety and reliable delivery of product.
Integration of a Fori Vehicle Management System (VMS) introduced further improvements to safety and reliability. Vehicle scheduling of moves, tracking and traffic control is coordinated through the Fori VMS. The Fori Tugger is a proven and robust product that can be applied to a variety of material handling applications.
For more information about Fori's Tuggers and other material handling systems, please visit our 
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 AGVs were developed to support a lean automated manufacturing methodology. The design intent was to build a vehicle that was modular and interchangeable. The AGV system is required to transport nine different tools, all with different weights and footprints. Due to tools exceeding lengths of 100 feet, the AGVs are required to dock at each end of the tool and move in tandem.
The automated docking utilizes a natural feature and camera based guidance system, which accommodates unexpected movement of the tooling. The system measures the surface of the tooling to generate angular offsets and utilizes a SICK camera and reflector based system for final location. Once positioned, servo driven couplers automatically pin spring loaded receivers mounted to the tooling. The tooling is also outfitted with safety scanners powered and controlled by the AGV.
Responsibilities of the AGVs include: automated docking, tooling identification and transport throughout the facility. A Fori Vehicle Management System (VMS) has been provided to monitor system I/O, communication between the AGVs, tooling, and automated assembly stations. Scheduling of moves also occurs between the vehicle Siemens Mobile Panel and the Fori VMS.
For more information about Fori Automation's aerospace products, please visit our 
The Fori AGV utilizes a 72VDC sealed lead acid battery as a power supply. The vehicles utilize PMAC motors that provide improved control and efficiency over the previous system which utilized DC brushed motors. Each vehicle had a safety bumper front and rear, as well as six safety scanners around the perimeter of the vehicle to provide added safety coverage.
A Fori Vehicle Management System has been provided to monitor system I/O, manage communication between the AGVs and scheduling of moves for production.
For more information about Fori Automation's high capacity AGV capabilities, 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.
