For this post we are travelling across the globe to our China location. Fori China supplied 10 end of line testing systems for an automobile group, with an annual output of roughly 1.5 million passenger vehicles.
These systems allow the customer to complete 30 to 45 jobs per hour creating a more efficient process and workload for their teams. For this customer we increased their production rate, accommodated future production increases and created a flexible end of line equipment process for multiple wheelbases. The systems Fori China supplied are adaptable for testing fuel vehicles and electric vehicles and for testing of automatic driving function modules.
Fori Automation remains a global leader in the manufacturing of wheel alignment, headlamp aiming technology and ADAS calibration systems. Interested in how we can help with your next project? Drop us a line.
In-floor headlamp aiming added to a wheel alignment machine with hi-resolution camera box provides accurate and repetitive means for adjusting vehicle headlamps for improved IIHS (Insurance Institute for Highway Safety) capability.
The (5) in-floor aiming systems provided for this project, were integrated to the existing Fori wheel alignment machines. Each system included the in-floor servo slide system for Y and Z automatic positioning to the vehicle headlamp, and a separate control panel with PC, Rockwell PLC and Rockwell servo motor drive components. The hi-resolution Fori-Vision camera box is mounted to the mast of the system. When automatically positioned to the headlamp center, the aiming process is initialized for finding the position of the lamp aiming point. The operator places the semi-automatic screwdriver on the lamp adjuster and the software sets the lamp to the required target.
The in-floor systems were used to provide better means of integrating to the existing wheel alignment machines versus the gantry systems. The gantry systems would have interfered with other existing overhead structures.
Upon installation of the systems, a more open environment was great for improved operator accessibility to adjust the headlamps. The latest hi-resolution aiming system has contributed to an improved headlamp aiming capability.
The 5 systems were installed over long holiday weekends and shutdown periods to not interfere with ongoing production.
Fori recently supplied (7) wheel alignment systems with integrated headlamp aim (HLA) and driver assist for a customer.
The wheel aligners and headlamp aimers feature the latest 3-D camera and digital headlamp aiming camera system that Fori offers.
Each wheel aligners can accommodate various tire styles and tread-width variations. The wheel base adjustment allows the machines to handle all of the different truck cab styles.
A gantry style target board system aligns the vehicle adaptive cruise control (ACC) module, lane departure warning (LDW) camera and several other onboard vehicle sensors.
The Fori wheel aligners supplied during this project are not the “typical” systems supplied in the past. Fori’s strong engineering group and past experience enabled us to take on these requirements and successfully implement them into the equipment.
Fixed Audit Headlamp Aiming (HLA) systems are stand alone and can be integrated within any existing wheel alignment machine, pneumatic centering platform, or other centering system.
The dual camera fixed audit headlamp aimer was developed for a customer and installed in 2018. The HLA system included a fixed gantry frame with the (2) high resolution camera boxes, a whiteboard that was collapsible for easy storage and a PC control panel.
The HLA application was used to perform headlamp aiming audits on various GM vehicles from the car and truck platforms. A simple manual cent
ering system and leveling plates were included to provide a low cost method for centering the vehicle during the audit process.
The (2) high resolution cameras provide an accurate method of finding the true headlamp center and headlamp aim position, to accommodate requirements set forth by the latest IIHS standard.
Fixed audit Headlamp Aiming (HLA) systems stand alone and can be integrated within existing wheel alignment machine, pneumatic centering platform or other centering system.
The heavy duty 3D wheel alignment system was developed by Fori Automation for a facility to accommodate the heavy truck loads and 110” wheelbase ranges of various truck models.
The equipment was developed to improve the wear capability of machine load components such as the floating plates and sliding access plates for accommodating the high throughput of the heavy duty truck models. Additionally, telescoping machine covers were provided to accommodate the long wheelbase adjustment range of 120-210”.
The machine included other special features for measuring and tracking underbody points with laser displacement modules during the truck’s suspension adjustment cycle. The machine also performed audit checks for caster measurement using the caster sweep audit process.
For HLA an above floor gantry system was provided with Y and Z servo motor positioning and the latest high resolution camera box for improving the HLA resolution and accuracy required by the latest IIHS standards.
End of Line pneumatic centering platform for ADAS calibration process.
(2) Pneumatic centering platforms were provided for centering the vehicle during the ADAS calibration process. The centering actuators also included integrated string encoders to track the actual position of the vehicle for verifying centering within tolerance as required by the customer ADAS specifications.
The project required the platform be mounted to the plant floor, so entrance and ramps were included for pulling into the platform and driving off. Heavy duty roller saddles were included for this system to handle the high throughput of the heaviest vehicles.
The system also provided the means for adding floor targets, for a calibration of the surround view camera system. Additional ADAS devices were also integrated with the supplied centering system.
Fori China designed, built and integrated an end of line testing system for an automotive manufacturer.
Features:
Jobs Per Hour: 65 jobs
Testing Completed:wheel alignment, headlamp aiming, roll and brake
Results: Increased production rate, reduced labor, improved quality
https://www.youtube.com/watch?v=uO3VIb39Ubc&t
The end of line testing system included: non-contact wheel alignment, automatic headlamp aiming and roll and brake testing.
The wheel alignment machine is designed for automatic measuring and manual adjustment of the vehicle parameters. The system was designed to measure toe and camber. The system is designed for a wide range of wheel bases and wheel tread width and tire sizes.
An integrated headlamp aimer measures the vehicle headlight intensity and position automatically and guide the operator to adjust the lamp position semi-automated. The “Fori Vision” aiming unit utilizes a camera based system to measure the intensity and position of the headlight.
Roll and brake testing is also completed on the end of line system, which includes testing for acceleration, cruise control, transmission, rear gear, dynamic braking and engine.
For more information about Fori Automation's end of line testing solutions, please visit our website.
Fori Korea supplied an Advanced Driving Assistance System (ADAS) to accommodate several vehicle platforms and test a variety of safety features.
Features:
Safety Testing: Lane departure warning, automatic headlights, over speed prevention, traffic signal recognition, distance warning
Results: Decreased infrastructure, increased production rate, accommodation of future vehicle models
ADAS test benches certify the operation of the vehicle cameras related to Lane Departure Warning (LDW), Automatic Head Lights (AHL), Over Speed Prevention (OSP), Traffic Signal Recognition (TSR) and Distance Warning (DW).
The ADAS system also validates functionality of the vehicles radar system which detects the moving elements in front of the vehicle from a significant speed and the operation of the vehicle. Examples include Adaptive Cruise Control (ACC), Advanced Emergency Braking System (AEBS) and Forward Collision Warning (FCW).
Another test completed by the ADAS is the AVM (Around View Monitor). This process is completed with four cameras (front, rear, two for side mirrors) and then displays the image captured by the cameras to the operator in their cones of vision (e.g., help for the blind spots, help for the car parking).
The ADAS system has reduced the infrastructure required for the various sensor testing that is completed on production vehicles. The system allows multiple tests to be completed in one station.
For more information about Fori Automation's end of line testing products, please visit our website.
Fori China designed, built and integrated an end of line system for an automotive manufacturer.
Features:
Jobs Per Hour: 30 jobs per hour
Testing Completed: Wheel alignment, headlamp aiming, roll and brake
Results: Increased production rate, reduced labor, improved quality
https://youtu.be/_GJYOmV-Ekc
The end of line testing system was integrated for a two vehicle inspection line. Testing completed included: non-contact wheel alignment, automatic headlamp aiming, roll and brake testing, and various other sensors.
The wheel alignment machine is designed for automatic measuring and manual adjustment of the vehicle parameters. The system was designed to measure toe and camber for a wide range of wheel bases, tread width, and tire sizes.
An integrated headlamp aiming system measures the vehicle headlight intensity and position automatically which guides the operator to adjust the lamp position with semi-automation. The “Fori Vision” aiming unit utilizes a camera based system to measure the intensity and position of the headlight.
https://www.youtube.com/watch?v=uO3VIb39Ubc
Roll and brake testing is also included in the end of line system which consists of testing for acceleration, cruise control, transmission, rear gear, dynamic braking, and engine.
For more information about Fori Automation's end of line systems, 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.
Robot Active Safety Cell Systems are completely stand alone and can be integrated within existing wheel alignment systems.
Features:
Fanuc 35iA CR collaborative robot
Auto tool change out
Results: Reduced personnel injuries, decreased infrastructure and installation time.
The Robot Active Safety Cell system (RASC) features the new Fanuc 35iA collaborative robot for positioning various targets that are used for Long Range Radar (LRR), Night Vision Calibration (NV), Headlamp Aim Box, and other devices used for End of Line testing.
When more than one device is required, an automatic tool change between the target, NV target, and headlamp aiming camera is included. The flexibility of the collaborative robot has enabled Fori to remove the conventional overhead gantry or in floor positioning systems that had previously been used throughout the industry for headlamp aiming and driver assist safety devices.
The Integration of collaborative robots has reduced the complexity of equipment required for calibrating “Driver Assist Safety” devices, and headlamp aiming. They also provide flexibility for integrating new “Driver Assist” devices for future vehicle platforms. It also provides for an open architecture, allowing more space for walk through areas, and for a better safe working environment.
For more information about Fori's End of Line Systems, please visit our website.
Fori Korea recently installed (3) complete End of Line Test systems for a large automotive OEM with a plant residing in Mexico.
The Fori End of Line System included three wheel aligners, headlamp aimers, roll and brake test stations and an under body test station.
Fori Wheel Aligner with 3-D Measuring Head
One of the unique design features was the vehicle measurement system, which resides on the wheel aligner. Sixteen weight measurement transducers are integrated into the four floating plates to equally measure the distributed load of the vehicle during the alignment process. Doing so eliminates the need for a separate weight measurement station.
(3) End of Line Test Systems were Designed and Built at Fori Korea and Shipped to Mexico for Final Installation and Buy-Off
The facility, capable of producing over 300,000 vehicles per year opened in 2016. The facility produces small cars for Mexico and South American countries.
For more information on Fori End of Line Systems, please visit our website.
Fori recently designed, built and integrated two new robotic wheel aligners with integrated dual mast headlamp aimers.
A total of four robots with Toe set gear heads are utilized for setting Toe within +/- 0.03 degrees from nominal. Front Toe is set by adjusting the tie rod with a Fori patented socket gear head which is driven by a nut runner. The Rear Toe is set by adjusting a cam bolt with a Servo driven gear head.
The equipment needed the ability to align three different vehicle models with uniquely different suspension configurations.
To achieve the cycle time requested Fori utilized a system called "predictor mode" for virtual real time toe and camber measurement. Once the initial tire run out is performed and mapped, all subsequent measurements are predicted based upon the known run out.
Elimination of the typical three second update time required after an adjustment is made, resulted in an average of ten seconds per machine cycle. Fori Robotic Toe Set System
Fori the first time, Fori implemented an auto tooling changeover system. Based upon the vehicle model identified prior to the alignment station, the robots will automatically disconnect and set the existing gear heads into fixture holding stands. The time required for this process simultaneously occurs while the current vehicle is driven off and the next vehicle is driven into the alignment station.
Fori has been supplying End of Line Testing equipment for over thirty years, for more information please visit our website or contact:
Fori recently supplied five wheel alignment systems with integrated single mast headlamp aim and semi-automatic front toe set.
Fori has been a leader in End of Line Testing equipment for more than 30 years. Supplying End of Line systems across the globe. End of Line Testing systems include, but are not limited to the following:
The Fori wheel aligners and headlamp aimers consisted of the following major assemblies: semi-automated front toe set with Fori patented dual socket gear heads to accommodate two different size tie rods. A semi-automated rear toe and camber secure tooling, caster sweep audit capability and ride height measurement capability were also included in the system.
The Fori system provided the ability for headlamp aiming with a headlamp aimer box and integrated light source. Auto-tilt positioning was provided for measuring and manually aligning the vehicle adaptive cruise control module.
Fori End of Line Testing Systems - Wheel Alignment, Headlamp Aim, Toe Set
Wheel aligners with the level of automation outlined above are not the "typical" systems supplied in the past. A strong engineering group and past experience ensured that the project would be a success.
For more information on Fori End of Line Testing systems, please visit our website.
l aligners and headlamp aimers feature the latest 3-D camera and digital headlamp aiming camera system that Fori offers.
Each wheel aligners can accommodate various tire styles and tread-width variations. The wheel base adjustment allows the machines to handle all of the different truck cab styles.
A gantry style target board system aligns the vehicle adaptive cruise control (ACC) module, lane departure warning (LDW) camera and several ot
her onboard vehicle sensors.
The 
latform, or other centering system.
The dual camera fixed audit headlamp aimer was developed for a customer and installed in 2018. The HLA system included a fixed gantry frame with the (2) high resolution camera boxes, a whiteboard that was collapsible for easy storage and a PC control panel.
The HLA application was used to perform headlamp aiming audits on various GM vehicles from the car and truck platforms. A simple manual cent
ering system and leveling plates were included to provide a low cost method for centering the vehicle during the audit process.
The (2) high resolution cameras provide an accurate method of finding the true headlamp center and headlamp aim position, to accommodate requirements set forth by the latest IIHS standard.
was developed to improve the wear capability of machine load components such as the floating plates and sliding access plates for accommodating the high throughput of the heavy duty truck models. Additionally, telescoping machine covers were provided to accommodate the long wheelbase adjustment range of 120-210”.
The machine included other special features for measuring and tracking underbody points with laser displacement modules during the truck’s suspension adjustment cycle. The machine also performed audit checks for caster measurement using the caster sweep audit process.
For HLA an above floor gantry system was provided with Y and Z servo motor positioning and the latest high resolution camera box for improving the HLA resolution and accuracy required by the latest IIHS standards.
ncoders to track the actual position of the vehicle for verifying centering within tolerance as required by the customer ADAS specifications.
The project required the platform be mounted to the plant floor, so entrance and ramps were included for pulling into the platform and driving off. Heavy duty roller saddles were included for this system to handle the high throughput of the heaviest vehicles.
The system also provided the means for adding floor targets, for a calibration of the surround view camera system. Additional ADAS devices were also integrated with the supplied centering system.
An integrated 
For more information about Fori Automation's end of line testing solutions, please visit our 
ADAS test benches certify the operation of the vehicle cameras related to Lane Departure Warning (LDW), Automatic Head Lights (AHL), Over Speed Prevention (OSP), Traffic Signal Recognition (TSR) and Distance Warning (DW).
The 
For more information about Fori's End of Line Systems, please visit our 
