Fori Automation recently installed a complex vehicle camera calibration and testing matched with high production requirements making new vehicle technology safe and effective. In an industry with constant pressure to boost efficiency and improve quality, automation becomes the key solution.
The FCM (Front Camera Module) Test System consists of specific targets to calibrate the Front Camera on vehicles with this option. The equipment included roof suspended calibration targets following the customers specifications in front of existing Fori alignment cells.
The FCM test system provides luminosity control, current (amps) monitoring, visual indication for failed lamp(s) and integration with the wheel alignment system(s) PLC to activate the system per vehicle options.
The FCM test system consisted of (6) FCM cells, each with 2 targets per wheel aligner with background luminosity protection. The FCM test systems also provide illuminance intensity metering for the maintenance team to validate the correct luminosity.
The new FCM test systems were installed during the last quarter of 2020 by the Fori Brasil Team.
The latest precision 3D wheel alignment provides for the high accuracy of toe and camber measurement as well as the best auditing of caster with the sweeping proves. Latest features of the Fori 3D technology prevent influence of temperature and have reduced the complexity of the electrical interface for PC top camera communication.
The specialized tooling for automatic front toe, camber-caster set and secure removes one operator from the pit, while providing the most accurate means for controlling alignment capability.
The specialized tooling for rear automation provides the capability to adjust and secure a small percentage of rear toe and camber on rear suspension modules. The tooling provides for a means of automatically adjusting the toe and camber once it is loaded on the suspension links and activated by operator to begin the adjust and secure cycle.
The headlamp aim audit system can be integrated with the production headlamp aimer. It is used to measure exact position of the location of the headlamp in reference to the bulb center. It can be used for verifying lamps are being aimed to tolerance and to assist with setting up new lamp models. It includes a high resolution camera to process and measure headlamps at 25 feet, a whiteboard that headlamps are projected onto, and a separate PC system for processing the lamps image.
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.
Fori USA recently designed, built, and integrated a wheel alignment system with headlamp aiming (HLA) and wheelbase adjust for a customer.
The End of Line system included: non-contact wheel alignment and automatic headlamp aiming. Wheel base adjust was also included in order to handle a variety of vehicle wheel bases.
The wheel alignment machine is designed for automatic measuring of toe and camber. Feedback is supplied to the operator, who completed a manual adjustment of the vehicle parameters. The wheel alignment equipment is designed for a wide range of wheel bases and tire tread width sizes.
An integrated headlamp aimer (HLA) measures the vehicle headlight intensity and positions the aimer automatically to guide the operator to the correct adjustment necessary. The “Fori Vision” aiming unit utilizes a 2.3 megapixel camera based system to measure the intensity and position of the headlight.
The latest hi resolution camera box was also included for improving the headlamp aiming resolution and accuracy required by the latest IIHS standards.
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.
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 China recently designed, built and integrated an end of line system for an automotive manufacturer.
Features:
Jobs Per Hour: 15 jobs
Testing Completed: Wheel alignment, headlamp aiming, roll and brake
Results: Increased production rate, reduced labor, improved quality
The end of line system was 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 & Camber with a wide range of wheel bases, tread width, and tire sizes.
An integrated headlamp aimer measures the vehicle headlight intensity and position automatically and guides 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 systems, 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.
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 
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The wheel alignment machine is designed for automatic measuring of toe and camber. Feedback is supplied to the operator, who completed a manual adjustment of the vehicle parameters. The wheel alignment equipment is designed for a wide range of wheel bases and tire tread width sizes.
An integrated headlamp aimer (HLA) measures the vehicle headlight intensity and positions the aimer automatically to guide the operator to the correct adjustment necessary. The “Fori Vision” aiming unit utilizes a 2.3 megapixel camera based system to me
asure the intensity and position of the headlight.
The latest hi resolution camera box was also included for improving the headlamp aiming resolution and accuracy required by the latest IIHS standards.
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.
An integrated 
For more information about Fori Automation's end of line testing solutions, please visit our 
The end of line system was included: non-contact wheel alignment, automatic headlamp aiming, and roll and brake testing.
The 
For more information about Fori's End of Line Systems, please visit our 
