ABCO Integrates NI PACs with Allen Bradley PLCs for Automotive Sensor

Author(s):
Kellie Hutchinson - ABCO Automation, Inc.

Industry:
Machines/Mechanics, Automotive

Products:
PXI/CompactPCI, LabVIEW, Industrial Network Interfaces

The Challenge:
Developing a high-speed, accurate, and open assembly line tester for automotive sensor assemblies that will acquire and analyze waveform data and communicate with an existing programmable logic controller (PLC)-based control system.

The Solution:
Using NI programmable automation controller (PAC) platforms based on PC-technology to deliver a full-line sensor assembly and test system solution to meet rigorous customer requirements.

The Need for Automation

In the current competitive climate, demands for more productivity and efficiency with fewer resources drive the need for more automation throughout the manufacturing process. It is difficult to deny that automation is a key component in delivering value and return on investment (ROI) to customers. One way to meet this demand in the current competitive automotive market is to develop more traditional, workhorse PLC-based assembly lines to be augmented by more cost-effective, PC-based testing methods to produce a better product.

National Instruments Alliance Partner ABCO Automation, a leader in manufacturing assembly and test automation, was asked to develop a full-line conveyer assembly and test machine for an automotive sensor manufacturer. The ability to manufacture and test each sensor throughout the assembly process is critical to meet the manufacturer no-defect standards.

Using NI Products to Meet System Requirements

The system requirements included that the sensor assembly throughput be increased to one part every 6 s and must be interoperable with the existing PLC-based systems from Allen Bradley. This project was a perfect example of implementing current technological advances because, now, engineers can seamlessly combine traditional PLC technology with the more cost-efficient and data-critical capabilities afforded by PC technology.

The project consisted of two large, designated machine sections, both of which used precision link indexing conveyors: a 14-station assembly and verification line and a 10-station final test line.

During the first 14-station assembly and verification phase, the system over molded the part and loaded it into the conveyor system, at which point it was completely assembled, verified, visually inspected, and ultimately welded. Using multiple DENSO robots, the system loaded and unloaded the sensor assembly into the 10-station testing line for final testing.

For the testing phase, we used the NI PAC platform to take advantage of the speed, accuracy, and interoperability with any control system. Using an NI PXI-1042 chassis and an NI PXI-8186 controller along with several NI PXI-6070E data acquisition (DAQ) modules, we acquired waveforms from an encoder connected to a tone wheel operating at specified revolutions per minute. The system analyzed the waveform data for duty cycle, high and low values, and other parameters that determined pass and fail grades. We sent acceptable parts to packaging and sent parts that failed to be isolated, marked, and added to a rejection pile.

 NI PACs and LabVIEW Increase Performance and Reduce Costs

A key factor in the project success was the LabVIEW OPC capabilities and interoperability with PLCs. The customer required that the new system be interoperable with multiple third-party modules and power supplies. Using LabVIEW DataSocket technology and RSLinx OPC server from Allen Bradley, we integrated NI PAC hardware with traditional PLCs and offered seamless control and monitoring of all data. The ease by which NI can speak to the Allen Bradley hardware saved us valuable programming and integration time on this delivery-critical job. As a result, our customer benefited from quality performance and cost savings.

While automakers and subsequently auto component makers fight for market share, the traditional PLC-based automation is being combined with powerful, cost-effective, and open PC-based systems. PC-based technology and the powerful LabVIEW development environment offer speed, performance, simplified development, and most importantly, interoperability with existing systems, resulting in faster, flexible, and more affordable solutions for system integrators and, in this case, the automotive industry. In the end, it is the customer who wins.

A National Instruments Alliance Partner is a business entity independent from National Instruments and has no agency, partnership, or joint-venture relationship with National Instruments.

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