Door assembly - Automated inspection and assembly solutions
- Aug 21, 2018
- Rail
L.B. Foster was approached by IAC Group Limited to supply bespoke automated machines to assemble components and perform inspection checks on car door assemblies for the new Land Rover Discovery.
Introduction
IAC has more than 160 years of automotive interiors technology expertise. The company is a tier one automotive manufacturer supplier and partners with engineering solutions specialists to deliver automated manufacturing capabilities.
L.B. Foster Automation specialises in the design, manufacture, testing, installation and maintenance of bespoke engineering solutions to automotive tier one component subassembly suppliers.
We enjoy a successful track record working with IAC Group Limited. Previous collaborations include the design of an innovative automated headliner assembly inspection solution for the automotive sector. So we were its partner of choice when IAC was approached by Jaguar Land Rover to develop automated door assembly and inspection machines for its new Land Rover Discovery.
Requirement
L.B. Foster Automation was approached by IAC Group Limited to supply bespoke automated machines to assemble components and perform inspection checks on car door assemblies for the new Land Rover Discovery.
IAC identified a requirement for four units. Each machine is purpose-designed to accommodate each door of the vehicle:
Front left hand
front right hand
rear left hand
rear right hand.
Specification
Robust framework with fork-lift pick-up points and painted to IAC colours
dedicated door handling tooling mounted to a manual rotating frame
high-resolution cameras to provide all ‘A surface’ component presence and colour checks
an E test block located on the main machine framework for continuity checks when an operator is working on the B surface
control system with operator push button controls
through-beam sensing
powered torque drives
barcode scanner
direct thermal printer
flat screen monitor
automated control system
overhead lighting gantry
Our solution
IAC’s specification for the new Land Rover Discovery door assembly and inspection units included a number of sophisticated functions as standard, as well as some ‘nice to haves’.
Our solution considered the best way to deliver the required functionality, whilst incorporating added value features and operational innovations as standard.
As the specification developed, we worked in collaboration with IAC to deliver best in sector solutions. Among the ‘added value’ capabilities designed into our solution is the ability to rotate each door automatically whilst clamped in the machine, allowing operatives to work on both the A and B surface of the door without the need to manually rotate doors.
We also modified the design of the switch pack within the door assembly to include additional vision sensing and moving bracketry to ensure the area is covered through the assembly process.
Benefits
Bespoke configuration delivers class-leading functionality
designed in safety features protect operatives
innovative automated door rotation function speeds up inspection and assembly process
application of state-of-the-art vision technologies ensures 100% accuracy
in-built fail-safe control systems prevent operative error.
This really was a case of starting with a blank piece of paper. We worked closely with L.B. Foster Automation to create a smart engineering solution that automates the door assembly and, at the same time, delivers a range of complex inspection checks.
