Vehicle Manufacturing Automation System Introduction Part 4 - EPS

1. Vehicle Manufacturing
Automation System
Introduction
Part 4 - EPS
Tallrain / Oct 2016

2. 1 – What’s
…EPS?

3.  EPS = Error Proofing System, or Fail Safe System.
 EPS is designed for Manual/Machine/Material
operations.
 EPS integrates with PLC.
 EPS integrates with ANDON/AVI systems.

4. 2 – EPS
Business

5. Part Scanning:
1. Operator scans VIN Label.
2. MES client requests to
refresh page.
3. MES returns part list and
verification rules.
4. Operator scans Part Labels.
5. MES verifies labels, and
alerts if wrong part labels
are scanned.
Part Scanning
MES Server
2
3
Request
Part
List
1
VIN
4 Part S/N
5
Verify
ID P/N S/N Length S/N Rule
1 BT12345 9 0-9
2 LT12346 9 0-9
3 CT12347 12 0-9,A-Z
4 QT12348 12 0-9,A-Z

6. Part Picking:
Mainly used in Engine assembly:
1. When engine arrives, PLC reads
Engine S/N via RFID Tag.
2. PLC sends VIN to MES.
3. MES downloads Part List and
Rack ID list into PLC.
4. PLC turns on light for each Part.
5. Each time Operator picks a part,
its light turns off by PLC.
6. After all parts are picked up, PLC
uploads result into MES.
Part Picking
OPC
MES Server
ME PLC
IT Layer
Control
Layer
1
5
RFID
Reader
2
3
4
6
P/N Station Rack ID
A0001 1001 1
A0002 1002 2
A0003 1001 2

7. Vehicle Torque Gun:
1. When vehicle passes through PBS Out
station, MES broadcasts it to whole shop.
2. MES sends VIN and Torque Gun
Command into Torque Gun Server.
3. When vehicle comes to Torque Gun
station, Torque Gun Server sends
Command into Torque Controller, which
controls Torque Gun to operation
accordingly.
4. Controller uploads Torque results into
Torque Gun Server.
5. Torque Gun Server sends result into MES.
Vehicle Torque Gun
RFID Reader
OPC
MES Server
Torque Gun Server
Controller
Torque Gun
Command
Result
1
Prepare
2
4
Command
3
Result5
PBS OUT PLC

8. Engine Torque Gun
OPC
MES Server
ME PLC
IT Layer
Control
Layer
1
5
RFID
Reader
2
3
4
6
Controller
P/N Station Gun ID
A0001 1001 1
A0002 1002 2
A0003 1001 2
Engine Torque Gun:
1. When engine comes to station, PLC
reads Engine S/N via RFID Tag.
2. PLC sends Engine S/N into MES.
3. MES downloads Torque Command,
including: Torque Gun ID, Torque Count,
etc.
4. PLC sends Torque Command into
Controller, which controls Torque Gun to
operate accordingly.
5. Controller sends actual Click Number
and Value into PLC.
6. PLC uploads actual Click Number and
Value into MES.

9. VIN Marking
Marking
5RFID Reader
OPC
MES Server
Mark PC
taskfile
Request
Result
1
Prepare
2
3
6
taskfile
4
Feedback7
PBS OUT PLC
PLC
VIN Marking:
1. When vehicle passes through PBS Out
station, MES broadcasts it to whole shop.
2. MES sends Marking Command into VIN
Marking PC.
3. When vehicle comes to VIN Marking
station, operator scans VIN Label.
4. Marking PC sends Command into PLC.
5. PLC controls machine to mark
accordingly.
6. PLC sends Marking result into Mark PC.
7. Mark PC sends Marking result into MES.

10. Filling/Gluing
Filling/Gluing:
1. When vehicle comes to station, PLC
reads VIN via RFID Tag, and sends it to
MES.
2. MES downloads command into PLC.
3. PLC controls machine to operate
accordingly.
4. PLC uploads result into MES.
OPC
MES Server
PLC
IT Layer
Control
Layer
1
2
3
4
RFID
Reader

11. 3 – EPS
& AVI

12.  RFID Tags are used in most vehicle plants
for vehicle identification.
 But in General Assembly Shop, Plain-
Chain Conveyors are used for most lines,
which is always moving continuously, so
it’s low efficient to read RFID in middle
stations.
 EPS PLC integrates Encoder to calculate
line speed and position, together with AVI
reading in Line Head/End stations, to
output each vehicle’s real time position.
 EPS PLC integrates position sensors, to
output pulse signal of 0%/70%/100%
position of station, which will be used for
Alarm and Stop.
RFID Reader
OPC Server
MES Server
EPS PLCComing Vehicle
Encoder
Line Position
Vehicle
Sequence
COUPLER
Conveyor PLC
Encoder
Position
Sensor
Vehicle Position
Line Position

13. 4 – EPS
& ANDON

14. In General Assembly Shop, EPS result
sends to Conveyor PLC via ANDON PLC:
1. When operation is completed,
operation data will be sent to MES.
2. Control PLC/PC sends
result(OK/NOK) into ANDON PLC.
3. ANDON PLC sends OK/NOK and
70%/100% position signals to
Conveyor PLC, which stops line
when condition matches.
OPC
MES Server
Control PCResult
Data
2
3
1
PLCANDON PLC
PLC
Stop

15. Thank you!
1