Bumper Production with Identification
System integrator Sigma uses Turck‘s BL ident UHF-RFID system and its Graidware middleware to ensure complete transparency in bumper production at car parts supplier Magna
In collaboration with Turck, the Saxony-based system integrator Sigma proved at car parts supplier Magna that, with the right technology and clever software solutions, fully automated UHF-RFID identification solutions can be mastered without having to install inconvenient shielding measures due to the long sensing ranges involved. Today the customer is able to fully exclude the possibility of false reads in its bumper production plant using intelligent software logic.
It was a major car parts supplier, Magna Exteriors and Interiors (MEI), for whom the Saxony-based system integrator Sigma implemented a seamless RFID-based production control system. Utilizing UHF RFID allows for long sensing ranges.
Decision for RFID and UHF Technology
Since August 2012 MEI Meerane has produced front and rear bumpers for the VW Golf VII and delivers these “just-in-sequence“ to Volkswagen Saxony at the site in Mosel. The management of MEI Meerane decided during the planning and development phase of the new site to use RFID technology for automated manufacturing and logistics management. At the beginning of the project, due to the longer reading range, UHF RFID was determined to be the standard
Transparent process
When the raw bumper leaves the injection machine it is immediately equipped with a RFID tag which is registered and managed by the software. This allows tracking and tracing the bumpers during the entire production and logistical process. Prior to lacquering, the position of the bumper inside the skid is detected by a reader, and captured by the middleware. This is used to track the production quality. After the lacquering process the entire paint shop data is automatically linked to the bumper.
Then the bumpers are placed into storage containers according to product type. Multiple RFID readers monitor the correct storage of the bumpers into containers. The AutoID middleware Graidware not only captures the signals, but also checks the signals for plausibility using sophisticated algorithms. Interference signals from neighboring transportation routes or passing forklifts are recognized as false signals and filtered out.
After the final production call the painted bumpers are equipped with harnesses, distance sensors, fog lamps, etc. depending on the configuration. The RFID tag controls the machine via an OPC server, displays the next production step, the configuration of the bumper and loads the appropriate machine program for the welding and punching operations.
The full range
Sigma utilized Turck‘s full range of automation products for the project, and this started with the UHF read/write heads in three housing styles. Sigma used the Q150 readers for the shorter ranges of up to 1.5 meters. Longer sensing ranges were required at other positions, which were implemented by the customer with Q240 read/write heads. For some special process steps, the largest type Q280 UHF readers were required which have maximum ranges of 5 meters.
“A major benefit of the Turck solution was the fact that the triggers, such as light sensors, or as in this case, a foot switch, could be connected directly to the gateway of the BL67 I/O system to which the modules for the readers are also connected – regardless of whether they are sensors from Turck or not,” Frank Pyritz, Sigma managing director, as he describes one of the benefits of the Turck system.
- Automotive
- Press Shop – Tool Identification
- Press Shop – Sheet Metal Thickness Measurement
- Body Shop – Welding Nut Detection
- Paint Shop – Skid Identification
- Body Shop – Area Guarding
- Final Assembly – Robot Assembly
- Body Shop – Automotive Welding Tip Inspection
- Final Assembly – Diagnosis of Leaks
- Tier 1 – Bumper Identification
- Body Shop – Manual Load Weld Cell
- Powertrain – Contactless Verification
- Body Detection in Automobile Production
- Final Assembly – Black Parts Detection
- Item-level Detection with UHF RFID
- Final Assembly – Moonroof Detection
- Final Assembly – Long-Range Inspection
- Powertrain – Rubber Washer Detection
- Powertrain – Part-In-Place Detection
- Electric Vehicle Detection
- Vehicle Detection in a Self-Serve Car Wash
- Success Stories
- RFID Guides AGV in Suspension Production
- IO-Link Wired Silencer Production
- Workpiece Carrier Identification in Rear Vent Production
- Weld Nut Sensing
- RFID Traceability
- RFID in Engine Production
- Bumper Production with Identification
- Solutions for Paint Shops
- Welding and Assembly Sensors
- Angle Sensors for Assembly Systems
- Tool Identification
- RFID Identification of Injector Nozzles
- RFID in the Body Shop
- IO-Link Eases Differential Gear Production
- Pick-to-Light Improves Cockpit Production
- RFID and I/O modules for Safe Tool Changes
- Chemical
- Detection of Pigs
- Remote Signal I/O
- Easy Connection of Field Devices
- Signal Processing with System I/O in the Control Cabinet
- Signal Separation with Interface Technology in the Control Cabinet
- Identification of Hose Connections
- Efficient Monitoring of Cabinets in the Field
- Monitoring of Quarter Turn Actuators
- Planning and Assembly of System Solutions
- Success Stories
- I/O System Excom Creates Space in the I&C Rooms
- Zone 2 and 22 RFID
- Efficient Testing Control
- Intrinsically Safe Field Communication
- Process Control System Partnership
- Hazardous Area Remote I/O
- Dual Valve Position Feedback
- Flexibility with Fieldbus
- Asset Management with Remote I/O
- Correct Positioning with RFID in Carbide Production
- Energy
- Food and Beverage
- Mobile Equipment
- Distribution Lines for Field Sprayers
- Measuring the Ground Clearance on a Field Sprayer
- Angle Measurement on a Field Sprayer
- Determining the Boom Angle Position
- Material Flow Monitoring on a Combine Harvester
- Equipment Compartment Illumination on Fire Engines
- Two-Axis Tilt Measurement on a Combine Harvester
- Collision Protection on Reach Stackers
- Success Stories
- Position Measurement with RFID and Encoder
- Speed Control via Radar Sensor QT50
- RFID Guides AGV in Suspension Production
- Block I/O Modules on Super Yacht
- Wear-free encoder on hopper dredger
- I/O for Dust Suppression
- Cabinet Cooling
- Quick Disconnect Connectivity
- Automation Solutions for Extreme Cold
- Remote I/O for Cranes
- Rugged Heavy Metal Lifting
- Rollercoaster Positioning
- Mobile Machinery Solutions
- Exact Height Positioning
- Critical Angle Sensing
- Angle Sensor Detects Platform Lift
- Oil and Gas
- Packaging
- Identification of Printing Color Cartridges
- Reliable Operation of Machines
- Container Check
- Monitoring of Caps in Filling Lines
- Monitoring Changeover Processes
- Identification of Test Bottles
- Level Monitoring of Ground Coffee
- Level Detection in Vessels
- Detection of Transport Containers
- Success Stories
- Pharma
- Monitoring of Quarter Turn Actuators
- Detection of Pipe Elbows
- Remote Signal I/O
- Planning and Construction of Super Skids
- Easy Connection of Field Devices
- Identification of Portable Tanks
- Identification of Cryovessels
- Identification of Mobile Containers
- Identification of Mobile Containers with Handheld Devices
- Identification of Hose Connections for Precursors
- Identification of Hose Connections in Sterile Areas
- Identification of Hose Connections in Ex Zone 1
- Identification of Big Bags and Bioreactors
- Identification of Single-Use Applications
- Success Stories
- Semiconductor