Factory Assembly Systems

Catalogue 2006 / 2007

Technologies . Systems . Solutions

Issue date 01.09.2006 We reserve the right of technical changes in the course of continous developement of our products Layout & Realization: © awiwa communications www.awiwa.de

Factory Assembly Systems

Catalogue 2006 / 2007

Technologies . Systems . Solutions 1

Factory Assembly Systems FAS

As an international partner of

Our customers’ requirements

Our main aim is to perpetually

the automotive industry Dürr

are the main focus of our activi-

open new possibilities for our

stands for leading edge techno-

ties when working out optimal

customers, to reduce their costs

logy, high quality and customer

process solutions and choosing

per unit and to increase their

proximity.

suitable products in cooperation.

competitiveness.

With the business unit Factory

To do this, we draw upon a

Assembly Systems (FAS) Dürr

comprehensive base of know-

FAStplant® – the modular way

takes also a leading position

ledge and experience resulting

of erecting, dismantling and

within vehicle’s final assembly

from customer relations with

modifying a complete assembly

and delivers high-end conveyor

nearly all automobile manufac-

line is only one example for

technology, products and systems

turers worldwide, ranging from

innovation made by Factory

for assembly processes in the

mass production to up-market

Assembly Systems.

automotive industry.

production or from compact car makers to light truck makers.

solutions – Dürr FAS is optimally

Our portfolio of products and services is based on extensive

From planning through to deli-

positioned to meet the demands

process competence which

very and service, FAS accom-

that the assembly of future-

translates into our products and

panies the entire life cycle of a

oriented and cost-conscious

which in turn allow FAS to cover

project. Our portfolio ranges

automotive plants brings.

more than 70 % of the total

from minute items of equip-

investment for equipment

ment to turn-key delivery of

required in a final assembly plant

entire assembly shops.

from in-house manufacture. Included are products such as

With production sites on three

marriage systems, axle assembly,

continents and a most profes-

filling systems, all kinds of con-

sional project management we

veyors, complete end-of-line

consistently produce high quality

equipment, glazing systems and

products and ensure schedule

handling equipment.

and budget adherence. Our strength of innovation results from our high process competence. Thus, we are setting on intensive development activities in all fields.

2

Technologies, systems and

Contents

Factory Assembly Systems FAS 2

Conveyor Systems : : : : : : : : : : 4 Survey/ System Elements : : : : : : : : : : : : 6 -

9

Overhead Conveyors FAStrolley : : : : : : 10 - 17 Floor Conveyors FASfloor : : : : : : : : : : : 18 - 29

Final Assembly : : : : : : : : : : : : 30 Fluid Filling FASprofill : : : : : : : : : : : : : : 32 - 41 Assembly Equipment FASsembly : : : : 42 - 63

Testing Systems FAStest : : : :64 Wheel Alignment : : : : : : : : : : : : : : : : : 66 - 75 Headlight Aiming : : : : : : : : : : : : : : : : : 76 - 81 Driver Assistance Systems Testing : : : 82 - 85 End of Line Function Test : : : : : : : : : : : 86 - 95 In-Line Testing : : : : : : : : : : : : : : : : : : : 96 - 103

Automation : : : : : : : : : : : : : : 104 Survey : : : : : : : : : : : : : : : : : : : : : : : : 106 - 107 Basic Software and Components : : : 108 - 109

Elektronics Testing and Server Systems FAStronic : : 110 Survey : : : : : : : : : : : : : : : : : : : : : : : : 112 - 113 Server Systems : : : : : : : : : : : : : : : : : 114 - 121 Test Stations : : : : : : : : : : : : : : : : : : : : 122 - 125 Mobile Diagnostic Systems : : : : : : : : 126 - 133 Measurement Systems : : : : : : : : : : : :134 - 137 Accessoires : : : : : : : : : : : : : : : : : : : : :138 - 141

Advanced Factory Solutions 142 Survey : : : : : : : : : : : : : : : : : : : : : : : : 144 - 145 Planning : : : : : : : : : : : : : : : : : : : : : : : 146 - 153 Cross Functions : : : : : : : : : : : : : : : : : 154 - 157 FAScontract : : : : : : : : : : : : : : : : : : : : 158 - 167

DÜRR Worldwide : : : : : : : : : : 168

3

4

Conveyor Systems

Survey : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 6 - 7 System Elements : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 8 - 9

Overhead Conveyors FAStrolley Power & Free : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 10 - 11 Electric Monorail System : : : : : : : : : : : : : : : : : : : : : : : : : : 12 - 13 Twin Trolley System® (TTS) : : : : : : : : : : : : : : : : : : : : : : : : : 14 - 15 Vertical Adjusting Conveyor : : : : : : : : : : : : : : : : : : : : : : : : : 16 - 17

Floor Conveyors FASfloor Skid Conveyor : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 18 - 19 Twin Trolley System® (TTS Inverted) : : : : : : : : : : : : : : : : : : 20 - 21 FASmatic® : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 22 - 23 Skillet Conveyor : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 24 - 25 Belt Conveyor / Modular Chain Conveyor

: : : : : : : : : : : : : 26 - 27

Slat Conveyor : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 28 - 29

5

Dürr conveyor systems: Innovative – efficient – and user-oriented „Just in time“ or „just in se-

In view of increasing demands

quence“ – Dürr conveyor systems

for the reliability of a plant verti-

from the Factory Assembly

cal adjustment conveyors with

Systems business unit meet all

modern belt technique and

requirements for more flexibility

water resisting modular chain

and cost effectiveness. We set

conveyors form an important

standards in respect of functio-

part of our portfolio.

nality and innovations with our extensive range of floor conveyors

Against the background of high-

and overhead conveyors. We

quality demands we conse-

offer maximum reliability with

quently improve our range of

reduced maintenance effort.

products.

Two examples are our patented innovation Twin Trolley System®

The market success of Dürr FAS

(TTS) with its modular structure

is the result of a continuous

and

FASmatic®,

the automatic

systems and the fulfilment of

system for non-contact energy

specific customer demands.

and data supply, can be in-stalled with almost all conveyor technologies. Thus, Dürr FAS continues with setting new standards for higher availability and less maintenance.

6

development of our conveyor

guided vehicle. FASmotion, our

Conveyor Systems Survey

Your Advantage

The Conveyor Systems Overhead conveyors FAStrolley

Floor conveyors FASfloor

High reliability Low maintenance effort

Power&Free

Skid conveyor

Electric Monorail System

TTS inverted

Twin Trolley System® (TTS)

FASmatic®

Vertical Adjustment Conveyor

Skillet conveyor

Future-proof thanks to standardized product range Non-contact energy and data transfer optional

Belt conveyor / Modular chain conveyor Slat conveyor

7

Twin Trolley System® (TTS) In this new technology, the drives are not accommodated in the trolleys but in the rail. This means that no on-board control is required. In a further development, TTS is combined with the Skillet technique.

Electric Monorail System (EMS) Equally suited to use on pure conveying sections at high speed and on work lines with adjustable speed. Further strength of EMS is its quiet and clean operation.

Vertical Adjusting Conveyor Vertical Adjusting Conveyors by Dürr stand for precise adjusting of height and maximum functionality. Its innovative belt technique allows minimized maintenance effort.

Power & Free Exceedingly rugged and simple chain conveyors. The scope of application of this conveyor comes to the fore primarily where machining or processing operations do not coincide timewise with materials flow.

Slat Conveyors The convincing features of this conveyor are its rugged chain drive and its high resistance to moisture, dirt and high temperatures.

8

Conveyor Systems System Elements

FASmatic® FASmatic® is controlled by a high-capacity supervisory system and operates with inductive energy and data transfer. On-board batteries and pits are no more necessary and changes in the layout can be executed with minimized effort.

TTS inverted TTS inverted is the floor guided version of the Dürr innovation Twin Trolley System® (TTS). The form-fitting drive system joins very high acceleration and exact positioning with minimized spare parts.

Skillet Skillets, optionally with integrated lifting device, allow an optimum working level for each section. In touch with state-of-the-art part logistics, it sets up the backbone of innovative "just in sequence" production.

Belt Conveyor / Modular Chain Conveyor As man movers and for vehicle body conveying, belt conveyors are popular in final assembly. The modular chain conveyor is a further development of the belt conveyor. It is insensitive against dirt and requires low maintenance effort.

Skid Conveyor Plant layouts in body, paint and final assembly shops are no problem with skid conveyors. Thanks to modular design, all material flow functions can be built in a flexible manner.

9

F A S t r o l l e y 10

Technical Data and Dimensions Overall size 4”

Overall size 6”

Chain pitch

4”

6”

Ultimate load

approx. 220 000 N

approx. 440 000 N

Conveying speed (standard)

0.5 - 18 m/min

0.5 - 18 m/min

Horizontal curves

15 - 180°

15 - 180°

Vertical curves

10 - 35°

10 - 35°

Max. payload capacity, double trolley

approx. 2,000 kg

approx. 2,400 kg

Higher payload capacities with multiple trolley possible

Overhead Conveyors FAStrolley Power & Free

System Elements Rail system, including suspension, consisting of Power & Free rail in size 4”and 6” Chain, including pusher dogs Horizontal curves Vertical curves Transfers Trolleys Power & Free systems can be

Owing to the simple, modular

used both as overhead con-

design, it is possible to imple-

veyor systems and as floor con-

ment different functions, such

veyor systems (inverted P & F).

as buffering, distribution, bran-

In the automotive industry,

ching or stopping very easily

P & F conveyors are used for

and at low cost.

in-plant transport in all sectors

P & F systems are very rugged

from the body shop through the

and can be used easily even

paint shop to final assembly.

under aggravated ambient

Standardized components of

conditions, such as high tem-

various sizes are available for

peratures or aggressive media

various loads.

or in welding lines.

Drive station Tensioning station Switches Stoppers Lifting stations Control system

Mode of Operation A Power & Free system consists of two rails arranged one above the other. A chain runs continuously in the upper rail (power rail) and this chain pulls the trolleys in the lower “free rail” by means of dog pushers. The bogies can be engaged and disengaged as required.

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F A S t r o l l e y 12

Technical Data and System Elements EMS Light VDI 500

EMS Medium

EMS Heavy-duty

Aluminum profile (rail)

180 x 60 mm

180 x 60 mm

240 x 80 mm

Payload capacity (hanger + load)

500 kg /trolley

750 kg /trolley

1,800 kg /trolley

Transport speed

up to 120 m/min

80 m/min

40 m/min

Curves

Switches

Track lengh

15°/30°/45°/90° 15°/30°/45°/90° 15°/30°/45°/90° in the case of radius 1,000 and 1,500 mm 45° in the case of radius 750 mm Optional rotary switches unlimited

unlimited

45° in the case of radius 1,000 mm unlimited

Overhead Conveyors FAStrolley Electric Monorail System

System Elements Rail, including energy supply (busbar or FASmotion) Single trolley Double trolley On-board control Horizontal curves Vertical curves Lifting stations The electric monorail system

EMS Medium

(EMS) is a modular-design over-

up to 750 kg payload

head conveyor system for trans-

capacity per trolley:

porting complete vehicles or ve-

This version is used to trans-

hicle bodies and also all pos-

port bodies in white and heavy

sible attachments, such as doors,

components. The principal di-

cockpits or seats. The principal

mensions of the aluminum pro-

dimensions are standardized in-

file are 180 x 60 mm.

Switches Hanger (with / without lift)

Field of Application Vehicle body transport

ternationally. This system offers all capabilities of line routing

EMS Heavy-duty

through an installation. It is also

up to 1,800 kg payload

possible to easily implement

capacity per trolley:

buffer functions, distribution

This version is used to trans-

functions and branch functions.

port vehicle bodies in the area

We are able to supply two ver-

of vehicle final assembly.

sions of electric monorail system.

The principal dimensions of

Transport of miscellaneous hardware and attachments, such as doors, cockpits and engines etc.

the aluminum profile are 240 x EMS Light with

80 mm.

500 kg payload capacity per trolley: This version is used primarily for transporting attachments such as doors and cockpit and for powertrain components such as axles and engines. The dimensions of the aluminum profile are based on the VDI 3643 Regulation.

13

F A S t r o l l e y 14

TTS - Light

TTS - Heavy

TTS - Skillet

Field of Application

Field of Application

Field of Application

Transport of components,

Transport of vehicle bodies,

Combination of TTS with

such as cockpits, doors and

e.g. in final assembly

skillet system. Used, for

powertrain components

instance, on work lines

in final assembly Transportation is performed using TTS Heavy outside of the work lines

Technical Data and Dimensions Type

TTS - Light

TTS - Heavy

TTS - Skillet

Payload capacity (hanger + load)

600 kg/2 trolleys

2,500 kg/2 trolleys 5,000 kg/4 trolleys

2,500 kg/2 trolleys 5,000 kg/4 trolleys

Conveying speed on straight sections

up to 150 m/min

max. 40 m/min

3 - 7.5 m/min

Conveying speed in curves

max. 30 m/min

max. 24 m/min

–

Overhead Conveyors FAStrolley Twin Trolley System®

Basic elements Straight section

Horizontal curve

The innovative Twin Trolley

appreciable wear. Provided

System®

with flexible hanger, the vehicle

(TTS) with its modular

drive concept overcomes

bodies can be lowered to any

upgrade sections without the

working height. It is also pos-

need for additional installations.

sible to operate with an over-

We can thus implement high

head skillet line in the further

speeds with no slip and no

development, the Skillet TTS.

Vertical curve

System Elements Type

TTS - Light

TTS - Heavy

TTS - Skillet

Straight rail section

4/5/6/7/8 meters

4/5/6/7/8 meters

4/5/6/7/8 meters

Curves

15°/30°/45°/90° at radius of 600 mm

15°/30°/45°/90° at radius of 1,500 mm

––

Upgrade/downgrade section max. 30°

max. 20°

––

Switches

30°/45°/90° at radius of 1,500 mm

––

30°/45°/90° at radius of 600 mm

Rail profile material (straight Aluminum section / curve / switch) extruded profile

Aluminum extruded profile

Aluminum extruded profile

Track lengths

unlimited

with 1 push drive 36-84 m, longer lengths on request

unlimited

Switch

Options Lifters Hanger (with / without lift)

Preferred values in bold

15

F A S t r o l l e y 16

Technical Data Type

Single scissors

Double scissors

Stroke

up to 2,500 mm

up to 4,500 mm

Payload (car body)

3,000 kg

3,000 kg

Lifting velocity

max. 10 m/min

max. 10 m/min

Overhead Conveyors FAStrolley Vertical Adjusting Conveyor

System Elements Overhead conveyors (EMS or TTS) Energy- and data transfer (non-contact with FASmotion or with bus bar) Upper frame with drive and safety equipment Lifting belts with integrated steel cables Lift scissors Subframe Load carrying equipment (C, T or 4-arm-hangers)

Field of Application Overhead conveyor with vertical adjustment in BIW paint and final assembly

With monorail and twin trolley

Both continuous and intermit-

systems, vertically adjustable

tent ope-rations are possible.

conveyor hangers can be used

The application of belt techni-

from the body shop right through

que reduces the maintenance

to the final assembly shop. Their

requirements substantially.

standardized modular design allows adjusting the height to the desired position and also meets high ergonomic requirements. The goods to be transported are loaded and unloaded by adjacent conveyors.

17

F A S f l o o r 18

Technical Data and Dimensions Standard

Options

Payload (skid+car body)

700/1,400/2,000 kg

Skid length

4,800 mm

3,400 – 7,000 mm

Transfer rate

60 units/h

on request till max. 100 units/h

Track

900 mm

650 – 1,150 mm

Conveying height

500 mm

on request

Roller pitch

1,064 mm

864 / 1,264 mm

Conveying velocity

24 m/min

on request till max. 100 m/min

–

Floor Conveyors FASfloor Skid Conveyor

System Elements Roller bed Excenter lift table Turn- / pivot table Transfer car Lifter for normal- und high temperature area Scissors lifting table (hydraulics, belt, spindle) Skid stacker Skid locking unit Transversal belt / chain Buffer belt / chain Suspension belt / chain Process conveyor through spray booth Process conveyor through oven (up to 220° C) RoDip Pendulum conveyor Skid conveyors are modular con-

Dürr offers pre-mounted, pre-

veyors customized to meet indi-

installed and tested mechatronic

vidual needs in body, paint and

systems fitted with belts in the

final assembly shops. Standar-

normal temperature range (no

dized mechanical and electrical

lubrication, thus low mainten-

systems using identical compo-

ance requirements), and fitted

nents permit keeping a reduced

with chains in the high tempera-

number of spare parts in stock

ture range (up to 220° C). Thanks

at maximum reliability (≥ 99.5 %).

to modular design, all material

Continuous and intermittent

flow functions such as buffers

operations are possible.

and distribution systems can be built in a flexible manner.

UBS-Shuttle

Field of Application Skid conveyors for bodyshop, paint and final assembly Application in high temperature area Application in wet area Application in ex-area

19

F A S f l o o r 20

Technical Data

Payload (tooling plate + work piece)

700 kg

Conveying velocity on straight sections

till 100 m/min

Conveying velocity in curves

max. 30 m/min

Horizontal curve

Radius = 1,000 mm

Vertical curve

Radius = 2,000 mm

Floor Conveyors FASfloor Twin Trolley System® TTS Inverted

Basic elements Straight section

Horizontal curve

The compact design of the Inver-

the range and number of spare

ted TTS conveyor system offers

parts that have to be kept in

good body accessibility and the

stock. In addition, the skillet ver-

incorporation of a toothed belt

sion of this system has the advan-

drive ensures exact positioning.

tage of needing fewer drive units.

Vertical curve

The high acceleration that is possible with an Inverted TTS makes it an ideal system for shuttle

Switch

applications. Using identical technology for both overhead and floor conveyors reduces the number of different conveyor systems required and this in turn reduces Field of Application Floor conveyor in body shop, paint shop and final assembly Continuous and intermittent operations are possible For operation in demanding environmental conditions (dirt, temperature), the toothed belt can be replaced by chain

21

F A S f l o o r 22

Technical Data Chassis- and steering concept

Payload (incl. tooling plate) Running velocity Energy transfer Line guidance Vehicle communication Superstructure

Track length References

4-wheel-concept Single wheel-steering front + back

4-wheel-concept Center pivote platesteering front + back

till 3,500 kg

till 60 m / min FASmotion (non-contact) inductive (non-contact) via funk (WLAN) scissors lifting table, lifting device, tooling fixture unlimited VW Mosel (Golf A5) VW Mosel (Passat B6)

BMW Leipzig, S-GM Shanghai MBUSI Tuscaloosa, KIA Zilina

Floor Conveyors FASfloor FASmatic®

System Elements Floor installation Stationary control Vehicle underframe with steering concept Lifting unit Tooling fixture (swimming function optional) Energy transfer FASmotion Line guidance Data transfer Safety equipment Onboard control

Field of Application Floor conveying in discrete manufacturing – Dress-up area – Unit assembly / fitting – Sub-assembly conveying FASmatic® is a new floor con-

designed freely, pits are no more

veyor system which is mainly

necessary. In energy supply, non-

used in discrete manufacturing

contact energy transfer FAS-

for dress-up stations and the

motion does replace batteries.

marriage process in general

This ensures trouble-free conti-

assembly. It is applicable in con-

nuous operation with high availa-

tinuous flow as well as in stop

bility and low maintenance effort.

and go-operation and offers free access from all sides. Its modular control system is an open concept composed of standardized components. The layout of plant and path can be

23

F A S f l o o r 24

Technical Data and Dimensions Payload capacity

2,500 kg (vehicle body)

Conveying speed

0.5 – 7.5 m/min. (adjustable)

Useful stroke of lifting table

approx. 1,000 mm

Dimensions

Length approx. 6,000 mm Width approx. 3,000 mm Other dimensions on request

Floor Conveyors FASfloor Skillet Conveyor

System Elements Skillets with/ without lifting table Lifting tables hydraulic/ with spindle/with belt Track Power supply busbar/ non-contact energy and data transfer FASmotion Main drive based on friction wheel Docking and undocking drives Roller beds Cross conveyors Lifters

This system is used in the sec-

an optimum working position.

The skillets may also be moved

tors of vehicle final assembly

The skillet can be powered via

on roller beds, lifters and cross

and body shop.

conventional busbars or also

conveyors outside of the actual

The skillets are suitable for foot

using non-contact energy and

skillet lines.

traffic and may be equipped

data transfer FASmotion.

with various superstructures

Besides the actual skillets, a

for accommodating the vehicle

skillet line contains the following

bodies. If eccentric lifting tables

chief components: docking

are used, the working height

drive, main drive, braking drive,

of the vehicle body can be ad-

undocking drive and roller strips

justed variably so as to ensure

on which the skillets lie.

25

F A S f l o o r 26

Technical Data Skid cross conveying

Man mover

Vehicle conveying

Vehicle conveying special applications

Case of operation

Cross conveying for Skid in bodyshell work, paint and final assembly

Conveying of men

Conveying of vehicles on wheels

Conveying of vehicles on wheels through leak test

Distance between axles

Standard till 15m

Standard till 100m

Standard till 100m

Standard till 100m

Payload

700/1,400/2,000 kg skid + workpiece

400 kg on 6m length

3,000 kg on 6m length

3,000 kg on 6m length

Transportvelocity

4 till 20m/min

0.5 till 10m/min

0.5 till 10m/min

0.5 till 10m/min

Width

1,400kg 2x100mm 2,000kg 2x200mm

maximal 4m

maximal 4m

maximal 4m

Floor Conveyors FASfloor Belt Conveyor / Modular Chain Conveyor

System Elements Base frame with track Modular chain conveyor Drive unit Deflection unit, if applicable with braking drive Drive unit

A distinction is made in the

Basically, there are two types:

Deflection unit

Drive

Base frame with track

case of belt conveyors and modular chain conveyors in the

Type 1:

sector of vehicle transport bet-

Wide belt with a width of

ween man movers and con-

approx. 1 to 4 m for transporting

veyor belts for vehicle body

vehicle body and, if applicable,

transport.

worker.

Man movers:

Type 2:

These are normally 1 to 4 m-

Twin-strand belt with a width

wide belts on which the wor-

of approx. 300 – 500 mm.

Field of Application Skid conveying Man mover

kers “ride” at the same process speed as the main line. The

Modular chain conveyors are a

vehicle body is transported

low cost alternate to slat and

in an overhead conveyor for

belt conveyors as it is possible

instance while the worker rides

to replace single modules, and

on a man mover below the

their low structure calls for far

vehicle body at the same speed

smaller pit dimensions. In con-

as the vehicle body itself.

trast to belt conveyors, these

Overhead operations can be

conveyors are driven by form-fit

configured ergonomically with

connection and not by friction.

this arrangement.

Since it is not necessary to

Vehicle body conveying Vehicle body conveying through leak test

weld belts on site, maintenance Vehicle body transport:

requirements, wear and tear

The vehicle bodies are normally

are notably lower than with

transported with their wheels

conventional belt conveyors.

on the belt or the modular chain.

27

F A S f l o o r 28

Technical Data and Dimensions Distance between axles

up to 200 m

Payload capacity

approx. 3,000 kg over 6 m length

Transport speed

1 – 7.5 m/min.

Width

Double-strand version approx. 300 – 500 mm Single-strand version approx. 3,000 mm

Floor Conveyors FASfloor Slat Conveyor

System Elements Chain with slats Base frame Drive unit Deflection and tensioning unit

Field of Application Transporting vehicle bodies Transporting vehicle bodies in the wet area (leak test)

On slat conveyors, vehicle bodies are transported through the body shop or vehicles are transported through final assembly. Owing to the rugged chain drive and the high resistance to moisture and dirt, this system is ideally suited to welding areas in the body shop, the car final area and leak test in vehicle final assembly.

29