Production line integration in car assembly plants

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Dr. Kiss Bálint
Department of Control Engineering and Information Technology

A car factory plant which is under development, currently produces two types of vehicle. The manufacture would like to produce a third type of car at the same plant. The manufacturing of all three types, wherever possible, should share the same production line segments. Modifications are necessary on shared production line segments, to manage all vehicle types. If program code modification is not enough, we have to transform the hardware too. The objective is that all robots and other manufacturing equipment are prepared to receive and assembly the new vehicle type. Every modification has to follow strict standards.

In this BSc thesis I present the modification process and the task of the integration on an existing manufacturer cell in the car body workshop. The production cell is responsible for the composition of the front of the chassis.

In the first part of the thesis I describe the technology, the hardware and the robots. Using an example I demonstrate the most important criteria of the standard in accordance what I have learnt as part of a training session. I also present the developer environment and the human machine interface focusing on the example task.

In the second part of the thesis I study the integration solution using a Siemens PLC developer environment. The PLC code was rewritten to be suitable for receiving the new model. To carry out these modifications, it was mandatory to thoughtfully understand the function of the production line and the contribution of all pieces of equipment in the work in addition to the understanding of the PLC program itself. I had to identify the parts which needed modifications and those who did not.

I also present the installation and the testing process where the new body part has already gone through on the production line. At the end of the thesis I briefly study another option where a new production line is installed instead of sharing the current one.


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