Production Analysis of AGV Suspension System of VDL Weweler Company in the Netherlands
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In the suspension system production area of the Dutch company VDL Weweler, an automated guided vehicle (AGV) provided by Movexx transports suspension system components from the basic production area to the painting line. Turck’s HMI VT250 with Codesys controller will control how the vehicle finds its destination. The process is also completed with the help of photoelectric sensors, RFID systems, angle sensors and status indication systems in Turck’s product portfolio. Turck BV demonstrated its ability as a true solution expert by not only providing components, but also completing controller programming. As AGV assumes the responsibility of transportation in production, the error rate of component transportation drops rapidly.
Turck provided Movexx with most of the automation functions required for automated guided vehicles, including programming of the Codesys controller on the HMI VT250
VDL Weweler, a truck and automobile supplier based in Apeldoorn, the Netherlands, wants to automate manual transportation operations, but they must be completed in accordance with the requirements of the production system.
The responsible production planner found that the transportation of truck trailer support elements and suspension systems needed to be optimized. Until mid-2015, these parts were still transported between the basic production area and the painting line by forklifts.
Manual transportation is inaccurate
The disadvantage of this solution is that it requires a lot of manual work by employees. In addition, personnel cannot always work as accurately as an automated vehicle, so production can be endangered. Therefore, in 2014 the decision makers of VDL Weweler decided to automate the transportation of the framework.
Movexx develops new AGV
The decision makers of VDL Weweler turned to the transportation experts of Movexx International BV and requested the development of an automated transportation solution. Movexx is a Dutch manufacturer of industrial trucks, offering many customized products. The manufacturer has successfully developed and manufactured automated guided vehicles (AGV). However, a new solution must be developed for this task.
The AGV must be able to move in both directions, because it can only move out of the target workstation in the reverse direction. The hydraulic lifting platform lifts the frame 2 cm from the ground for transportation.
Comprehensive automation solution from Turck BV
In order to develop the transport vehicle, Andreas Versteeg asked Turck to participate in the planning phase. Movexx has used Turck sensors and LED lights in its products before. However, the project also requires solution experts and other suitable components.
The biggest challenge is the two-way control of the AGV on the ground of the factory. Turck recommends the use of combined RFID contrast belt control.
RFID system for destination control
The best line tracking is combined with RFID tags, which are pasted on the factory floor at key points on the line. The tag at the turning point instructs the AGV whether to continue driving or stop. The AGV itself does not make a decision. The intelligence comes from the networking of the AGV with a higher-level IMS system (Integrated Manufacturing System), which instructs the AGV to move to a specific point.
Turck’s VT250 HMI-PLC runs on AGV. It communicates with IMS through a wireless connection, and responds as a Profibus master station with a BL20 gateway, which contains the input and output of all signals connected to the vehicle.
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