Вы находитесь на странице: 1из 31

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. Technologies, systems and
Our portfolio of products and solutions – Dürr FAS is optimally
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 set-
ting on intensive development
activities in all fields.

2
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 development of our conveyor
guided vehicle. FASmotion, our systems and the fulfilment of
system for non-contact energy specific customer demands.
and data supply, can be in-stalled
with almost all conveyor techno-
logies. Thus, Dürr FAS continues
with setting new standards for
higher availability and less main-
tenance.

6
Conveyor Systems
Survey

The Conveyor Systems Your Advantage

Overhead conveyors Floor conveyors High reliability


FAStrolley FASfloor
Low maintenance effort
Power&Free Skid conveyor
Future-proof thanks to
Electric Monorail System TTS inverted standardized product range

Twin Trolley System® (TTS) FASmatic® Non-contact energy and


data transfer optional
Vertical Adjustment Skillet conveyor
Conveyor
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 techni-
que 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 lay-
out 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

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

10
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 Drive station
used both as overhead con- design, it is possible to imple-
Tensioning station
veyor systems and as floor con- ment different functions, such
veyor systems (inverted P & F). as buffering, distribution, bran- Switches
In the automotive industry, ching or stopping very easily
Stoppers
P & F conveyors are used for and at low cost.
in-plant transport in all sectors P & F systems are very rugged Lifting stations
from the body shop through the and can be used easily even
paint shop to final assembly. under aggravated ambient Control system
Standardized components of conditions, such as high tem-
various sizes are available for peratures or aggressive media
various loads. or in welding lines.
Mode of Operation

A Power & Free system


consists of two rails arran-
ged 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.

11
F A S t r o l l e y

Technical Data and System Elements

EMS Light EMS Medium EMS Heavy-duty


VDI 500

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 15°/30°/45°/90° 15°/30°/45°/90° 15°/30°/45°/90°


in the case of radius 1,000 and 1,500 mm

Switches 45° in the case of radius 750 mm 45° in the case of


Optional rotary switches radius 1,000 mm

Track lengh unlimited unlimited unlimited

12
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 Switches
head conveyor system for trans- capacity per trolley:
Hanger (with / without lift)
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- Field of Application
dimensions are standardized in- file are 180 x 60 mm.
ternationally. This system offers Vehicle body transport
all capabilities of line routing EMS Heavy-duty
up to 1,800 kg payload Transport of miscellaneous
through an installation. It is also
hardware and attachments,
possible to easily implement capacity per trolley:
such as doors, cockpits and
buffer functions, distribution This version is used to trans- engines etc.
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
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 po-
wertrain components such as
axles and engines. The dimen-
sions of the aluminum profile are
based on the VDI 3643 Regu-
lation.

13
F A S t r o l l e y

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

Conveying speed up to 150 m/min max. 40 m/min 3 - 7.5 m/min


on straight sections

Conveying speed in curves max. 30 m/min max. 24 m/min –

14
Overhead Conveyors
FAStrolley
Twin Trolley System®

Basic elements

Straight section

Horizontal curve

The innovative Twin Trolley appreciable wear. Provided


System® (TTS) with its modular with flexible hanger, the vehicle
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- Vertical curve
We can thus implement high head skillet line in the further
speeds with no slip and no development, the Skillet TTS.

System Elements

Type TTS - Light TTS - Heavy TTS - Skillet


Switch
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° 15°/30°/45°/90° at ––


at radius of 600 mm radius of 1,500 mm

Upgrade/downgrade section max. 30° max. 20° ––

Switches 30°/45°/90° 30°/45°/90° at ––


at radius of 600 mm radius of 1,500 mm

Rail profile material (straight Aluminum Aluminum Aluminum Options


section / curve / switch) extruded profile extruded profile extruded profile
Lifters
Track lengths unlimited unlimited with 1 push drive
36-84 m, longer Hanger (with / without lift)
lengths on request

Preferred values in bold

15
F A S t r o l l e y

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

16
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 require-
ments. The goods to be trans-
ported are loaded and unloaded
by adjacent conveyors.

17
F A S f l o o r

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

18
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 UBS-Shuttle
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- Field of Application
systems using identical compo- ance requirements), and fitted
nents permit keeping a reduced with chains in the high tempera- Skid conveyors for bodyshop,
paint and final assembly
number of spare parts in stock ture range (up to 220° C). Thanks
at maximum reliability (≥ 99.5 %). to modular design, all material Application in high tempera-
Continuous and intermittent flow functions such as buffers ture area
operations are possible. and distribution systems can be
Application in wet area
built in a flexible manner.
Application in ex-area

19
F A S f l o o r

Technical Data

Payload 700 kg
(tooling plate + work piece)

Conveying velocity till 100 m/min


on straight sections

Conveying velocity max. 30 m/min


in curves

Horizontal curve Radius = 1,000 mm

Vertical curve Radius = 2,000 mm

20
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 Vertical curve
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.
The high acceleration that is pos-
sible with an Inverted TTS makes
it an ideal system for shuttle Switch
applications. Using identical tech-
nology for both overhead and
floor conveyors reduces the num-
ber 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

Technical Data

Chassis- and 4-wheel-concept 4-wheel-concept


steering concept Single wheel-steering Center pivote plate-
front + back steering front + back

Payload (incl. till 3,500 kg


tooling plate)

Running velocity till 60 m / min

Energy transfer FASmotion (non-contact)

Line guidance inductive (non-contact)

Vehicle communication via funk (WLAN)

Superstructure scissors lifting table, lifting device,


tooling fixture

Track length unlimited

References VW Mosel (Golf A5) BMW Leipzig, S-GM Shanghai


VW Mosel (Passat B6) MBUSI Tuscaloosa, KIA Zilina

22
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

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

24
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

Technical Data

Skid Man mover Vehicle Vehicle conveying


cross conveying conveying special applications

Case of Cross conveying Conveying Conveying of Conveying of


operation for Skid in bodyshell of men vehicles on vehicles on wheels
work, paint and wheels through leak test
final assembly

Distance Standard till 15m Standard till 100m Standard till 100m Standard till 100m
between axles

Payload 700/1,400/2,000 kg 400 kg 3,000 kg 3,000 kg


skid + workpiece on 6m length on 6m length on 6m length

Transport- 4 till 20m/min 0.5 till 10m/min 0.5 till 10m/min 0.5 till 10m/min
velocity

Width 1,400kg 2x100mm maximal 4m maximal 4m maximal 4m


2,000kg 2x200mm

26
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 Deflec-
tion unit

Base frame
A distinction is made in the Basically, there are two types: Drive with track
case of belt conveyors and mo-
dular 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.
Field of Application
Man movers: Type 2:
These are normally 1 to 4 m- Twin-strand belt with a width Skid conveying
wide belts on which the wor- of approx. 300 – 500 mm.
kers “ride” at the same process Man mover

speed as the main line. The Modular chain conveyors are a Vehicle body conveying
vehicle body is transported low cost alternate to slat and
in an overhead conveyor for belt conveyors as it is possible Vehicle body conveying
through leak test
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
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

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

28
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 bo-


dies are transported through
the body shop or vehicles are
transported through final as-
sembly. Owing to the rugged
chain drive and the high resi-
stance to moisture and dirt, this
system is ideally suited to wel-
ding areas in the body shop, the
car final area and leak test in
vehicle final assembly.

29

Вам также может понравиться