The Problem: Worker injuries and downtime were a persistent problem on an automotive assembly marriage line. They needed a decking loop with better ergonomics and capacity to run more than one job per minute without interruption.
The RedViking Solution: A Wingspan™ battery-free AGV decking system with integrated lifts to automatically synchronize with overhead conveyors.
Operator Injuries and Unacceptable Downtime
A premier automaker was experiencing problems with their exhaust decking system. First, the ergonomics of the system were poor and operator injuries were persistent. Second, their conductor bar conveyance was susceptible to interference from anything dropped in the track and also highly susceptible to wear. Because of the structure of conductor bar systems, finding failure points was time consuming. This single loop was slowing down the rest of the assembly process, and previous attempts to speed up the process had not only been unsuccessful, but had increased worker injuries.
Integrated Lift Synchronizes with Overhead Conveyor
RedViking designed and built a Wingspan™ battery-free AGV decking system with an integrated, inductively powered lift. The automotive chassis is brought in on an overhead conveyor, the AGV automatically synchronizes with it, and the integrated lift brings up the exhaust system to be decked. Bolts and pins accidentally dropped onto the floor by operators are handled by the Wingspan debris management system. Wingspan AGVs use inductive power transfer for continuous operation, 24/7. Safety scanners are configured to provide 360° access to the product. There is virtually no maintenance required and the flat floor design eliminates the wear and interference problems associated with conductor bar.
Wingspan™ Battery-free AGV Assembly Lines
Battery-free AGV assembly lines are chosen for their scalability, ergonomics and cost efficiency. Wingspan™ AGVs are intelligent, automated conveyance with full positional awareness, without the expense or environmental concerns of batteries or chain-based conveyance. Since power and communication are inductively sourced, virtually any payload can be carried and virtually any tools and automation can be powered by the AGV’s continuous power source. Unattached to the facility and unencumbered by pits and chains, battery-free AGVs create a portable, virtually invisible assembly line conveyance.
Turn-key Automated Assembly Lines
Applications of this technology include decking lines, engine and powertrain assembly lines, commercial generator production, stamping lines, aircraft assembly and more. We design, build and integrate turn-key assembly lines for automotive, aerospace and off-highway vehicle manufacturers as well as military MROs.