Highly Customized Test Cell for Tier 1 Automotive Supplier

A tier-1 automotive supplier needed a turn-key solution that allowed them to test functionality and perform final processes on a transfer case product line. The end-of-line test systems had to support two different products and be designed to fit within the existing infrastructure. We designed and built an end-of-line transfer case test and assembly cell. This cell included two test stands, robotic part transfer, and integrated final processing conveyors. Additionally, RedViking designed a Manufacturing Execution System (MES) for the entire assembly line, including the RedViking end-of-line test cell.

Key Benefits:

  • Robotic Part Transfer
  • Processing Conveyors
  • Dual Test Machines
  • MES Integration
  • Multipart Testing 
  • Automated Tooling
  • Automated Load / Unload
  • Vsync™ Reporting

Automating the Electrical Connection to the Transfer Case

The machine was designed by our engineers to fit within a tight customer-specified footprint and handle automated changeover for a mix of products. The robot EOAT was designed to allow any combination of models in the grippers so changeover between parts is seamless.  The Duplicate test stands allows for even more functionality without sacrificing throughput and the system can support varied test profiles based upon model variation or other complexity. This longer test time allows for more functional testing on each part and improves quality assurance of the product for the end-user.

Automatic Spline Engagement

Automated tooling designed to engage each transfer case both mechanically and electrically allows each test stand full control of all test article functions.  

Automated Load, Unload and Real-Time Changeover Between Products

Parts are automatically loaded and switching between part types is seamless eliminating downtime from part changeover.

Vsync™ Detailed Reporting

RedViking’s proprietary Vsync™ platform includes all of the fundamentals needed to run the dynamic testing software system. The test executive includes a highly configurable sequence editor which allows engineers to change the sequence without software code changes.  With manual and automatic control, the user can see an overview of the unit under test, trend screens, have access to basic user management, access active alarm views, and see maintenance tracking tools.

Turnkey MES Solution

RedViking also provided a turnkey MES solution to run both the main assembly line and our end-of-line test and related systems. Our solution provides functionality including recipe download to each line PLC, full component and batch level traceability, customer serial-number generation and hand-off of part characterization data. 

Argonaut© Integration

Though we offer our own Argonaut© platform to manage, this customer preferred us to use their existing MES platform to integrate the line. Our manufacturing execution systems team worked with our customer to develop custom part tracking software for the line within their existing framework which tracks each part through the full assembly/test process and builds each part a birth certificate. Our configurable apps architecture with an innovative and flexible edge-of-network IIoT device securely connects your plant and allows you to deploy and control it from any location. When new parts/processes are added to the line, the app can be easily reconfigured.

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