Application of wireless technology in automobile assembly workshop

    Automation networks in automotive assembly plants have begun to evolve, changing fundamental operating parameters, increasing productivity, and enhancing economics. Plant managers and system designers are increasingly turning to wireless technologies to connect robotic systems and assembly machinery.

challenge

    Like many other manufacturing facilities, these shop floors are not ideal environments for data and process control cabling. Because assembly machinery often operates at a constant speed, it is common for network cables to kink or break, and for connectors to fail or detach. In addition, hazardous chemicals and oils can corrode the cables, greatly shortening their lifespan.

    Worse still, troubleshooting and repairing broken cables and faulty connectors is not only time-consuming but also costly. Inspecting the control cables that snake through a plant, isolating a bad cable from a bundle of cables covered in dust, metal shavings, and grease, and finding a faulty or damaged connection is no simple task. This type of maintenance can take hours, if not days, and every minute of downtime can cost thousands or even tens of thousands of dollars in lost productivity.

Wireless options

    Many plant managers feel that it is more economical to ditch the cables and connectors and install a wireless network. Technicians can quickly install a wireless network, and even after adding in the cost of the equipment and installation fees, the return on investment of switching to a wireless network can be easily seen.

    Ongoing maintenance of wireless infrastructure is also easier. Industrial network systems, such as Honeywell Sensing & Control's Limitless series, often include "health" monitoring features that ensure that wireless switches or sensors are functioning properly. If a problem is detected, an alert is sent immediately. Intelligent health monitoring technology overcomes temporary signal interruptions caused by moving vehicles and equipment. For example, Limitless technology retransmits the signal to ensure reliable data transmission.

    Many wireless systems offer power diagnostics for battery-powered devices, which not only ensures proper functioning of the device, but also provides early warning when the battery is low and needs to be replaced or recharged.

The value of flexibility

    Another factor driving the automotive industry’s adoption of wireless technology is the ease with which these networks can be reconfigured. Every few years, automakers introduce devices that represent new vehicle designs. Re-routing network cables to new locations is a major source of expense. By using wireless networks to link nodes on installed machines, shop floor engineers can simply power up the sensors and the devices will automatically reconnect to their respective controllers, eliminating the need to repeat the identification and pairing process during installation.

    In some instances, the initial assembly structure and design may require minor adjustments. However, with wireless technology, plant managers do not need to spend time and money to modify or adjust wiring because the wireless devices will easily find and communicate with the appropriate router and controller network.

Advantages

    Easy and economical installation, low maintenance requirements and high flexibility are the main factors driving the widespread use of industrial wireless technology. With the rapid development of this trend and the increasing popularity of applications, the face of manufacturing networks will undergo fundamental changes.