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Chrysler Construction StandardsAME – PT Plants

Revision Date: 11/12/2007

SECTION 15195 – Material Handling Systems

1.1.1 PART1 - GENERAL1.1 SUMMARY

A. This section includes the following:

1. Conveyors.

2. Buffer Systems.

3. Robots.

4. Gantry Systems.

5. Part Feeders

6. Blue Steel Gravity System

7. AS/RS (Automatic Storage and Retrieval System)

B. Related Sections: The following Sections contain requirements that relate to this Section:

Section 05500: Metal Fabrications

Section 15231: Cutting Machine Coolant Piping

Section 15980: Total Maintenance Spare Parts / TPM Ready

Section 16050: Basic Electrical Materials and Methods

Section 16120: Wires and Cables

Section 16443: Motor Control Centers

SMI – 109: SAFEGUARDING OF ROBOTS. (http://endeavor.tcc.chrysler.com:83/)

SMI – 119: SAFETY GUARDING FOR ASSEMBLY LINE. (http://endeavor.tcc.chrysler.com:83/)

SMI – 145: AUTOMATION SAFEGUARDING REQUIREMENTS (http://endeavor.tcc.chrysler.com:83/)

ETI – 103: Supplier Regulated Substance Certification Report. (http://endeavor.tcc.chrysler.com:83/)

Section – 16: http://ame.ctc.chrysler.com/tooldesign/section16page.htm

AMEPT Controls Specifications https://gsp.extra.daimlerchrysler.com/mfg/amedd/control/index.htm

Web site address for General Safety Specifications https://gsp.extra.daimlerchrysler.com/mfg/amedd/powertrain/specs/Ptsafety.pdf

Standards referenced in this Section:

Electrical and Fluid Power Specifications

Material Handling Systems 15195- 1 of 35

https://gsp.extra.daimlerchrysler.com/mfg/amedd/powertrain/specs/Ptsafety.pdf%20

https://gsp.extra.daimlerchrysler.com/mfg/amedd/control/index.htm

http://ame.ctc.chrysler.com/tooldesign/section16page.htm

http://endeavor.tcc.chrysler.com:83/






Electrical Safety for Arc Flash Hazard, Section -16 page #30 of General Safety Specifications.

QUALITY ASSURANCE & QUALITY CONTROL

A. The Supplier shall be responsible for the following:

All design, detail, engineering, materials, fabrication, installation supervision and testing of all equipment required to provide a complete and functional material handling systems to the satisfaction of the Chrysler and in accordance with all applicable design and installation standards.

B. Lubricate:

Bearings and gear boxes prior to start up or testing of equipment.

C. Paint:

Touch up all scratches caused during installation with a minimum of one coat of matching paint per section 09910.

D. Environmental:

Prior to the construction of the material handling equipment, the OEM will fill out “Appendix A” of ETI-103 and forward it to AME Powertrain for review by the AME Environmental

Specialist.

1.1.2 SECTION 1.0 – GENERAL CONVEYOR SPECIFICATIONS1.1 GENERAL

1.1.1 Equipment furnished shall meet, as a minimum, the requirements of these specifications. Compliance with the specifications shall not relieve the supplier of his obligation to provide a complete and workable system, which conforms to the description of operations. The Owner will not be responsible for the accuracy of the specifications as they relate to the satisfactory performance of the total system.

1.1.2 A request for deviation from the specifications shall be submitted in writing. Only a deviation that is approved in writing will be permitted. The Chrylser plant engineer or supervisor shall be the final authority on all proposed substitutions and/or changes.

1.1.3 The supplier shall attempt to select common components (e.g. manufacturer, sizes) for similar functions in order to simplify the stocking of spares.

1.1.4 These specifications apply to all new and reworked systems. In reworked systems all components that are modified or relocated are to meet these stated specifications unless otherwise in work scope.

1.1.5.1 The automation shall be of sufficient construction to support the component and pallet (where applicable). All components of system must be designed and built with maximum consideration for quality and long term reliability as a benchmark.

1.1.5.2 The design of the transfer system must be compatible with automatic/manual operations. Transfer shall not interfere with value added operations.




1.1.5.3 Non-synchronous automation shall be capable of continuous accumulation from the start of conveyor to the finish and through all escapements, elevators, and intersections.

1.1.5.4 Load and unload stations shall` not be used to perform an automatic or manual "value added" operation.

1.1.5.5 The design of the material handling system shall be coordinated with the design and function of all machinery (dimensions, location, etc.).

1.1.5.6 The movement of the component shall not alter the condition of the part during transfer, locating, clamping; so that no damages (burrs, nicks, scratches) occurs to the components critical surfaces.

1.1.5.7 The system shall be designed applying principles of ergonomics for human interface to reduce stress and therefore improve the overall efficiency of the system (http://ame.ctc.chrysler.com/tooldesign/section15page.htm).

1.1.5.8 System design shall not allow for part to part contact during transfer or an operation (unless identified otherwise in the scope of work for the RFQ). System shall not allow for pallet to pallet contact during a value-added operation.

1.1.5.9 System design shall not leave witness marks on parts during picking or placing or transfer of parts.

1.2 SYSTEM DESIGN1.2.1 All equipment shall be designed to be fail-safe. Any malfunction, misalignment, breakage,

loss of power, or loss of signal that prevents the equipment from being operated will be corrected at no additional cost to Chrysler.

1.3 CONSTRUCTION1.3.1 Bolted Construction: Strength of all bolted joints shall be equal to that of the joined members.

Bolts shall be long enough to allow the use of a full nut and one lock washer with minimum one (1) complete thread exposed. Bolt holes shall be drilled or punched in all structural members. The burning of holes in structural members is not allowed.

1.3.2 Modular Construction: Overhead Power & Free and Inverted Power & Free. The conveyor will be assembled in a precision fixture. This fixture will enable the supplier to assemble all conveyor components symmetrically. This type of fabrication and assembly requires all joints to be oil tight. All sections will be bolted to one another with a common bolt pattern that has been calculated to accommodate conveyor loading. Conveyor components, such as stops, anti-backups, anti-runaways, etc. will be installed on the conveyor prior to shipping. All electrical components that are required to operate conveyor devices will be installed on the conveyor rail and wired to a junction box.

1.4 FLOOR LOADING1.4.1 Load bearing pressure exerted by equipment footings on any floor shall not exceed the rated

floor loading and must be approved by the Owner or his representative. Particular attention must be given to live load increases on elevated floors when transfer or lift equipment is used.

1.5 VIBRATION PROTECTION




1.5.1 Equipment shall be isolated from the vibrations of other equipment. Wherever components supported by separate structures interconnect, there shall be provision for any relative motion that occurs between the structures.

1.5.2 All pillow and flange blocks must be blocked to prevent any movement if the bolts loosen.

1.6 GUARDS1.6.1.1 Ref. to section 16.13 of the Do’s and Don’ts.


1.6.2 All V-Belt drives, sprocket drives, and couplings and other moving drive components shall have individual guards easily removable without removing adjacent equipment. Guards are to be constructed of 1/2" diagonal flattened expanded metal with angle framing on all edges or solid sheet metal / Aluminum, shall be mounted to permit quick removal or replacement with the use of hand tools. Refer to TMS requirements, utilize lexan where feasible to allow immediate detection of drive belts or chains.

All new guards shall meet A.M.E. Specifications even if reworking an existing system.

1.6.3 All rotating head and tail shafts on floor or platform level shall be protected with individual guards constructed of 2” diagonal flattened expanded metal with angle framing on all edges. Guards shall be mounted to permit quick removal or replacement with the use of hand tools.

1.6.4 All Inverted Power and Free and Chain-On-Edge conveyor take-up and drive combinations mounted on the finished floor shall be provided with perimeter Chrysler standard safety fencing. In addition, an electrical gate plug shall be installed. Lubricators or greasers that require filling shall be refillable without unplugging safety gate or violating intent of this specification. Manifold blocks, which require greasing, shall also be accessible without unplugging safety gate.

1.6.5 All elevated conveyor take-ups shall be provided with perimeter 1” x 1” mesh guarding to protect plant personnel from moving components. An opening will be provided in the take-up guarding to permit movement of take-up air cylinder. Take-up guarding shall be designed such that maintenance personnel can easily access components on the take-up, that is, guarding shall be easily removable and replaceable with the use of hand tools.

1.6.6 All return chain that is not in a trench on Overhead Monorail, Overhead Power & Free, Inverted Power & Free and Chain-On-Edge Conveyors shall have guarding on all portions of the conveyor where the track, chain, chain attachments, chain trolleys, etc., are within an elevation of 7'-0" from the finished floor, platforms, pits, screen guard, or catwalk and in the normal path of maintenance personnel as they service drives, take-ups and access the carrier repair spur. All deviations must be reviewed by AME and approved prior to their use. All guards shall be constructed of 1/2" flattened expanded metal or sheet metal with angle or bar framing on all edges. All guards shall be built in 8'-0" maximum sections. The guards for all turns shall be fabricated in rolled sections and shall be of the same cross section as the guard for straight track. Guards on Inverted Power & Free and Chain-On-Edge conveyors shall be designed to withstand personnel stepping or standing on them.

1.6.7 All chain in drive pits, machine pits, and screen guard (below 7'-0"), etc., shall be finger guarded.

1.6.8 Inverted Power & Free conveyors shall have side guards on all portions of the conveyor with stabilized track (production areas) and on all portions of conveyor which is not within screen guarding where the elevation of the caster track is above the finished floor, platform, deck,




etc. The side guards shall be constructed of No.12 gauge sheet metal and shall have a 90° continuous lip bent toward the center of the conveyor. The side guard height shall be designed to go from the carrier caster wheel-riding surface to the top of the finished floor, platform, deck, etc. The side guard shall attach to the conveyor track in sections no longer than 5’-0”. Side guards shall be easily removable and replaceable for ease of maintenance.

1.6.9 Inverted power & free and overhead power & free track shall have guarding covering access to the chain. Guarding shall be secured between the yokes and is required at all locations where chain is below 7'-0" from the floor. Guarding shall be provided in lengths of maximum 5’-0”.

1.6.10 Perimeter guarding shall be per Chrysler corporate safety specifications.

1.7 EQUIPMENT ACCESSIBILITY1.7.1 Equipment shall be accessible for maintenance without the removal of adjacent equipment.

Minimum clearance for a person shall be 28".

1.7.2 The supplier shall provide 3'-0" sq. access hatches for ease of maintenance at the head, tail, drive, take-up, etc., sections of floor conveyors. Access doors, 1'-6" square minimum, shall also be provided over sprocket turns, roller turns, traction wheel turns, bearings, rollers, wheels, limit switches including rotating cam limit switches, lubricators, solenoid valves, etc., located in pits or trenches for ease of maintenance.

1.7.3 Access door hinges and lift handles shall be the hidden type that does not protrude above the floor, Bilco or Owner approved equal. The hatch shall be equipped with a hold open device that acts as a safety stop and hand railing for the hatch opening. Hand railing shall move into place as hatch is opened. Access openings along conveyor trench must be lift out type.

1.7.4 All floor plates associated with the conveyor's head end, tail end, or drive pits shall be bolted. The floor plate shall be bolted in place with 5/8" diameter bolt, with 3/8" wrench size, hex socket, flat head screws. The nuts shall be tack welded in place after aligning the holes in the cover plate and the support member use the screws as a guide.

1.8 BEARINGS1.8.1 All conveyor head shafts, tail shafts and jackshafts shall incorporate spherical roller bearing

pillow blocks or ball bearing. Ball bearing pillow blocks are only acceptable on shafts for gravity rolls, power rolls, limit switch actuators and cylinder pivot devices.

1.8.2 All ball and roller bearings shall be provided with external lubrication fittings, which are accessible outside of all guarding.

1.8.3 Identify lube point with frequency and plant approved lube type on a tag (see section 1.13.9). Identify expected life cycle of all bearings.

1.9. COUPLINGS, SPROCKETS AND SET SCREWS1.9.1 Couplings and sprockets shall allow the removal of one (1) component without the removal

of adjacent components. All couplings shall have one (1) keyway and two (2) set screws;




one setscrew located over the keyway and one located at a 90-degree angle to the keyway. Roller conveyor sprockets shall be designed for a hex shaft.

1.9.2 Cone point set screws shall be used on all conveyor sprockets and couplings where the setscrew contacts shaft. Cup point set screws shall be used on conveyor sprockets and couplings to secure the key to the shaft.

1.9.3 Set screws shall be drilled through the head with a wire locking device to prevent set screw from backing out.

1.9.4 Do not use powdered metal sprockets or gears.

1.10 DRIVE MOUNTING1.10.1 It is preferred that the drive is mounted directly to the driving shaft onto the conveyor.

1.10.2 When required by design, the drive, coupling, coupling guard, and driven device shall be driver to drive. The owner prior to fabrication must approve exceptions to this type of mounted on a common, rigid base plate. This rigid base must be adjustable to align devices. All devices of this type shall be laser aligned.

1.11 LIMIT SWITCH AND PROXIMITY SWITCH ACTUATORS1.11.1 All devices including stops, positioners, track switches, lifters, etc. using sensor switch

actuators shall be prefabricated from engineering drawings submitted to Chrysler representative for approval. See controls specifications for details.

1.11.2 Switches shall have top shields for protection against coolant and physical damage. Switches must have 3 axis and radial adjustments.

1.12 TAGS1.12.1 See controls specifications for device/control tags including fluids. All drives, take-ups, track

switches, stops, limit switches, power units, etc., shall be quipped with tags mounted in an easily visible location. The tags shall give a word description and component number matching the description in the electrical description of operations. All overhead conveyor tags shall be approximately 4” x 6” with 1” high engraved or embossed black letters on a white background and constructed of heavy gauge plastic. Supplier is required to submit prototype tags for prior approval by Chrysler.

1.12.2 Tags shall be hung in a professional manner, mechanically secured using drive screws. The use of chains to hang tags is unacceptable unless approved by Chyrsler.

1.12.3 Unless otherwise noted, all carriers and body trucks shall be numbered consecutively with tags that may be easily read from the floor. Tags shall be mounted on each side of the carrier and on each side of the body truck with self-tapping screws. All carrier tags shall have approximately 2" high engraved or embossed black letters on a white background and constructed of heavy gauge plastic except on carriers or body trucks that travel through ovens or spray booths unless otherwise approved by Chrysler.

1.12.4 All tags mounted to floor plate shall be embossed or engraved steel nameplate with 2" black letters. Prototype shall be submitted to Chrysler for prior approval.




1.13.5 All pneumatic equipment including valve boards, take-ups, positioners, and track switches shall have lamacoid tags showing recommended pressure settings. See Controls specifications section 8.

1.13.6 All meters, shot pins, diverters and blenders shall be tagged.

1.13.7 All elevators, automatic storage units, belt conveyors, silos, etc. shall be labeled.

1.13.8 All pallets shall be numbered sequentially without repeating.

1.14 TESTING AND ADJUSTMENT1.14.1 All mechanical components and devices shall be adjusted and tested after final installation

prior to 20-hour conveyor test (could consist of a single shift on multiple days to accumulate an equivalent number of hours and again after system is filled with parts (representing maximum production conditions).

1.15 SHAFTING1.15.1 All steel shafting is to be made in accordance with the best manufacturing practices.

Surfaces are to be smooth and free from blemishes, with all lengths commercially straight. Shafting shall be furnished in medium carbon SAE 1040 (or better) open hearth steel. All roller conveyor shafts shall be a hex cross sectional shape unless noted otherwise by the owner representative.

1.16 CHAIN PULL ANALYSIS1.16.1 The Contractor shall verify drive locations with a detailed, thorough and accurate chain pull

analysis for each conveyor included in the Contract. Chain pull analysis shall be furnished for each system and each possible combination of drives on multiple drive systems showing static pulls, balanced pulls and maximum chain tensions. Supplier shall provide Horsepower requirements (including service factors used) for each unit. Chains must be pre-stretched before installing to conveyor.

1.16.2 Triple strand roller chain shall be pre-stretched prior to assembly.

1.17 SUBMITTALS

1.17.1 Drawings & Manuals: Within four (4) weeks of receiving a purchase order, the OEM shall submit one (1) hard copy and one (1) electronic set of prints to AME-PT engineer for Chrysler‘s approval. With shipment, the OEM shall supply and ship one (1) set of paper copy drawings with machine and one CD of drawings and operation and maintenance manuals to the responsible AMEPT engineer. Once installed and qualified, the OEM shall update and ship three (3) paper sets of operation and maintenance manuals showing component parts such as pumps, fans, motors, automatic valves, bearings, etc. to the plant representative as directed by the responsible AME-PT engineer. A signed copy of the Letter of Transmittal and a CD containing all “as installed” drawings of the equipment, operational maintenance manuals, and scanned electronic copy of all individual component specification (“cut”) sheets and all spare parts lists to the responsible AMEPT Engineer.




1.17.2 Chrysler will supply the brass tag shortly after the purchase order is issued.

1.17.3 All floor plan drawings must show the complete plan view of the entire material handling system as it sets on the floor. Its base, including projections for leveling or anchoring, shall be shown in heavy dashed lines. Heavy solid lines shall be used for any and all projections above the base including platforms, load and unload locations, panels or any other part of the system. Clearance for service, including panel and access doors (open position) shall be shown in the proper location. Show all service drop locations. Ancillary equipment such as electrical panels shall be shown in correct relation to material handling system and dimensioned. In no case shall the equipment be located so as to prevent ease of access for service or repairs of any component of the machine or ancillary equipment.

1.17.4 The scale floor plan drawings shall be updated each time a revision is made and submitted for approval to Chrysler prior to altering the material handling system, ancillary equipment or orientation.

1.17.5 All engineering drawings shall be developed using the CAD software and version agreed upon in CAA (Cad Administration Agreement). All engineering drawings, upon successful completion of this project become the property of Chrysler Corporation.

1.17.6 Maintenance Manuals in English shall also be developed in an electronic format utilizing Microsoft Word or Adobe Acrobat. All graphics must be embedded into the document, not linked.

1.17.7 The OEM shall provide a recommended spare parts list for all of the supplied equipment. Included in this list shall be a “where-used” list, current cost of parts, and lead-time in weeks. The spare parts list shall be per Chrysler TMS electronic format (per the Chrysler web site). Note- spare parts shall be available from sources within the country where the equipment is intended for use.

1.17.1 Where the work performed by a supplier or contractor is an extension of or revision to an existing conveyor, the supplier shall provide a new drawing of the entire conveyor, not just the revisions. This requirement is in addition to the drawings called elsewhere in these specifications.

1.18.1 Field Utility routing to equipment and gages including planned placement of all cranes, pull boxes, disconnects, control panels, isolation valves, (including lockout valves), supports, flow balancing valves, flow meters, gages and anchors and sway bracing. Do not route utilities in the path of the automation such as gantries or in the path of any cranes.

1.19.1 Wiring diagrams in controls submittals for all field-installed wiring showing panel terminated insulation labels and color of wire.

1.20.1 All installation submittals must show code clearances such as 42 inches from front of a control panel to any obstruction and 48 inches from the fronts of two opposed facing control panels.

1.21.1 All means of egress between equipment must have a minimum of 28 inches.

1.18 METERS, DIVERTERS & BLENDERS




1.18.1 All stops shall be designed such that mechanical failure shall not prevent the stop from closing.

1.18.2 All conveyors that are automatically loaded or unloaded by robots, machines or conveyor transfers shall have positioners and floor stabilizers or stabilized track at owner’s discretion, at that station. Positioners shall be electrically actuated and locate the carrier within +/- 1/16" repeatability or as specified for application.

1.18.3 The air-actuated positioners shall force the carrier against a solid stop and not allow the carrier to ride back against the anti-backup.

1.18.4 Positioners shall have some adjustment, +/- 2 inches without removing and relocating positioner. The positioner shall not utilize a gravity type slide assembly, where by the hold back arm relies on gravity to center itself before the positioner is accuated to hold the carrier or pallet.

1.18.5 All Stops and escapements shall be electric activated.

1.18.6 All meters, diverters, and blenders shall be electric activated.

1.18.7 Directional valves to meet fluid power and electrical specifications.

1.18.8 High-level limit switches will stop the meters and prevent parts from entering lanes that are full.

1.18.9 Part clear switches for each lane at the exit of diverters. The diverter will not change lane until part clear switch is made.

1.18.10 Limit switches shall be installed on diverters and blenders to give a positive indication of lane position.

1.18.11 Limit switches shall be installed in blenders so that no more than one part can be metered through at a time.

1.18.12 Each meter shall have ability to time part metering and have associated limit switches.

1.18.13 Diverters and blenders shall have detented valves.

1.18.14 Part present switches shall be used in conjunction with timers to automatically shut off conveyors when parts are not present and short cycling of motors will not occur.

1.19 PALLETS/TRANSFER FIXTURES (WHEN APPLICABLE)

1.19.1 Pallets/fixtures shall be of sufficient design and construction to accommodate the intended operation. Submit drawings to Chrysler engineer for approval.

1.19.2 All perishable (part contacting) details must be designed for ease of reproduction and replacement. All components must be interchangeable from pallet to pallet when there are a multiple of fixtures.

1.19.3 Pockets are to be avoided to prevent the accumulation of chips, dirt, etc.

1.19.4 All part clamping and/or locating will be designed to avoid placing undo stress on the component.

1.19.5 Pallets/fixtures require a means for positive location (i.e. shot pins) for automatic and/or manual operations. The method for location must be replaceable due to wear (i.e. removable bushing). Part locating pins to be assembled in replaceable liners.



Revision Date: 11/12/2007 1.19.6 Pallets shall have an adjustable part nest to allow adjustment and flexibility. Mounting plates

shall consist of elongated or oversized bolt holes to permit adjustment of detail if necessary.

1.20 DRIP PANS1.20.1 The Conveyor Contractor shall provide drip pans under all drives, expansion joints, traction

wheels, and automatic lubricators. It must also be provided under any conveyor where liquids and/or lubricants may drop onto parts, personnel, floor or equipment below.

NOTE: All drip pans shall contain dry floor guarding1.20.2 All drip pans shall be constructed of aluminum or steel sheet metal with a 1" minimum high

lip all around and shall have a minimum 1 1/2"diameter drain lines with raised mesh cover. All drip pans shall be oil tight. Drip pans under drives shall be easily removable for servicing without burning. Drip pans shall be designed to extend 2" minimum beyond the perimeter of the equipment they are under.

1.20.3 Drip pans must be sloped (1%) or greater to the nearest machine. A sump pump unit must be provided, when the coolant in the drip pan can not be returned to the nearest machine through a sloped drip pan.

1.20.4 Drip pans for RGVs (Rail Guided Vehicles) must also collect coolant and use either a tip tray at the end of traverse motion to empty coolant into a stationary automation drip pan or pump coolant to drip pans.

1.20.5 All overhead and inverted conveyors shall be drip free, unless specified by plant.

1.20.6 Drip pans shall have ¾” or 1” welded couplings plugged for cleaning.

1.21 CONVEYOR SYSTEM INTEGRATION 1.21.1 The conveyor supplier is required to coordinate with tooling suppliers for the interfacing of

conveyor systems with tooling equipment. Supplier is responsible for obtaining dimensions and tolerances from the tooling suppliers to ensure a complete and workable system.

1.21.2 The supplier shall furnish interlocks to provide a reliable system, which is error proofed and will allow independent operation of the conveyor system to load or unload machinery and equipment.

1.22 CARRIER & PALLETS GAGES1.22.1 A gauge shall be supplied for every set of carriers supplied under this contract.

Chrysler must approve the gauge.

1.22.2 Gauge tolerances must be documented to meet the tolerances as required for all assembly or machining equipment to meet product part print or exchange tolerances between devices.

1.22.3 The gauge will measure each point that touches the product and will reference (or be referenced to) the conveyor track.

1.22.4 A go/no-go gauge will be used for each detail-to-metal carrier point and shall clearly identify acceptable ranges on each gauge. Gauge shall be certified.

1.23 CYCLE TIME



Revision Date: 11/12/2007 1.23.1 Automation shall be capable of achieving and maintaining the cycle time as described in the

package for quotation.

1.23.2 The transfer and clamp time must be included in the overall cycle time specified, however, transfer and clamp time are necessary non-value added operations and must be kept to a minimum.

1.23.3 Material handing supplier must coordinate with machine builders to assure through – put cycle time is satisfied and must validate the designated cycle time.

1.24 COMPONENTS1.24.1 Bearings shall be "Lube for Life" when feasible, and conform to all AFBMA standards.

1.24.2 All roller chain shall be riveted and have a minimum safety factor of 10 over calculated chain pull.

1.24.3 Chain shall be a minimum size of R-50 and meet all ANSI standards.

1.24.4 Design considerations shall utilize lube for life roller chain where feasible.

1.24.5 Chain driven roller shafts to be driven by a daisy chain set-up, no continuous chain.

1.24.6 Stainless steel chain shall be used through washers and flush units to minimize corrosion, stainless steel shall be of a composition to minimize wear.

1.24.7 Steel Rollers must be carbon hardened and oil impregnated.

1.24.8 Rollers shall be of the eccentric design especially at load and unload areas and at meters, this will reduce part slippage due to coolant.

1.24.9 Utilize CPVC to fix roller’s position on shafts.

1.24.10 Shafting to be hardened in the wear area. Use Hex shafting when possible.

1.24.11 Sprockets to conform to ANSI standards and have hardened teeth, “A” style hub are not acceptable.

1.24.12 All guarding to conform to OHSA/MIOSHA and Chrysler specifications, refer to Section #10 of Power Train Operation Specifications.

1.24.13 All reducers to be standard catalog units and meet or exceed AGMA ratings. Units must not exceed manufacturer ratings.

1.24.14 All holes to be drilled or punched not burned.

1.24.15 All welded joints must meet or exceed AWS standards.

1.24.16 Aluminum extrusion rails shall always be utilized for conveyor construction unless noted otherwise.

1.24.17 Guide rails must be made of SURE Alloy or equivalent (work hardened steel) and not leave witness marks on parts.

1.24.18 All prox. or whisker switches must have positive stops, to stop devices prior to damaging switches.

1.25 KEY LESSONS LEARNED



Revision Date: 11/12/2007 1.25.1 Do not control automation from a machine tool control panel. All automation shall have an

independent control that can operate to unload an upstream operation or load a downstream operation safely while either machine is down for repair.

1.25.2 All overhead delivery systems (gantries, robots on rails, etc.) serving multiple operations must use interlocked guard hatches and interlocked shot bolts to allow safe automation operation during machine downtime.

1.25.3 All in process buffers must be located immediately after the upstream operation and allow for a part to bypass the buffer for gauging. The buffer must have a purge sequence for removal of suspect parts.

1.25.4 All rotating assemblies must have a fail-safe Electro/mechanical method to verify proper rotation.

1.25.5 All part locating pins must have a fail-safe Electro/mechanical method to verify proper part engagement in grippers, i.e. prox. switches are not allowed as the only means of verify part seating.

1.25.6 All gantry load and unload areas on conveyors must have a zone clear signal prior to load and unload of parts. The gantry supplier shall provide all necessary hardware to conveyor supplier for installation of the required zone clear switches.

1.25.7 The gantry supplier shall wire the zone clear switches directly to their gantry panel for a total direct control.

1.25.8 Where dual roller sections are required, double bearings and double side rail thickness provisions must support cantilevered rollers.

1.25.9 Side shuttles areas, where gauge check parts are shuttled off of the line, the double bearing and double side rail thickness must also be used.

1.25.10 Conveyor speed must be sufficient to support the machining system throughput requirements. The automation speed must be at least 25% faster than the machines to account and allow for natural buffering of the system.

1.25.11 Where parts need to be positively located or positioned for part I.D., buffer load/unload, gantry load/unload, etc., the “System OEM” must provide the means to do so, including controls and integration.

1.25.12 PFMEA must be conducted prior to final system design approval. This process must be accounted for in the supplier project time line.

1.25.13 All replaceable nests must be made of Nylatron or equivalent.

1.25.14 On conveyor corner turns: rollers shall guide and track parts as they make the turn.

1.25.15 Load conveyors with rough heavy parts to have roller top flight chain.

1.25.16 Buffer location shall be determined based on simulation results.

1.25.17 High level determination to include some for run-out parts.

1.25.18 All wiring or pneumatic tubing shall be placed in conduits that are imbedded (or saw cut) into the floor or routed high within flumes to allow unobstructed passage through automation access gates.

1.25.19 All cable trays associated with automation shall be a minimum 150 mm above the floor to allow for reasonable housekeeping.




1.25.20 Gripper shall hold the part even without air, hydraulic or power.

1.25.21 Automatic energy savings mode and auto recovery upon start up.

1.25.22 All Buffers shall implement FIFO (first in first out)

2.0 CONVEYOR TYPES2.1 Indexing palletized conveyors: Shall be bi-directional.

2.2 Accumulating palletized conveyors.

2.3 Friction roll conveyors (power and free rollers):

2.3.1 Rollers shall be eccentric at load and unload points and at meters.

2.3.2 Roller material shall be a steel roller, carbon hardened and oil-impregnated.

2.3.3 Utilize hex shafts as a standard. No key ways

2.3.4 Utilize CPVC pipe as a spacer between rollers on shafts.

2.3.5 Utilize a safety yellow chain covers on conveyors. Provide a window where needed.

2.4 POWER ROLLER CONVEYOR2.4.1 Zone control accumulating conveyor

2.4.2 Saw tooth conveyors: Part nests shall be made of Nylatron or equivalent.

2.4.3 Walking beam conveyors: used to transfer connecting rods.

2.4.4 Flat top chain conveyors: Utilize Plastic Flex chains, Stainless Steel chains, and Steel chains.

2.5 AUTOMATIC STORAGE & ELEVATORS2.5.1 Provide selector to choose storage or fast track operation. Load and unload preference

shall be from mode selected, as primary source, the unit shall automatically change to secondary source if parts are available. When parts are available again from primary source, unit is to switch back automatically.

2.5.2 High-level limit switches shall be installed down stream of the unload, at all elevators, so that when the conveyor is full the elevator will not be loaded and will shut down.

2.5.3 All cylinders for air operations to meet fluid power specifications.

2.5.4 Use proximity switches for detecting "flight in position" on all elevators. Build a shroud or locate the switch so that it will not get damaged from falling parts. Make provisions so that the switch can be easily replaced.

2.5.5 Buffer systems shall include an automatic and a manual purge mode down stream from operation.

2.5.6 Integrate part identification system controls into a storage system to allow tracking for purge of any suspect parts back to a clean point. Refer to AMEPT Controls: Marking & Reading Standards Section 17.




SECTION 3.0 – ROBOTICS

3.1 Design3.1.0 Refer to Chrysler Controls Specifications and Safety Specifications.

https://gsp.extra.daimlerchrysler.com/mfg/amedd/ameptcr/index.htm

3.1.1 Movement shall be on a controlled path repeatable to plus or minus .010 in. of a programmed position.

3.1.2 The robot shall be capable of maintaining its position after a power shut down, OEM to specify maximum drift at maximum rated load with quotation.

3.1.3 All steel details that come in contact with the cast surfaces of the part are to be hardened and machine ground.

3.1.4 All clamps shall have replaceable nosepieces unless otherwise indicated and shall not leave witness marks on the parts.

3.1.5 All locating and clamp points shall be protected from chip lodging.

3.1.6 All areas shall be designed to provide continuous chip shedding.

3.1.7 All fasteners and connections subject to loosening due to vibration are to incorporate non-self loosening designs.

3.1.8 The robot controls shall be placed to reflect the layout of the robots in the station. This placement shall provide a clear view of the robot while utilizing the controller.

3.1.9 The design Supplier shall provide installation drawings for each robot workstation. The drawings shall be per Chrysler CAD standards (AMEPT CAD Specifications https://gsp.extra.daimlerchrysler.com/mfg/amedd/ameptcr/index.htm)

3.1.9 The drawings shall provide the necessary views, sections and dimensions to install the robot and its associated equipment in the workstation. Any and all details, supports, units, transfer rails, etc., that are located within the robot's work envelope shall be shown. The installation drawings shall be submitted for review and approval as early in the design phase as possible.

3.1.10 All hard-stops, Restricted Space, Operating Space, and Operating Space plus 18" must be shown in the design layout.

3.1.11 It shall be the design Supplier's responsibility to develop the location of the robots and the robot's associated equipment. The robots work assignment and the end effector(s) used in the application shall determine the subject locations. Strong considerations shall be given to the efficiency of the robot and its associated equipment in its specified operation, as well as service ability and safety.

3.1.12 The robot shall be shown in the following positions:

1. Pounce

2. Work

3. Fully extended

4. Fully retracted






5. Maximum height

3.1.13 The product shall be shown at its work position and at its transfer position, when applicable.

3.1.14 The end effector shall be shown in its intended location on the robot's gear train with its tool center point referenced from the dowel hole on the robot's mounting face.

3.1.15 The design of the robot and its end effector must be within Chrysler electrical, mechanical, and pneumatic standards.

3.1.16 It shall be the integrating supplier responsibility to obtain approval of loading (mass), center of gravity, and moment of inertia about the 6th axis centerline of all robot end effectors. Material handling application mass properties shall be calculated with and without body assemblies. The approval process requires the integrating supplier to complete a "Robot Loading Analysis" form and "Robot Tooling Inertia" form for each robotic application. Spot weld guns can be entered as a single line item on the "Robot Tooling Inertia" form. If the result of the single line entry is within the robot’s inertia limit, no further inertia analysis is required. If the result exceeds the robot’s inertia limit, a detailed analysis must be performed this analysis may give an acceptable result because the single line method will typically give a conservative result.

3.1.17 Robot end effectors of all types, require detailed inertia analysis. The Robot Manufacturer shall supply the appropriate forms for each robot model used. Integrating supplier mayuse the supplied forms or their own equivalent. The completed forms, indicating mass properties analysis of end effector components and body assemblies (material handling) along with mechanical drawings, shall be submitted to the AME Plant Engineer for approval.

3.1.18 The design supplier is required to retain copies of the approved forms for review by Chrysler and the Robot Manufacturer. The integrating supplier shall provide copies of the approved forms to the build sources for use in setting robot load parameters and robot programming. The Robot Manufacture will review a random quantity of completed forms to audit the utilization of the forms and robot loading specifications.

3.1.19 Each sealing robot shall include a setting (calibration) gauge.

3.1.20 All material handling robot gripper designs must be of a single point of contact on the part. All contact shall be on flat surfaces. One jaw of the gripper shall remain stationary. Panel size and weight will be the deciding factor.

3.2 Robot Identification3.2.1 The build Supplier shall provide "Hard Stop" indicators on the robot's base. These indicators

must be clearly visible and indicate the reduced work range of the robot (i.e. Tiger striping).

3.2.2 All robots shall be assigned a non – repeating robot number designation.

3.2.3 The Supplier shall stencil identification on the following items:

1. Robot Control Consoles - the system name and number if available, IE: R##, R###, etc., in a contrasting color letters/numbers proportionally sized (minimum of 2") on the front of the robot control console.

2. Robot Base/Riser - The station "S02" fixture number, system name, R##, R###, in a contrasting color letters/numbers proportionally sized (minimum of 2") on the front of the robot Riser/Base.




3. Robot - Robot Number IE: R##, R###, in a contrasting color letters/numbers proportionally (minimum of 2") sized on (4) sides of the shoulder and (2) sides of the wrist.

3.2.4 The robot supplier shall provide limit switches and adjustable actuators as follows:

For selection of limit switches follow controls specifications.

Arm back limit switch with adjustable actuator. (Arm Back Limit)(1) Base limit switch with an adjustable actuator. (Base Limit #1)(3) Base limit switches and separately adjustable actuators will be provided with material handling robots. (Base Limits #1, #2, and #3)(3) Base limit switches and separately adjustable actuators will be provided with robots utilizing tool changers. (Base Limits #1, #2, and #3)(3) Base limit switches and separately adjustable actuators will be provided with dual process robots. (Dual process defined but not limited to multiple end effectors and/or working stations and/or functions. i.e. dual pedestal welders, sealer and welder, material handling and welder). (Base Limits #1, #2, and #3)

Robot limit switches will be defined as follows:

Arm Back Limit"ARM BACK"This limit switch is located on the arm or elbow of the robot with an adjustable actuator. The "Arm Back" limit switch is installed on all robots. This switch is to be monitored by the PLC. The signal will be high when the robot is clear of all tooling motion. The signal shall remain high when the robot is in the programmed "Home Position". The switch and actuator will be supplied by the robot manufacturer and shall be adjusted and wired by the Tooling Supplier. (Ref: "Project" Robot WD)

Base Limit #1"AT TIP DRESS POSITION ( for welding robots only)"This limit switch is located on the base axis of the robot (axis #1) and monitors the position of the arm in relation to the stationary base of the robot. The "Base Limit #1 is installed on all robots. The signal from this limit switch will be high when the robot is at its programmed "TIP DRESS" position. The "TIP DRESS" position shall be clear of the fixture(s), transfer and any movable tooling dumps, etc.

"AUXILIARY CLEAR"This limit switch may also be used for robot clear (i.e. material handling, sealer) of line/fixture/dumps when clear of pick-up and drop-off (ref. Base limits #2 & #3) are not adequate for this function.

Base Limit #2"CLEAR OF PICK-UP"This limit switch is located on the base axis of the robot (axis #1) and monitors the position of the arm in relation to the stationary base of the robot. The "Base Limit #2 is installed on all Material Handling Robots. The signal from this limit switch will be high when the robot is at its programmed "CLEAR OF PICK-UP" position.

"CLEAR OF FIXTURE #1"Simflex Robots




"CLEAR OF GUN/TOOLING CRADLES"Stud welding / Tool Changing Robots

Base Limit #3"CLEAR OF DROP-OFF"This limit switch is located on the base axis of the robot (axis #1) and monitors the position of the arm in relation to the stationary base of the robot. The "Base Limit #3 is installed on all Material Handling Robots. The signal from this limit switch will be high when the robot is at its programmed "CLEAR OF DROP-OFF" position.

"CLEAR OF FIXTURE #2"Simflex Robots

Clear Limit #4"ROBOT END OF ARM TOOLING CLEAR"This switch may be used for robot clear of line/fixture when the Arm Back Limit switch is not adequate for this function. (I.e. weld gun, end effector) The Launch Technician will define the use and location of this switch. The Build Supplier shall provide and install this switch. This limit switch is wired directly back to a PLC input.

"ROBOT CLEAR OF CONVEYOR"This switch may be used to indicate to the conveyor that the robot is clear of the conveyor and/or carriers with or without parts on them. The Build Supplier shall provide and install this switch. This limit switch is wired directly back to the tooling PIP and is interlocked with the conveyor PLC. The signal is powered, monitored and controlled by the conveyor PLC.

Note: All documentation shall include the base limit switch number and identification.

3.2.5 A Chrysler representative will address robot identification procedures. The format for identifying robots and equipment is available from a Chrysler Controls Coordinator.

3.3 Robot Construction/Installation3.3.1 Prior to the 50-hour reliability run the robot's operation and safety must be approved and

verified by a Chrysler Plant Engineer and or a corporate safety engineer in accordance with the programming checklist.

3.3.2 Programming practices to achieve line cycle rates that create unsafe machine operation is not permitted.

3.3.3 The Build Supplier shall provide, and is responsible for, the installation and adjustment of all limit switches and hard-stops required to meet Chrysler and O.S.H.A. standards.

3.3.4 When manual back-up capabilities are used in the process, the build Supplier shall provide and install a limit switch to indicate when the robot is in the stored position. This position shall be clear of any back-up personnel required to perform manual back-up procedures. An interface shall be provided to the applicable conveyor systems and transfers.

3.3.5 Robot pinch point safety distance between robot operating space and any obstacle shall be per the Chrysler Safety Specifications

Note: Design layout shall minimize the difference between the operating space and the restricted space.




3.3.6 The system and its robots shall be in accordance with the DaymlerChrysler, Manufacturing Technical Instruction for Safeguarding of Robots and Robot Systems, O.S.H.A., and A.N.S.I./R.I.A. R15.06 – latest adopted standards on robot safety.

3.3.7 Robot installations shall be provided with safety circuitry to hold the program count, while de-energizing robot actuator drive power.

3.3.8 The build Supplier shall provide manual back-up capability for all automatic load/unload stations. This shall include all safety-related items required to manually back-up the robot assignment.

3.3.9 Supplier shall provide a pneumatic lockable type ball valve, with a safety exhaust feature, for service air to each tip dresser and robot.

3.3.10 The build Supplier shall provide pressure sensitive safety mats in areas defined by Chrysler Safety Department and Chrysler Launch Technicians.

The safety mats shall be wired back to the power source in their area. See controls specifications for details.

1. Safety mats shall be installed in an approved manner.

2. Provide all platforms required for safety mat installation.

3.3.11 Construction Group and Plant Manufacturing/Builder shall ensure that the robot manufacturer designs and constructs industrial robots in accordance with 3.3.14 through 3.3.23 of this instruction.

3.3.12 Reconstruction and Modification: Anyone reconstructing/modifying an industrial robot shall do so in accordance with 3.3.14 through 3.3.23 of this instruction.

3.3.13 Hazards to Personnel

1. Moving Parts Hazards shall be eliminated by design or protection shall be provided against the hazards.

2. Component Malfunction: Robot components shall be designed, constructed, secured or contained so hazards caused by breaking or loosening, or released stored energy are minimized.

3. Sources of Energy: A means of isolating all sources of energy to the robot with lockout/tagout capability shall be provided. (Reference ANSI Standard Z-244-1982 and M.T.I. SMI-107)

1. Hazards from Stored Energy Means shall be provided to release that stored energy. This energy may be in the form of air and hydraulic pressure accumulators, capacitors, springs, counter balances and flywheels. An appropriate label shall be affixed to each stored energy source.

2. Electromagnetic Interference and Radio Frequency Interference The design and construction of the robot shall incorporate good engineering practices of shielding, filtering, suppression and grounding to eliminate the effects of Electromagnetic Interference (EMI) and Radio Frequency Interference (RFI).

3.3.14 Actuating Controls

1. Protection from Unintended Operation Actuating controls that initiate power or motion shall be constructed or mounted so as to prevent inadvertent operation. For example, a guarded pushbutton, key selector switch.




2. Labeling Actuating controls shall be labeled to clearly indicate their function.

3. Remotely Located Controls - Each robot that can be controlled from a remote location, shall be provided with an effective means, that when used, will prevent that robot's motion from being initiated from any location other than at the individual robot to stop.

3.3.15 Emergency Stop Device – See Controls Specifications and Corporate Safety Specifications for details

1. Every robot shall have an emergency stop device using hardware-based components. The emergency stop device shall override all other robot controls, remove drive power from the robot actuators, and cause all moving parts of the robot to stop.

2. Each operator control station, including pendants capable of initiating robot motion, shall have an emergency stop device.

3. Pushbuttons that activate an emergency stop device shall be red, unguarded, and unobstructed. In addition, except for those on pendants, they shall be palm or mushroom head type.

4. Provision shall be made within the emergency stop circuit to include additional stop devices.

5. Following the use of the emergency stop device, restarting the robot shall require a deliberate action by the operator to initiate a prescribed start-up procedure. In multiple robot installations, such deliberate action may be accomplished by resetting the individual robot control panels, or resetting the single emergency stop push button (maintained contact lockable type only) which was operated, in addition to resetting a process control panel.

3.3.16 Pendant – See control specifications for details

1. It shall not be possible to place the robot into automatic mode using the pendant.

2. All buttons and other devices on the pendant, which cause robot motion, shall stop motion when the button or device is released. (Live person type control.)

3. The pendant shall have an emergency stop device.

4. The pendant shall be designed so that when the robot is under pendant control; all robot motion shall be initiated only from the pendant.

5. All motion of the robot that is initiated in 'teach' mode shall be at slow speed. Refer to Safety Specification for allowable speeds.

6. Robots delivered after June 2001 requires (3) position Enabling Devices.

3.3.17 All robots capable of hazardous motion shall have a controlled slow speed. The maximum slow speed of any part on the robot shall not exceed 250 millimeters (10 inches) per second due to the action of any individual axis. The robot shall be designed and constructed so that in the case of any single reasonable foreseeable malfunction, the slow Speed shall not be exceeded when the slow speed is intended.

3.3.18 Mechanical stops shall be capable of stopping the motion of the robot under rated load and maximum speed conditions. Mechanical hard stops and control soft stops are required when the robot must be stopped short of the designed capacity in order to avoid contact with adjacent Robots when rear or side swing causes pinch points. A minimum clearance of




eighteen inches (18") must be maintained between the operating space and the end effector (with suspended part on material handling applications) and non-point of operation structures.

3.3.19 Required Information:

1. Function and location of all controls

2. Robot specifications including range and load capacity

3. Precautionary information

4. Operating instructions

5. Maintenance information

6. Information required for installation

7. Special environmental requirements - including EMI and RFI

3.3.20 All electrical connectors used on robots, which could cause hazardous motion if mismated, shall be keyed to prevent mismating. Electrical connectors which could cause hazardous motion of the robot if they are separated or if they break away, shall be designed and constructed so as to guard against unintended separation.

3.3.21 Power Loss or Change

1. Robots shall be designed and constructed so that loss of electrical power or voltage surges or changes in oil or air pressure will not result in hazardous motion-of the robot.

2. End Effector Design

3. End effectors shall be designed and constructed so that loss of electrical power or oil or air pressure shall not result in a hazardous condition. Clamping mechanisms shall have locking characteristics.

3.3.22 Robots shall be designed and constructed so that any single failure shall not cause hazardous motion of the robot.

3.3.23 Group and Plant Manufacturing/Production Engineering shall ensure that the robot system is installed in accordance with the following instructions:

1. The robots or robot systems shall be installed in accordance with manufacturer specifications.

See controls and electrical safety specifications for item # 2, 3, 4 & 5

2. Electrical ground shall be provided in accordance with robot manufacturer specifications and/or applicable codes.

3. Electrical power provided shall meet the robot manufacturer specifications.

4. Robot and associated controls requiring access during automatic operation shall be located outside the barrier enclosure.

5. The robot control console shall be positioned so that the robot is in full view. Placement of consoles in positions that reduce visibility of the unit and its restricted space must be avoided. Consoles must not be used as barriers in place of barrier guard panels.

6. The robot system shall be installed to avoid interference with buildings, structures, utilities, other machines, and equipment.




7. Each installation shall have a means to shut off power to the robot located outside the barrier guard or enclosure. This means shall have a lockout/tag out capability.

8. Hard stops shall be positioned to establish restricted workspaces to restrain the motion of the robots, so as not to destroy cabling or hoses.

9. All environmental conditions, including but not limited to explosive mixtures, corrosive conditions, humidity, dust, temperature, EMI and RFI, shall be evaluated to ensure compatibility of the robot with the anticipated operational conditions.

10. Robot systems shall be installed so that shut down of associated equipment will not result in hazardous motion of the robot.

11. The restricted workspace shall be conspicuously identified by line markings on the robot base.

12. Each robot operator station shall be provided with an emergency stop device. See control specifications of details.

3.3.24 Provide a separate fused disconnect for each robot controller. See controls specifications for details.

3.3.25 A buy-off is required at the final installation site. This buy-off will consist of operation, safety programming and cycle time. The guidelines established and implemented at build Suppliers facility will be used.

3.3.26 After installation at the unit plant all robot programs shall be "touched-up" as required to insure that each robot performs within its allotted cycle time

3.3.27 The build supplier shall set all programmable software over travel limits to activate prior to engaging the major axis over travel limit switches and minor axis hard stops. This shall be done after all hard stop locations have been determined and set.

3.3.28 The "Arm Back" limit switch shall not be actuated during the robot work program.

3.3.29 The Supplier shall provide and install all limit switches required to maintain an end of arm tooling clear signal when at home position if the end of arm tooling can be rotated into tooling motion while the robot "Arm Back" signal is high. (Ref: 3.2.4 "Clear Limit #4)

3.3.30 The build Supplier shall supply any platforms (risers) required to elevate robots into an acceptable work height.

3.3.31 The build Supplier shall assemble in their facility, by special means, if necessary, the complete setup for each robot. These setups shall include all of the equipment necessary to complete a functional tryout.

3.3.32 All robot cables and hoses shall be of sufficient length and shall be mounted in such a manner as to provide a minimum of wear throughout all robot motions. See controls specifications for details.

3.3.33 Install all cables entering robot cabinet in such a manner as not to create a strain on the connector end. See controls specifications for details.

3.3.34 All material handling robots must be ready to load parts at the beginning of the next cycle and within system cycle rate limits.

3.3.35 Overhead structures must have proper clearances so that the robot can be moved to its alignment positions without removing the end effector.




3.3.36 The build Supplier shall determine the location and set all electrical, mechanical, and software limit stops.

3.3.37 The build Supplier shall provide a list of all hardware and software jumpers used for reliability

Run.

3.3.38 All Dry Cycle Run jumpers must be removed at the completion of the Dry Cycle run and prior to system buy-off.

3.3.39 Include stepping process step controls.

3.3.40 The build Supplier shall provide laminated I/O plates mounted on each robot controller showing :

Follow controls specifications.

1. I/O assignments

2. I/O numbers

3. I/O designations.

3.4 Robot Teach (Pinch Point) Protection3.4.1 Mat Circuitry will be active in any mode.

3.4.2. The circuitry will affect only the robot or robots associated with the sensed area (Robot Pinch Point). The circuitry will not effect other automation.

3.4.3. With the System in Automatic mode the circuitry will cause the effected robot(s) to be put in a safe hold condition when the device is violated.

3.4.4 With the robot in Robot Teach Password Protect Mode the circuitry will cause the effected robot(s) drive power to be removed when device is violated. Stepping out of the sensed area will restore drive power.

3.4.5 Teach permissive circuitry is required when the robot’s maximum restricted space overlaps or they work on a common fixture.

3.5 Safeguarding 3.5.1 Group and Plant Manufacturing/Production Engineering/Builder shall ensure that safeguards

are provided and used in accordance with this Sections 3.5, and Sections 16.13 of the Do’s and Don’ts: : http://ame.ctc.chrysler.com/tooldesign/section16page.htm

The means and degree of safeguarding including any redundancies shall correspond directly to the type and level of hazard presented by the robot system consistent with the robot application.

3.5.2 One or more of the following shall prevent intrusion by personnel into the restricted workspace or enclosure:

A. Presence Sensing Devices

1. Presence sensing devices are safeguarding devices that use a sensing field and may include but are not limited to light curtains, mats, and proximity detectors or vision safety





systems. A failure of the presence sensing devices shall interrupt the operation of the robot system.

2. The presence-sensing device shall be designed and constructed so that its proper operation is not adversely affected by ambient factors.

3. The presence sensing device shall be designed and installed so that operation of the robot ceases or is inhibited when the sensing field is violated by entry or reaching into the restricted workspace.

4. Resumption of robot motion shall require removal of the sensing field violation.

5. Where entry to the restricted workspace does not cause a continuous violation of the sensing field, the deliberate activation of the controls shall be required to resume robot motion.

B. Barrier Guard

1. A barrier shall prevent personnel from reaching over, under, around or through the barrier into the restricted work space. It shall be necessary to use tools to remove the barrier or its section in order to gain entrance to the restricted workspace. A barrier shall be per the Corporate Safety Specifications..

C. Interlocked Barrier Guard

1. An interlocked Barrier guard shall prevent access to the restricted workspace except by opening an interlocked gate. Opening of the interlocked gate shall:

a. Stop the robot and remove drive power to the robot actuators.

b. Prevent automatic operation of the robot and any other associated equipment that may cause a hazard. Returning to automatic operation shall require both closing the interlocked gate and deliberately activating the controls used to restart the automatic operation.

D. Awareness Barrier

1. An awareness barrier shall be constructed and installed so that a person cannot approach the restricted workspace of an industrial robot without sensing the presence of the barrier. The awareness barrier shall be located so as to prevent inadvertent entry into the restricted workspace. Use of such a method will require additional safeguarding be used.

E. Awareness Signal

1. An awareness signal device shall be constructed and located such that it will provide a recognizable audible or visual signal to individuals of an approaching or present hazard. When awareness signals in the form of lights are used to warn of hazards in a work envelope, sufficient devices shall be used and located so that an individual facing in any direction in the proximity of the work envelope will see the light.

2. Audible awareness devices shall have a distinctive sound of greater intensity than the ambient noise level.




3. Use of such a method will require additional safeguarding be used.

3.5.3 Operators of industrial robots are personnel who initiate the intended production operation of a robot system. The users of a robot system shall insure that safeguards are established for each operation associated with the robot system. Safeguards shall prevent the operator from being in the operating space during robot motion or prevent motion when any part of an operator’s body is within the operating space.

3.5.4 Operators of robot systems shall be trained to recognize known hazards associated with each assigned task involving the robot system. Operators shall be instructed in the proper operation of the control actuators for the robot system and shall be instructed in how to respond to recognized hazardous conditions.

3.6 Manual Back-up of Robots in Automated Processes3.6.1 In line replacement of disabled robots by personnel in the robot restricted space can be

acceptable only if the necessary manual work station have been planned and installed in a manner consistent with maximum operator safety.

3.6.2 The following measures or their equivalents must be taken in the establishment of in line manual back-up workstations:

1. The operator must have full control of each cycle of the machinery from the backup workstation.

2. Drive power must be interrupted to the robot.

3. The robot boom, end effector and any suspended part must be moved to a predetermined position which does not interfere with the manual operation.

4. Workstations must be bordered with frontal and side barriers sufficient to prevent the operator from inadvertently becoming exposed to machine movements or adjacent operating robots.

5. Care must be taken during design to assure that manual back-up stations are free of unnecessary obstacles that could impede operator movement in the workstation. Protruding junction boxes, transformers, drive mechanism, hoses, electrical cables, etc. are examples of such potential obstacles.

6. Presence sensing devices shall be incorporated with manual controls unless the task can be accomplished safely without placing any part of the body in the movement path of the machinery or parts in process.

7. Secondary presence sensing shall be added to prevent personnel entry beyond the manual back up workstation.

3.7 Simflex Robotic Systems3.7.1 Simflex robotic systems shall be in accordance with all sections of this instruction, in addition

to the following.

A. Automatic Loading/Unloading When feasible, loading or unloading devices shall be designed and installed to allow the completion of necessary manual functions, from a point entirely outside operating the restricted work space of any robot or robots in a Simflex system.




B. Manual Loading/Unloading When loading or unloading must be accomplished in the restricted work space of a robot, the following conditions must be met:

1. The operator shall have full control of each robot cycle.

2. Workstations shall be bordered with a combination of barriers and presence sensing to prevent an operator from inadvertently becoming exposed to machine movement.

3. Presence sensing devices shall be utilized in conjunction with cycle controls. These devices shall be installed in workstations in a manner that will prevent access to the interior of a system through a workstation, without crossing the barriers indicated in item (2) and activating the presence sensing devices. Such devices must be positioned to assure that presence sensing occurs before any part of the body enters the operating space.

4. A combination of hard wire circuitry and presence sensing devices must be provided in order to prevent any robot that services more than one work station from entering an occupied station.

3.8 Safeguarding the Teacher3.8.1 The teacher shall be trained on the particular model of robot and shall be familiar with the

recommended "teach" procedures.

3.8.2 Before teaching a robot, the teacher shall visually check the robot and operating workspace to assure that conditions, which may cause hazards, do not exist. The teach controls of the pendant shall be function tested to ensure proper operation. Any damage or malfunction shall be repaired prior to commencing the teaching operation.

3.8.3 When the teach mode is selected, the following conditions shall be met.

1. The robot shall be under sole control of the teacher.

2. The robot shall operate at slow speed only.

3. The robot shall not respond to any remote interlocks or signals that would cause motion.

4. Automatic movement of the other equipment in the workspace shall be under the sole control of the teacher if such movement would present a hazard.

5. All robot system emergency stops shall remain functional.

6. The teacher shall be required to leave the barrier guard enclosure prior to initiating the automatic mode.

3.9 Safeguarding Maintenance Personnel

3.9.1 Personnel who perform maintenance on robots or robot systems shall be trained for the procedures necessary to safely perform the required tasks.

3.9.2 Personnel who repair and maintain robot systems shall be safeguarded from injury due to unexpected or unintended motion. The means and degree of safeguarding, including any redundancies, shall correspond directly to the type and level of hazards presented by robots and robot systems.




3.9.3 The most effective means of safeguarding is to shut the robot off. A procedure shall be followed that includes lockout/energy control of sources of power and releasing or blocking of stored energy.

3.9.4 When it is not feasible to follow a lockout/energy control procedure, alternate-safeguarding methods shall be established as required to prevent injury.

3.9.5 Personnel performing maintenance tasks within the restricted operating space when drive power is available shall have total control of the robot or robot system. This shall be accomplished by the following:

1. The control of the robot shall be removed from the automatic operations.

2. Robot control shall be isolated from any remote signals that could initiate robot motion.

3. Movement of other equipment in a robot system shall be under the control of the person in the workspace if such movement would present a hazard.

4. All robot systems emergency stop devices shall remain functional.

5. The robot system shall only be reset for automatic operation after the person leaves the work cell.

3.10 Robotic End-of-Arm Tooling Guidelines3.10.1 Fail-safe designs shall be utilized in clamping and holding operations to guarantee safe

operation, and minimize part and equipment damage. Clamp position shall be maintained in the event of air loss.

3.10.2 All designs shall incorporate ease of maintenance and repair.

3.10.3 All standard purchased components shall be chosen from the Chrysler Approved Source list.

3.10.4 Fatigue calculations and durability certification shall be provided for all components.

3.10.5 Torque specifications shall be supplied with each tool and also listed in the EOAT (end of arm tooling) service manual.

3.10.6 FMEA’S on all manufactured components shall be supplied at concept approval stage, and provided on all as-built documents, as well as in the service manual.

3.10.7 All suppliers shall use existing Chrysler Standards, Do’s and Don’ts, and standard machining practices as per the Machinery Handbook.

3.10.8 Construction shall be bolted, except with prior, written engineering consent.

3.10.9 Paint-dot and safety wire all torque, bolted connections, after torque verification. (Use bright fluorescent orange paint.)

3.10.10 Design concept and detail layout shall contain provisions for efficient deployment of cables and / or hoses.

3.10.11 Air lines shall be a minimum size so as not to detract from any gripper or end of arm tooling performance due to pressure losses.

3.10.12 Facility air supply operating pressure shall be assumed to be 60 psi. See controls specifications for details.




3.10.13 Whenever possible, robotic EOAT shall be protected from damage through the use of a mechanical or pneumatic breakaway device, mounted between the robot tool mounting

flange and the EOAT.

3.10.14 Where feasible, aluminum modular components shall be considered for EOAT design and construction, in place of steel.

3.10.15 In applications where weight requirements dictate the use of steel rather than aluminum components, or where any type of welding is utilized in the construction process, such welds shall be tested for weld and component integrity, with the minimum test being Magna fluxing. Test results shall be included in the EOAT service manual.

3.10.16 Both Supplier and installation contractor shall be licensed and inspected regularly to insure conformance to standard steel and aluminum welding practices.

3.10.17 If any type of welding is used in the construction of the EOAT, the supplier of the tool shall be registered with a recognized welding association. ( Documentation shall be provided with the EOAT service manual).

3.10.18 Stencil total weight on all end effectors.

3.10.19 Mistake proof end effector tool or fixture to mating adapter shall be the Suppliers responsibility.

3.11 Robot Control Program (OEM to develop details)3.11.1 Provide a freestanding robot control console for each robot, with operator controls located 40"

to 52" from the floor.

3.11.2 Provide a minimum of 15 feet interconnect cables between the robot and the control console.

3.11.3 Provide IBM compatible interface.

3.11.4 Provide a portable teach pendant with a 25 ft. cable.

3.11.5 The build Supplier shall provide (2) sets of the robot programs to a Chrysler Launch Technician prior to line shipment. The storage devices shall be clearly marked and must

contain all robot system definition or parameters.

3.11.6 The robot's program must be developed to insure that the end effector does not pull, bend, twist, or drag on the product or any related equipment.

3.11.7 The mainline and back-up process (if required) shall be done in the most efficient manner relating to robot movement.

3.11.8 All robot programs and related storage blocks not related to the process must be eliminated from the robot's memory before the 20-hour run.

3.11.9 Robot programs shall follow Chrysler Standard programming, flow charts and programming standards.

3.11.10 The PLC shall consist of the logic necessary to automatically or manually control the entire robot cell. It shall be structured to easily interface with the other areas of the entire system and follow Chrysler PLC robot logic standards.

3.11.11 The PLC program shall control individual robot activity. Program must be IBM compatible. Memory capacity shall be 20 percent beyond what is required for system




operation. The robot’s program must be stored in EPROM or backed up for 60 days with battery back up for any volatile memory.

3.11.12 The PLC program shall keep track of styles as the part moves through the system. This style information shall be used to instruct the robot to execute various cycles dependent on style or back-up requirements. Refer to Control specifications for details.

3.11.13 The controller shall provide for multiple robot program selection. This shall conform to the robot's back-up requirement plus (2) programs.

3.11.14 Provide diagnostics, which will alert personnel to problems with robots and workstation automation.

4.0Gantry Systems (Refer to Controls Specifications and Safety Specifications)4.1 The following sections are applied in the design and implementation of a gantry system:

Section 16.12.1/2/3/4/5: http://ame.ctc.chrysler.com/tooldesign/section16page.htm

4.1.1 Movement will be on a controlled path repeatable to plus or minus .010 inch of a programmed position.

4.1.2 The gantry shall be capable of maintaining its position after a power shut down, OEM to specify maximum drift at maximum rated load with quotation.

4.1.3 All steel details that come in contact with cast surfaces of the parts shall be hardened and machine ground.

4.1.1 All areas including clamp points shall be designed to provide continuous chip shedding.

4.1.2 All grippers shall be designed to pick up parts on non critical surfaces where this is impossible , details shall be softer than the surface being contacted and a means for chip flushing or blow off must be included to minimize chip lodging on the gripper details.

4.1.3 All fasteners and connections subject to loosening due to vibration are to incorporate non-self loosening design.

4.1.4 The supplier shall provide installation drawings for each gantry. The drawings shall be per

Chrysler CAD Standards. See item # 1.17 for details.

4.1.5 It shall be the supplier’s responsibility to develop the location of the gantries with relation to part delivery to machines and or other automation.

4.1.6 It shall be the supplier’s responsibility to integrate the gantry control (interlock) with all associated equipment and automation.

4.1.7 All gantries shall be designed with sloping drip pan with a minimum one-inch NPT threaded drain connections. Drip pan shall have structural integrity to restrain the gantry or parts from protruding through the drip pan in the event of any malfunction of the gantry.

4.1.8 All “in-pan” buffers on the gantries shall utilize hardened and machine ground locators or nests that do not touch the parts on any critical surfaces. All locators or nest shall have tapers or lead-in designs. Provide windows in drip pans to visually see all parts stored in overhead buffers from the floor level

4.1.9 All grippers on gantries shall be compliance types allowing movement to properly align the grippers to pick up or to drop off parts.

4.1.10 The gantries shall be designed with “hard stops” and soft stops to control the gantries within their designed travel limits.





4.1.11 Each gantry control panel shall be located to allow the most practical full vision of the gantries range of motion. Each control panel shall have full diagnostics for trouble shooting and rapid recovery of faults.

4.1.12 For all “teach pendants” requirements refer to the Controls Specification

(Section 5 – Controls Architecture) and (Section 6 – Safety)


4.1.13 Provide locking pins on the gantries motions to securely limit or hold the gantry during limited motions or during lockout and service. Where gantries service multiple operations, provide manual sliding pan doors and with locking interlocking pins accessible from the floor without ladders or lifts to allow continued service of the operations while an operation is in a tool change or locked out for maintenance.

4.1.14 The gantry supplier shall provide all guarding for the gantries including guarding for all pick up points or drop off points. Provide a minimum 18 inches clearance between any moving feature of the gantry or gripper and the guarding. Provide a minimum 36-inch reach tunnel guard from moving components of the gantry or gripper. All guards shall have at least one interlocked gate door with request to access.

4.1.15 For all Lubrication requirements refer to the Controls Specification(Section 14 – Lubrication)

4.1.16 Prior to a 20 hour run and during installation, supplier shall validate that all lubrication tubing is purged of all contaminant and bled before start up.

4.1.17 All devices used to orient parts associated with gantries must be located and programmed such that during a fault or shut down, the gantry can recover quickly by restarting and re-orienting the part for rapid recovery to full cycle.

4.1.18 Provide semi-spherical mirrors strategically placed along the travel path of the gantry to allow visual inspection of the operation from floor level.

4.1.19 Provide a permanently marked (0, 0, 0) location for the gantry for ease of recovery from a system crash or fault.

4.1.20 All gantries shall be equipped with crash prevention and crash recovery in all axis of travel (Z-X-Y)

4.1.21 Provide a guarded work zone for each gantry with an interlocked gate to service end of arm tooling from floor level.

4.1.22 All gantries shall be equipped with a break away system that works on an air coupler (or equal) that when the gantry gets into a bind the coupler breaks and stops the movement on the gantry.

4.1.23 Gantry grippers shall have an Electro/mechanical part verification to ensure axial and radial part orientation and complete part seating in grippers.

4.1.24 All attempts to pin gantry shall be located where end effectors shall be repaired from the floor level. Grippers shall hold parts with power off and no air or hydraulics.

4.1.25 All gantries shall utilize an automatic lubrication system, refer to Controls Specifications. Provide ETI-103 for lubricants.

4.1.26 Provide teach pendants for gantries.

5 .0 PART FEEDERS





5.1 The OEM shall insure that said equipment is designed such that products are not damaged in any way, as they are processed through the equipment.

5.2 The OEM shall provide with the quotation package statistical downtime/uptime history as a percent, for the system being proposed. The data shall be from prior jobs, projects and customers where this system is currently being utilized.

5.3 The equipment shall be subject to all Chrysler run-off procedures and policies to be determined by Purchaser and OEM. If OEM does not have the quality run-off procedures, it is their responsibility to contact the Purchaser and request such documents.

6.0 BLUE STEEL GRAVITY SYSTEM6.1 Chuting shall be SAE grade 1075 scaleless blue spring steel, tempered to 45-48 Rockwell “C”

with a No. 1 round edge on both edges and a minimum of .062 inches thick. It shall be a minimum of 5/16 inch bolted construction on 4 inch centers including Cadmium plated hex head bolts and locknuts. A removable hold down rail shall be used on all chuting except at manual load and unload areas.

6.1.1 Floor supports shall be double pipe construction. Mounting bracket shall be designed to provide a minimum of one inch clearance on both sides of the chuting and 3 to 4 inches clearance from the bottom of the chuting. Distance between floor supports shall be no more than 10 feet in straight sections and 8 feet in curved sections.

6.1.2 Overhead supports shall be the inverted “U” type construction.

6.1.3 Gravity storage units shall be helical type with 3 inch channel iron minimum welded construction frame with adjustable feet to allow plus or minus 6 inches “minimum” adjustment. Drip pans shall be provided on all units.

6.1.4 Meters; cylinders shall have a bolt-through flange type mounting. Plungers and guides shall be of heavy duty construction, rigid and wear-resistant. Plungers shall be solid steel with tips (RC-48-52). Where part damage is a major consideration, urethane plungers of 90 durometer “A” scale shall be used. Meters shall be pre-piped with flow controls and solenoids mounted in place. Meters shall be equipped with replaceable plungers.

6.1.5 Standard roller conveyor; rollers sizes, widths and spacing shall be suitable for the part or container Bearings shall be Mathews series #29000 or equal. The shaft shall be of hex steel, spring loaded. The frame shall be steel channel welded construction suitable for application.

6.1.6 Pneumatic shuttle; shuttle features welded construction frame to handle at least double the expected requirements for wear and smooth operation. Shuttle frame shall be mounted on two linear rod and linear motion bearings with mounted cylinders. All units shall be pre-piped with flow controls and solenoids in place.

6.1.7 Pneumatic over/under drop gate diverter; swing gate moving details shall operate on a through shaft and linkage with oilite bearing pivots. Cylinders shall have a clevis type mounting. Tooling shall be of heavy construction, rigid and wear-resistant. Gates shall be constructed to handle at least double the expected requirements for wear and smooth operation.

6.1.8 Side gripper type elevators; elevators shall hold parts in a center line vertical position while gripping the outside diameter. Parts are fed to and from the elevator via roller bearing track. The track width shall have an adjustable feature. Heavy duty welded frame construction with necessary safety guards.




6.1.9 Alpine storage unit; unit shall be capable of transporting and accumulating parts by using an inclining or declining chain pitch. Two ½ h.p. “minimum” drives shall be used. Hold down rails and side guides shall be used throughout the unit to prevent shingling of the accumulated parts. No ladders, platforms or hoops shall be used.

6.1.10 Pneumatic rocker arm meter part stops shall be off cam follower construction. Bearings shall have pivot points fitted with oilite bearings.

6.1.11 Pneumatic part lift; pneumatically operated lift unit utilized in its design a machine quality guide bar system with case hardened rods and linear motion bearings. The unit shall also be supplied with lift carriages, position switches and a proximity type part present switch.

6.1.12 Elevators cam lift; cam type pocket lift elevators shall be of welded construction. This design utilizes fixturized chain, roller bearing buckets, autogard clutch with kick-out switch, Wilkerson RFL unit, metered intake, guards on all pinch points, safety hoop, ladder, platform and a combination starter/disconnect. All units shall be pre-piped and pre-wired.

6.1.13 Waterfalls; waterfalls shall be constructed of sure alloy steel unless the weight or size of the part force a deviation from this standard. Waterfalls which deviate from this standard shall be constructed from blue tempered spring steel.

6.1.14 Twist chutes; twist chutes shall be constructed of 3/8 inch minimum work hardening steel rods. Adjustable mounting brackets shall be provided on both ends for connecting track.

6.1.15 Blenders and dividers; guides shall be of heavy duty construction. Gates shall be constructed to handle at least double the expected requirements for wear and smooth operation. Swing gate shall be mounted with a ball bearing pivot. Movable details shall operate on precision cam rollers. 12 inches of track section shall be mounted at input and discharge. All units shall be pre-piped, with flow controls and with solenoids mounted in place. All meters shall be pre-assembled to units where practical.

6.1.16 Silent chain conveyors; silent chain conveyor to feature the following:

1. Welded frame construction/aluminum.

2. C-flange motor/reducer on adjustable base.

3. Constant torque clutch.

4. Metal guards on all pinch points.

5. Adjustable mounting supports.

6. Combination starter box/safety disconnects. (See electrical safety specification for arc flash hazard)

7. ½ inch pitch silent chain or equal.

8. All conveyors above 7’-0” from the floor to have a part retainer.

6.1.17 Steel table top chain conveyor; the frame shall be welded construction/aluminum with adjustable mounting supports and metal guards (#16 gauge minimum) on all pinch points. C-flange motor reducer package via RC-60 drive chain with a constant torque clutch, carbon steel table top chain or equal and a combination starter/disconnect box will be used. All conveyors above 7’-0” from the floor shall have a part retainer.

6.1.18 Wire mesh conveyor; the frame shall be of welded construction/aluminum with adjustable mounting supports. A C-flange motor reducer on adjustable base, constant torque clutch and




combination starter/disconnect box and wire mesh (1/2” x 1” openings or equal shall be used). Metal guards on all pinch point (#16 gauge minimum) shall be used.

6.1.19 Inclined slider bed type belt conveyor; the frame shall be of welded construction/aluminum with a maximum slope of 25 degrees. Side guides shall be used and retainer rails for heights over 60 inches. Heavy duty rough top, oil proof, cut and tear resistant conveyor belts and drives consisting of a motor reducer via chain to sprocket on a driven shaft through a slip clutch shall be used. Guards on the pulleys shall be utilized (#16 gauge minimum).

6.1.20 Elevator bucket type; standard elevators shall be welded construction with rigid supports on both sides of the cross section. All bolts shall be 3/8” diameter minimum. Heavy duty welded lift pallets shall be used. The drive motor shall be ½ h.p. minimum Delco “U” frame TEFC or equal and mounted on a sliding base. The shaft diameter shall be 1 7/16” minimum. All bearings shall be lubricated for life, self aligning with eccentric locking collars. The elevating chain shall be RC-2080 and a constant torque clutch with kick-out switch shall be used. Guards shall be made up of individual panels, a single panel being no more than 48 inches. Tower guards shall be full length (#16 gauge minimum) and piano hinged on one side. Elevators over 7 feet in height shall have an aluminum maintenance ladder and safety hoop. Lift chain and drive chain shall be fully guarded.

All units shall have an electrical disconnect box/combination starter with a push button switch (on/off jog reverse) mounted on the bottom of the disconnect box/combination starter. (See electrical safety specification for arc flash hazard)Pneumatic meters shall be used at the input.All units shall be pre-piped and pre-wired with wiring terminating at an electrical disconnect box/combination starter and pneumatic piping terminating at a regulator-filter-lubricator mounted no more than five feet above the floor.

6.1.21 Elevator flow thru type; standard elevators shall be welded construction with rigid supports on both sides of the cross section. All bolts shall be 3/8” diameter minimum. Heavy duty welded lift pallets shall be used. The drive motor shall be ½ h.p. minimum Delco “U” frame TEFC or equal and mounted on a sliding base. The shaft diameter shall be 1 7/16” minimum. All bearings shall be lubricated for life, self aligning with eccentric locking collars. The elevating chain shall be flat top with welded attachments. A detented clutch with kick-out switch shall be used. Guards shall be made up of individual panels, a single panel being no more than 48 inches. Tower guards shall be full length (#16 gauge minimum) and piano hinged on one side with interlock. Elevators over 7 feet in height shall have an aluminum maintenance ladder and safety hoop. Lift chain and drive chain shall be fully guarded.


6.1.22 Elevator blade type; standard elevators shall be welded construction with rigid supports on both sides of the cross section. All bolts shall be 3/8” diameter minimum. Heavy duty welded lift pallets shall be used.




The drive motor shall be ½ h.p. minimum Delco “U” frame TEFC or equal and mounted on a sliding base. The shaft diameter shall be 1 7/16” minimum. All bearings shall be lubricated for life, self aligning with eccentric locking collars. The elevating chain shall be RC-2060 with B-1-1 attachments. A detented clutch with kick-out switch shall be used. Guards shall be made up of individual panels, a single panel being no more than 48 inches. Tower guards shall be full length (#16 gauge minimum) and piano hinged on one side with interlock. Elevators over 7 feet in height shall have an aluminum maintenance ladder and safety hoop. Lift chain and drive chain shall be fully guarded.


6.1.23 Tip-up/tip-down units; units shall utilize a meter at the intake to insure one part at a time in the unit. Unit shall also utilize a pneumatic pusher at the intake and a pusher at the discharge. Guards shall be hinged with an interlock switch.All units shall be premounted to conveyors wherever possible.

6.1.24 Zig-zag storage units; storage units shall utilize steel frame construction with blue tempered spring steel ride rail style storage chutes. Elevation changes at the end of chutes shall be made by utilizing urethane details to change direction of flow. Units shall have an exit meter pre-mounted at the discharge.

6.1.25 Profile gage; a standard profile gage which consists of a steel cut-out which checks for OD and height only. Parts which are incorrect shall not pass through the gage.

7 .0 AS/RS SYSTEM

7.1 This specification shall outline general requirements for automatic storage and retrieval systems and shall be used in conjunction with the material handling specifications above. A design concept and detailed equipment/component detail list must be furnished with quotation. In brief, the function of the multi-robot system is to unload machined parts from the machining line, feed and store them in a robotic ASRS system for retrieval and presentation to downstream assembly / automation.

The system shall also be configured to allow the purging of parts which commands the ASRS robot to unload parts and feed an indexing conveyor for manual offloading of the selected parts to be purged.A storage / retrieval system shall have at minimum the following features:1. Ability to by-pass the buffer system at floor level, shall a problem occur.2. Ability to quarantine potentially bad parts.

3. Operate as close as possible to FIFO.4. ID and track part type and locations throughout the buffer.5. Ability to remove parts from the buffer to a manual by-pass, unload station.6. Tie into the FIS for part tracking inventory / build scheduling.7. Tie into the Operator Station loading the front end of the machining / assembly line.




8. One common design and process shall be used for all parts, per program.9. Suppliers must have ASRS systems as a core function.

10. Minimum outsourcing shall be allowed.11. Systems must be “User friendly”.12. System to have the ability to handle a batch of one (incoming or outgoing).13. Part to be stored individually in rack (not in multi-part trays).14. System to utilize 3D Vision to locate parts/nests in storage rack.15. Part can be reintroduced, one at a time, back into the system via the purge conveyor.16. System to have the ability to by-pass damaged fixtures/part nests in storage rack.17. Ability to purge individual parts from storage rack.18. System to have the flexibility to add additional storage capacity as volume is required.19. System to use proven technology with the utilization of Robots and Gantries.20. System to use Robot Gantry for accessing and tending the storage racks.21. Gantry Robot shall be used for feeding and removing parts to and from the ASRS system.22. Supplier to furnish the following with quotation:

a. System process descriptionb. Robot/Gantry Payload etc.c. Controller d. Storage and Retrieval Automatione. Robot Hardware and Software including all Product Documentation

8.0 Warranty8.1 Warranty for all material handling systems shall be one year from final plant safety

acceptance. Refer to SMI-105 for complete requirements.

END OF SECTION


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