OPC-UA Application - Automotive Industry

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⌚Timestamps:
00:00 - Intro
02:05 - Sensors
03:46 - Robots
04:28 - OPC-UA configuration
07:03 - Summary

Automobile manufacturing is a complex assembly of multiple work cell operations that form, weld, attach, paint, test, and inspect each of the tens of thousands of parts that are used to assemble a vehicle. It is imperative to collect and analyze a wealth of data from these many operations.

OPC-UA, built on TCP/IP is perfectly suited to provide these data collection services from each work cell in the plant and to supply these data to central servers and monitoring systems.

Because OPC-UA communicates using TCP structured command statements, it can integrate seamlessly into the plant’s manufacturing networks.

The automotive factory floor is a symphony of precision and coordination. This coordination is made possible through the use of various sensors.

Leading this effort are position sensors, which stand vigilant, ensuring parts are delivered to each work cell precisely when and where they are needed and ensuring that every car part aligns perfectly, down to the millimeter.

These position sensors use inductive or capacitive technology, detecting the exact position of car parts during the assembly process and ensuring precise alignment and fit.

Torque sensors, deployed on robotic arms and tools, help guarantee that the correct force is applied when attaching components, like fasteners and bolts. Too little torque and components might come loose; too much torque, and there is a risk of damage.

Optical sensors are used for many purposes, including inspection of sub-assemblies to verify proper fit and to monitor the quality of paint and coatings application, checking for uniformity and spotting any imperfections.

Each car component, especially critical ones like the engine or transmission, carries an RFID 'identity' embedded on a small tag.

Automotive plants require the movement and placement of oddly shaped and heavy parts, such as side panels, axles, stiffeners, and roof sections. Each must be placed precisely and welded together.

These movements and welds are -performed by robot arms, providing a safe and efficient way to complete these tasks. Controlled by PLCs (Programmable Logic Controllers), these robot arms can execute these tasks precisely.

Their actions need to be synchronized to prevent collisions and ensure efficient assembly as the vehicles move down the assembly line.

OPC-UA is a central part of collecting, analyzing, and storing multiple streams of data. Records specific to each vehicle, customer order, and the assembly process are captured and securely stored to provide proper order fulfillment, assist marketing efforts, support maintenance reminders, and support any future recall if required.

OPC-UA operates in real time and can adapt to changes in the production line. This is called adaptive production. As an example, if an RFID scanner detects a variant or change, such as the unavailability of a required part, the subsequent assembly steps can be adjusted automatically.

A very important function OPC-UA can assist with is predictive maintenance. Collection of runtime data, diagnostic codes, number of movements or cycles of operation, and time in service are used to determine when failures in production equipment may occur or need routine maintenance.

To protect data streams and to ensure data integrity, OPC-UA has the latest cybersecurity features built directly into the protocol.

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