1. APIC Systems AVI, Tracking Image, & Quality Alert System 2 TNG Training Presenter: Marcus Sternberg
Last updated: 2007 Jan

2. Agenda
1. Overview
2. AVI
3. Tracking Image
4. QAS Workcell

3. APICS Lots of products Automatic Vehicle identification
AVI subsets: Colorwheel, Mix bank
Tracking Image, QAS/ALS
Mistake proofing
APICS Mercury
PFCS

4. Development and Implementation
APICS
Development arm
ASLM
Assembly System Launch Management
Implementation arm of all APICS products
FIS Implementation
As required

5. APICS

6. APICS - Smile

7. APIC web site

8. ASLM / FIS implementation

9. AVI / QAS Main Components
Automatic Vehicle Identification - Barcode reader - Floor PLC - Panelview
Station sequencing & Automatic line stop - QAS WCC - QAS configuration database server (HMI)
Tracking image - Floor PLC - Panelview

10. AVI Used to provide bar code label data to the Floor QAS PLC. Main
Backup

12. AVI Components

13. AVI Reader Function Read job mounted bar code labels
Decode the scanned information
Forward the information to the tracking image application within the PLC

14. Associated Stack Lights
Flow
Bar code is sent to the AVI/VMS driver located in a PLC associated with that particular point
AVI/VMS driver validates the bar code
Label is sent to QAS Tracking Image Application
Barcode Readers and
Associated Stack Lights

15. Empty Carrier Photoeye Function
Determines if there is an empty carrier
If empty, photoeye sends a signal to the AVI/VMS driver that there is no vehicle on the carrier
Empty Carrier Photoeye

16. Video Camera/Monitor Function
The camera is positioned to display the bar code or VIN
In the event of a No Read, the line will stop and the label will display on the monitor, allowing the operator to manually enter the number on the PanelView

17. Video Camera/Monitor

18. AVI Stack light

25. QAS
Provides vehicle sequencing that displays vehicle ID on PFS terminals in sequencing stations
Sequences vehicle IDs for marriage with tool data in PFCS
Provides Automatic Line Stop (ALS) capability to contain problems within a station or production zone

26. QAS Components

27. Floor QAS PLC Function
Contains the QAS Tracking Image Application and the AVI/VMS driver used by QAS
Can be implemented into the conveyor PLC or existing on its own PLC with up to 4 other other tracking images (“Concentrator PLC”)

28. Flow
Receives the bar code label data from the AVI/VMS reader, then the bar code data is sent to the AVI/VMS driver.
The driver sends the bar code label data to the QAS Tracking Image Application.
The Floor QAS PLC sends the tracking image to the QAS WCC for every 1-foot of travel on the conveyor.

29. Floor QAS PLC Panel

30. Encoder Function
A device that uses the mechanical rotation caused by the conveyor movement to produce an electrical signal.
The electrical signal of the encoder is converted to feet, which is used to determine the distance the conveyor has traveled for vehicle position.

31. Flow
The encoder generates an electric signal due to the rotation caused by the wheel or gearing.
This electric signal, when combined with an initial tracking image, monitors the position of a vehicle along a conveyor.

32. Meshing

33. Two variations of encoder mountings
Ceiling Mounted Encoder and Friction Wheel
Skillet Conveyor Encoder

34. Very High Speed Counter Module (VHSC) Function
Performs the high-speed count of the encoder pulses.
The module is an intelligent block transfer I/O module that interfaces with the Floor QAS PLC

35. Flow
Counts from the module’s memory to a designated area in the Floor QAS PLC processor data table using Block Transfer instructions
The VHSC module counts encoder pulses because of the high rate at which the encoder sends its pulses

36. VHSC Module

37. PanelView Function
Provide the user with an array of screens that display tracking image information, such as bar code numbers and location on the conveyor in feet

38. Purpose
Operators can use this information to verify that the proper vehicle is in station and to back up reader input in the case of a fault or No Read condition
Communicate with the Floor QAS PLC for all information requests and use block transfers to send and receive information

39. PanelView and Associated Control Panel

41. QAS Workcell Function
A PC dedicated to running the QAS SoftLogix5 engine.
The SoftLogix5 engine is a software implementation of an Allen Bradley PLC-5
The QAS WCC is responsible for sending job arrival messages to PFCS, where it is married to tool data for the appropriate station

42. QAS Compaq WCC

43. Tool Controller Function
Gather input data from station tools and send this data to PFS through PFCS

44. Flow
Tool data is sent to PFCS, where it is married with the ID of the job received from QAS
This marriage is sent to PFS for logging
Tool Controller

45. QAS WCC Configuration ACC
Known as “Human Machine Interface for QAS workcell”
Contains the configuration database used to update the Realtime database
Specifies the location of stations, tools, and terminals along the line where arrival messages are to be generated
Identifies warning points, timer values, conveyor interlocks and annunciation device locations for ALS and Timed PFS stations

47. ALS Station Hardware
Station Lights- Used to announce ALS events to local operators
Restart Pull Cords- Used to restart the line after an automatic line stop, bypassing the condition that caused the line to stop
PFS terminals also annunciates ALS conditions, bypass vehicle in station, restart line and show product ID

48. Green: The SoftLogix engine is running in the Remote Run mode.
Grey: The SoftLogix engine is running in the program mode.
Black: The SoftLogix engine is stopped and in the program mode.
Yellow: Uploading or Downloading of information.
Flashing Red: Fault Condition