From the late 1990s, our regional resource base struggled to meet programming demands. Specifically, there was a lack of skilled PLC programmers that understood industry standards. We recognized this shortcoming was a critical need for the coming automation revolution and started to plan and problem solve. Initially, we brought designers in to work on third party projects and over time increased our own capabilities with those services. Eventually, through recruiting and development, we began to offer turn-key design, wiring, testing, and integration services.
Today, CSI is the leader in this domain. We have built a network of highly skilled resources worldwide to support your needs, offering a full range of mechanical and electrical services. We have in-house mechanical/electrical design, assembly, wiring, robot teaching (offline and re-teach), and integration. We are positioned to craft a solution turn-key or to facilitate the design/build/integration of imported or domestic third party equipment. Our team works with current and new technologies to incorporate solutions in material handling, conveyance, welding, and special work processing. Taking requests from customers and delivering solutions that exceed expectations related to safety, quality, and ease to maintain is our primary goal.
Our PLC design group are experts in Toyopuc style controls. Our professionals have worked with Toyota standards for over 20 years mastering multiple generations of technology. We keep up to date with new technology and as standards are revised, we lead projects to bring existing equipment up to speed. As Omron style controls grow more common, our team has become the relied upon resource to introduce the PLC to Toyota standards.
Beyond Toyopuc, and Omron, our professionals can also bring your project to life Allen Bradley, Mitsubishi PLC systems as well.
Capabilities
- Design Build
- Vision Systems
- Control Panel Design and Build
- Automation and Controls
- Project Management
- Process Control and Engineering
- Electrical and Instrumentation
- System Training
- Panel Fabrication
- PLC Design, including Toyopuc, Omron, Allen Bradley and Mitsubishi PLC systems.
Case Studies
Front & Rear Door Conveyors
How Do We Optimize Small Spaces and Intelligently Use Existing Operators?
THE SITUATION
Space constraints meant that our client’s Front Door/Rear Door lines impeded part delivery from shell body lines to the final door installation conveyor. The closest spot the parts could be picked up was at the rear of the cell, and another operator would be necessary for delivery.
THE REQUEST
We needed to find a solution for part delivery without adding additional operators. The part delivery needed also to operate with an AGV system.
THE PROCESS
In the limited space provided for part delivery, and trying to avoid adding operators, the area was measured and an AGV system was investigated. During the investigation we determined that the drop off location for the door installation to final line was too far from the operator. This could potentially harm the installation cycle time. We recommended finding a solution for both issues, in addition to the original AGV pickup and delivery request.
THE RESULT
CSI concluded that a powered conveyor would be the best option for part delivery. This allowed the current operator to switch to loading at the front of the shell body line. With the added complication of loading to an AGV, CSI added switches and locks, along with circuit programming for auto loading to the AGV. For the final door installation, we prepared an additional conveyor to bring the part within reach of current operators.
Panel Upgrades
How Do We Bring Legacy Main Body Production Line Control Panels to the Highest Safety Standards?
THE SITUATION
Our client has production lines with legacy PLC/safety PLCs that are no longer in production or supported by the manufacturer. The stock was depleting, programming support was dwindling, and safety standards had evolved. ·
THE REQUEST
CSI was tasked with figuring out the best way to upgrade the PLCs system-wide without negative · impacts to current production.
THE PROCESS
We evaluated the line and researched the best method to upgrade the panels. We recommended replacing the panel as the most beneficial and cost-effective approach. This upgrade would yield a line controlled by the latest PLC/safety PLC and HMI technology. We reviewed the impact of a separate project to install new robots on the current line and identified previously unseen risks: the old PLC and new robots created some communication gaps as well as safety gaps.
THE RESULT
Our newly designed station controllers were installed, and we completed the upgrade of controls with the latest client standards. We improved operation with new HMI screens, and function block programs resolved issues with overall line control. In addition to upgrading the PLC, we were able to elevate the line to current safety standards by including new safety PLCs.
Robot Deployment
Realtime Robotics Needed to Showcase its Dynamic Controls Program, So They Came to Us.
THE SITUATION
Boston’s Realtime Robotics had a cutting-edge autonomous welding solution for a major Japanese automotive manufacturer, but they needed help integrating this technology to its clients’ real-world robots.
THE REQUEST
CSI has an accomplished history with this Japanese automotive manufacturer, so Realtime was sent to us. In less than a month before a demo, how could we marry and deploy Realtime’s technology into a production suitable environment?
THE PROCESS
Our team of global robotic/automation experts worked with Realtime to isolate the unique functionality their technology offered. Then, we created a test environment mirroring current production practices while highlighting Realtime’s technology.
THE RESULT
Realtime Robotics held a successful demo and advanced the development of the next generation of welding. We allowed them to highlight their technology against real-world client use-cases so engineers could focus on actual improvements, not just theoretical.
Body Shell Line Modification
Sometimes the Best Laid Plans Still Need to Change.
THE SITUATION
The client’s production line served multiple model types, but wasn’t able to keep up with the desired cycle time. Its current process required a jig to be swapped out for different models. The clients original plan called for a long lead time, with plenty of time to plan and execute during a scheduled plant shutdown. However, external factors prevented that shutdown period from being available, so the client looked to CSI to develop alternative plans.
THE REQUEST
Our client, a leading Japanese automotive manufacturer, asked CSI to upgrade a Body Shell line by adding a small, swappable jig. The new jig would reduce jig-swap time from approximately 13 seconds to 6 seconds. This allowed the line to support multiple model types more efficiently.
THE PROCESS
CSI had prepared the designs and schedules required for this upgrade over a prolonged period of non-production activity at the plant. The project was complicated, so it was best for the lines to be down during this plant shutdown, instead of interwoven during normal production hours. CSI’s original approach was to remove the current stations/line and add in the new stations/line. So, when CSI was asked to shift gears, CSI designed a temporary modification to the current line to accept new model car parts that were not originally compatible with the legacy line. CSI continued to design and test the new equipment offline until they were ready to be integrated with the existing complete manufacturing line elsewhere in the factory.
Missing Robots
During the original designs, CSI expected the availability of a specific robot, however our client ended up using this robot for a different process in the current line, leaving CSI without a key piece of equipment. CSI reconfigured its design based on the newly provided replacement robot, on the fly.
THE RESULT
CSI’s iteration and testing process revealed key opportunities to improve the final product, including:
By adjusting the angle of a part loading mount, part momentum was reduced to acceptable levels without taking drastic actions to modify part metal types.
By adding shock absorbers to a jig and increasing speed, CSI addressed cycle time overages while protecting part and equipment integrity and safety.
To protect safety amid space constraints, CSI experimented with light curtain placement, robot angle, and speed, to ensure cycle time was met safely.
Ultimately CSI was able to make these complicated adjustments in real time, and was able to deliver the client the equipment and processes the client needed.