Product category:
Inspection and testing (non-metrology)
News Release from: Cirrus Technologies | Subject: Cirrus Stratus4 suite test stations for vehicles
Edited by the Manufacturingtalk Editorial
Team on 14 May 2002
Shopfloor test stations networked for
BCS
The latest test installation for the new Range Rover model consists of 32 shopfloor test stations that are networked to support the vehicle Build Control System.
The test installation for the new Range Rover is the latest implementation of the Cirrus Stratus4 suite Steve Hayes, Technical Director of Cirrus Technologies, states: " This project marks a very significant milestone in the deployment of Stratus4 based test systems
This article was originally published on Manufacturingtalk on 4 Aug 2003 at 8.00am (UK)
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The previous Range Rover (38A) was Cirrus Technologies' first fully integrated test solution back in 1992.
Land Rover's confidence in the system has seen its expansion and deployment to all production lines, and it has now turned full circle to the new Range Rover.
" Land Rover operate more than 140 Cirrus test stations at Solihull, and others at Land Rover sites worldwide such as South Africa, Thailand and Malaysia.
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The installation for the new Range Rover consists of 32 shopfloor test stations, made up of 21 on-line stations and a further 11 in the off-track areas.
These stations are networked back to the main Stratus4 server, either wired or, in the case of the portable rectification stations, wireless.
That comprises a high-resilience Compaq NT cluster located in Land Rover's data centre.
Not only does it act as the main system results database, but it also supports all of the applications necessary to serve the shopfloor stations and the vital system configuration, test sequence editing and data reporting processes that enable the system as a whole to deliver quality assurance to the customer.
Stratus4 accepts data feeds from a number of sources including Land Rover's Build Control System (BCS), which fully details the specification of the vehicle, with engine manufacturers providing engine-specific calibration data and third-party facility suppliers giving, for example, component traceability data.
Then Stratus4 outputs data to a number of systems including Land Rover's sales buy-off system (ensuring that no vehicles are passed into the sales pipeline with outstanding issues), long-term data archiving systems and remote monitoring / support.
A number of key tasks are carried out by the on-line stations and can be broken down into the following main areas.
* Data Capture - these stations carry out the essential role of ensuring that the correct critical components are fitted to the vehicle and that unique serial numbers are captured for long-term storage and traceability.
* ECU Programming - these stations program the various electronic control units (ECU's) within the vehicle to match exactly the specification of the vehicle and market territory requirements.
* DC Tooling stations - these stations execute the function of a data capture station, but then secure the component to the vehicle with full traceability of the fastening rundown data, showing that bolts have been inserted and tightened to specification, a safety-critical factor on airbag crash sensors, brake and suspension fastenings, and so forth.
* Sub-Assembly stations - these stations interface to the sub-assemblies generally using discrete I/O and test these assemblies to ensure correct operation prior to fitting to the vehicle.
* Configuration and Test - these stations interface to the vehicle by serial diagnostics through the OBD J1962 connector and set up or test the vehicle at important stages of the manufacturing process.
Tasks typically fulfilled off-line include the following.
* Rectification - enabling the rectification of major faults which could not be cleared up earlier on the assembly track.
* Suspension setting systems - setting of air suspension and roll control systems to ensure that the vehicle handles correctly on the road.
* Rolling roads - testing comprehensively the dynamic features of the vehicle's engine, transmission and braking systems.
* Post-rolling road - emissions testing and setting.
Sales buy-off / transit mode setting: a final check of the Stratus4 database for outstanding faults and a final fault code read of the vehicle to ensure that no new faults have arisen in the off-track area.
Assuming all is OK, the vehicle is set into transit mode, with many ECU functions disabled to avoid battery drain, for despatch via the dealer pipeline.
Stratus4 offers the only complete test and validation solution to fully integrate with the customer's manufacturing process, whilst Cirrus Technologies provides genuine, no-quibble, 24-hours-a-day, 7-days-a-week service and support contracts to customers, ensuring not only the smooth running of the system, but even specialist engineering support for the manufacturing process itself.
The test equipment supplier plays a vital part nowadays in keeping the driver happy with vehicle performance, quality and value, in satisfying the ever increasing demands of legislation and in minimising warranty claims on the OEM.
What is more, the time-to-market is being reduced for the constant stream of innovations which will require checking in situ on vehicles.
You can see for yourself how Cirrus Technologies' latest test system solutions impact upon those areas.
Overall, Cirrus Technologies offers four core automotive engineering competencies - rolling roads (whether for the end of the production line or as dynamometers both for laboratories and for motorsport constructors and tuners); electrical assembly testing; wheel-and-tyre assembly and inflation machines; and special-purpose, automated assembly lines to equip Tier One suppliers.
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