The AutoAlliance facility in Flat Rock, Michiganmanufactures the Ford Mustang and the Mazda6.More than 3,700 employees work at this 2.7 mil-lion square foot operation. AutoAlliance makesextensive use of CC-Link networking in themanufacture of approximately 1,200 vehiclesper day. This application article describes thebody assembly and paint operations. More than400 robots are used to make over 6,000 bodywelds on each vehicle. 61 robots and 10 auto-matic paint machines apply sealants, sounddeadening and 19 paint colors.

The ease of assembly line start-up and excel-lent reliability of CC-Link has translated into ahighly productive manufacturing facility. Thespeed at which these new lines were installedand comissioned resulted in significant savingsin comparison to other networked systems usedpreviously. Control engineers at AutoAlliancehave commented that they have had no CC-Linknetwork failures but that they have experienced anumber of failures with Ethernet networks andwith 2 other commonly used fieldbus networks.

Ford Mustang Assembly. . .

. . . Uses CC-Link

Conveyor SystemA series of conveyors, controlled via CC-Link,move car bodies through the numerous weld-ing, assembly, and painting stations. Eachvehicle travels approximately 13 miles in thecourse of production. Pictured here is a Powerand Free (P&F) conveyor. The motors thatpower the conveyors throughout the facility arecontrolled by Mitsubishi VFD Drives communi-cating via CC-Link. An interesting fact concern-ing P&F conveyors is that, mechanically, theP&F conveyors are essentially the same asthey were on Henry Ford’s early assembly lines.However, the sophistication of the control sys-tem has changed greatly . . .

. . . for example, the load on one particular con-veyor line requires 2 motors each having itsown networked Mitsubishi VFD drive in order todeliver sufficient power to the line. To do this theMitsubishi controller must coordinate the drivesto accomplish proper load-sharing between the2 motors so that each motor provides an equalamount of torque to the conveyor line.

Typical Control PanelShown here is one of the control panels for theMustang sub-assembly within the Body Shopportion of the AutoAlliance facility. It handles thecontrol for the assembly of the driver’s side panelof the Mustang auto body. This panel includes aMitsubishi Q Series Controller with five CC-Linknetwork masters. One of the five networks pro-vides communication between other controlpanels within the body shop. The other CC-Linknetworks handle control of the material handlingequipment, robots and welding operationsdescribed below. There are approximately 125control panels of this type within the MustangBody Shop. The Mazda Body Shop in thisAutoAlliance facility also uses approximately 125control panels of this type to provide similar con-trol functions for Mazda assembly.

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Body Panel Assembly and Welding OperationsCC-Link networking is also used to communi-cate and control the VFD drives that power themotors for moving a JIG bed. A JIG is a largefixture with remote pneumatic I/O that canclamp, fold and hold a section of the auto body.Mounted on the JIG and connected to CC-Linkare Mitsubishi IP67-rated I/O modules that con-trol the various clamps and actuators. DifferentJIG beds are used for different functions of theauto body assembly. There are numerous fixedand movable JIG beds.

A CC-Link network handles communication andcoordination of the Kawasaki robots within thisspecific manufacturing cell. Some of these robotsmove parts within the cell and . . .

. . . other robots perform welding of the bodypanel assemblies. The CC-Link network initiatesand stops robot movement and also enablesthe robots to communicate their positions toeach other in order to avoid collisions.

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There are multiple remote JIG beds in this cell,although only one remote JIG bed communi-cates with the controller at a time. When thetime comes for the remote JIG bed to operateand communicate with the controller, the bed isautomatically plugged into the network via alarge connector. At this point the remote I/O onthe JIG bed receives power and is connected toCC-Link to receive commands from the QSeries Controller. After the JIG bed completesits portion of the assembly operation, it is auto-matically unplugged and removed from the net-work. The tight motor control necessary to plugand unplug each JIG bed from the network iscommunicated to the VFD drives via CC-Link.With each JIG bed going on and off the net-work, this shows the capability of the CC-Linknetwork to handle the removal and replacementof devices while operating under power withoutfaulting the network.

After the side panel is complete, another robotmoves the panel onto a power & free conveyor.

A line of CC-Link connected Kawasaki robotsfinishes welding the body panels together.There are approximately 400 robots in the BodyAssembly portion of the facility. Each robot isconnected to a Mitsubishi controller via the CC-Link network. One CC-Link network typicallycontrols between 10 and 12 robots. In addition,Mitsubishi VFD drives control the pumps thatprovide coolant water to the robot welding guns.

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connector

Typical Operator Interface PanelNumerous Mitsubishi GOT Operator InterfacePanels are used to depict production informa-tion and status on their LCD screens. The VFDdrives and Operator Interface Panels communi-cate to the PLC controllers via CC-Link.Upwards of 95% of the controls within the BodyAssembly portion of the facility are connectedvia CC-Link.

Application of Sound-Deadening MaterialCC-Link controlled ABB robots apply the LASD(Liquid Applied Sound Deadening) material andjoint sealant within the body of the car prior topainting. Five different body types can be runthrough this line (Mustang Coupe or Convertibleand Mazda6 Wagon, Hatchback or Sedan).Each body styles requires a different materialapplication routine.

The LASD replaces the mat insulation that pre-viously was used and which had to be installedmanually. Depending on the type of auto frame,the LASD and joint sealant can be applied to 12different areas of the vehicle. As within the bodyshop, the CC-Link network tells the robots whenand where to apply the material. It also providesa method of communication between the robotsin order to prevent collisions while operating.

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This LASD Body ID Operator Station is con-nected to the Q Controller via CC-Link. TheOperator Station utilizes lasers to scan theincoming vehicle frame to determine the bodystyle, which then is communicated via CC-Linkto the ABB robots to properly apply the LASDand joint sealant. The Operator Station can alsobe used to “teach” the LASD line to recognize anew body style.

Paint LineMitsubishi PLCs control the paint line wherestate-of-the-art Fanuc P500 robots apply thefinish color. These robots can apply 24 differentpaint colors.

After the finish color has been applied, anotherline of robots sprays two coats of clear paintover the vehicle body.

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Pollution AbatementThe AutoAlliance facility also uses the latest inpollution abatement equipment. The strongfumes generated during the body paint processare incinerated to neutralize harmful com-pounds before being vented to the atmosphere.The process is called RCO for RegenerativeCatalytic Oxidizer.

A Mitsubishi PLC controls the RCO process andcommunicates, via CC-Link, to 5 MitsubishiVFD drives.

Each VFD drive controls a 500 HP fan. Theprocess involves exhausting the fumes from thepaint line and passing the fumes through a cat-alytic oxidizer. There are 6 oxidizer beds (2incinerators, 2 regeneration, 2 standby).

This CC-Link network used in the RCO processalso includes a Mitsubishi 800 Series GOTOperator Interface to display current systemstatus and to allow the operator to interact withthe control system.

500 Corporate Woods ParkwayVernon Hills, Illinois • USA 60061

Phone: 847-478-2341 • Fax: 847-876-6611E-mail: info@cclinkamerica.org • www.cclinkamerica.org

© 2006 CC-Link Partner Association – North AmericaCLPA-1602