Solution for Assembly Tool Positioning System

Present Situation And Pain Point

Assembly tools are the core tools for bolt fastening in automobile assembly, which are directly related to vehicle safety and reliability. In automobile assembly process, assembly tools are mainly used for chassis line, interior trim line and power assembly line.
Traditional assembly tool management scheme takes manual operation as the core. Although it plays an important role in early production, it has such pain points as large accuracy fluctuation, low traceability efficiency and weak error-proof ability.
RFID、 The positioning management modes such as bluetooth are not suitable as the preferred solution for intelligent tightening gun positioning due to large metal interference in the assembly workshop and low positioning accuracy.

Requirement Analysis
♦Difficulty in finding tools：It is time-consuming to find by manpower, laborious in tool handling, inefficient, and high rate of missing inspection by manual invento.
♦Through the positioning function, the real-time position of the tool is acquired, the historical track is queried, and the tool is retrieved at the first time to improve the production efficiency.
♦Difficulty in location management：Manual operation can not eliminate the risk of misuse, and the gun body without electronic fence and other functions can be used in a non-designated station, resulting in wrong parts, wrong sequence and wrong torsion.
♦Through the electronic fence function, the gun body is limited to be activated only at the authorized station to avoid cross-zone misoperation. Electronic fence+process interlock, gun body only active within fence.
♦Difficulty in data analysis：Paper records are difficult to support rapid traceability and in-depth analysis.
♦The location and time stamp are uploaded to the MES in real time through positioning to support full life cycle traceability.

Solution
High-precision Positioning Based on UWB
1.UWB positioning base stations are installed in the on-site workshop to provide signal coverage for the positioning area, and positioning tags are mounted on tightening guns to obtain real-time location information, which is uploaded to the server. Users can view the real-time positions of the tightening guns on the GIS map on the main page of the positioning service software.
2.Based on the already installed and deployed hardware of the UWB positioning system on-site, customers can set up electronic fences for each workstation via the positioning service software. Once a tightening gun crosses the boundary, the system will immediately trigger an alarm and link with the tightening gun management system to implement a process lockout, preventing employees from operating the gun if they pick up the wrong one.
3.The system stores real-time positioning data. Users can check the historical movement trajectories of designated areas or specified objects through the positioning service software. It also supports pushing real-time location and timestamp information to the user’s MES system, assisting in the full lifecycle management of tightening guns.
In addition to the positioning management of intelligent tightening guns, within the coverage of on-site base stations, users can manage the positions of personnel and materials through personnel positioning badges, hard hat tags, and material tags. All positioning objects share one set of positioning system and GIS map.

Tool Positioning Tag
High Precision: Achieves centimeter-level positioning accuracy, ensuring accurate identification of tightening points.
Anti-interference & Reliability: Operates stably in complex industrial environments with Wi-Fi and Bluetooth interference, and maintains precision in harsh conditions.
Sturdy & Durable: Features an IP65 protection rating for dustproof and waterproof performance. Adapts to a wide operating temperature range of -20°C to 60°C.
Shock & Vibration Resistance: Withstands vibration and impact on production lines.
Easy Installation: The structural design enables secure and convenient mounting on tightening guns.
Built-in RFID: Compliant with ISO14443A 13.56M IC card standard.
Multi-functionality: Equipped with low-battery alert, LED indication, drop detection, and other functions.