🏆 Industry 4.0 Smart Factory | ISO/TS 16949 | IATF 16949 | SIL 2 Safety | MES/SCADA

ARG Smart Automotive

Integrated Manufacturing Automation Platform

Press Shop | Body-in-White | Paint Shop | Trim & Final Assembly | Quality Gate | EOL Test

512
Robots
60
JPH
99.5%
Uptime
96.5%
FTT
4,200
Spots/BIW
<50ms
PLC Scan
100%
Traceability
Zero
LTI
🔄 Production Flow

زنجیره تولید خودرو

🔨
Stamping
Press Shop
→
⚡
Body Shop
Welding
→
🎨
Paint Shop
Coating
→
🔧
Assembly
Trim/Final
→
✅
Quality
Inspection
→
🚗
Delivery
🏭 ARG Automotive - Live Production Layout
LIVE Production 60 JPH Capacity 512 Robots Shift A: 06:00-14:00
PRESS SHOP Blank 800T Draw 2500T Trim 1200T Strokes/min 12 OEE 89% BODY SHOP - BIW Underbody 4 Robots | 850 Spots Framing 4 Robots | 1200 Spots Closures 3 Robots | 650 Spots BIW Spots 4,200 Robots 142 OEE 89% Takt 62s PAINT SHOP PT/ED 200V DC 20μm Primer 35μm Base 15μm Clear 45μm BAKE OVEN 180°C × 25 min DFT 115μm Robots 48 OEE 85% Defects 0.8/u TRIM & FINAL Interior Trim 15 Stations Chassis 12 Stations Final Line 18 Stations Fluid Fill Auto Fill ✓ Stations 45 OEE 91% FTT 96.5% QUALITY In-Line Vision Gap & Flush EOL Functional OK Direct Run 94.2% Audit 4.2 Today Production 856 Target: 900 | Plan: 95.1% JPH 58 Target: 60 Plant OEE 87.2 % FTT 96.5 % Takt Time 62 seconds Robots 512 98.5% Uptime Downtime 12 min today 🛡️ Safety Record 458 Days Zero LTI | Zero Harm PRESS RUN | 12 SPM BODY RUN | 142 Robots PAINT RUN | 180°C Oven TRIM RUN | 45 Stations FINAL RUN | Fluid OK QUALITY OK | EOL Pass SHIFT A | 06:00-14:00 Next: Shift B @ 14:00
58
JPH
96.5%
FTT
87.2%
OEE
62s
Takt
512
Robots
98.5%
Uptime
4,200
Spots/BIW
115μm
Paint DFT
856
Daily
458
Safe Days
⚡ Body Shop - BIW

سالن بدنه‌سازی

142 ربات جوشکاری | 4,200 نقطه جوش | Cycle Time: 62 sec

📋 Weld Schedule Database - Material Stack-up Parameters
Stack-up Thickness (mm) Current (kA) Force (kN) Time (cy) Squeeze Hold Tip Ø
0.8 + 0.8 Steel1.68.53.2122056mm
1.0 + 1.2 Steel2.210.24.0152566mm
1.2 + 1.5 + 0.83.512.85.0183088mm
1.5 + 2.0 HSS3.511.55.52035108mm
Al 1.2 + 1.22.428.04.5815410mm
⚡
Spot Weld Controller
Bosch PSI 6300 / Harms&Wende
● WELDING
// Adaptive Weld Control Algorithm IF Stack_Detect THEN Schedule := LookupWeldSchedule(MaterialCode); Current_SP := Schedule.Current × AdaptiveFactor; Force_SP := Schedule.Force; IF WeldStart AND GunClosed THEN StartWeldSequence(Squeeze, Weld, Hold); // Expulsion Detection IF dI/dt > 2.5 kA/ms THEN TriggerExpulsionAlarm(); WeldQuality := SUSPECT;
SignalTagValueUnit
Weld CurrentWC001.PV10.5kA
Electrode ForceWC001.Force4.2kN
Weld TimeWC001.Time15cycles
Tip WearWC001.TipWear78%life
🔒 Safety Interlocks
Water Flow OK Gun Pressure OK Tip Aligned Shunt Current OK Expulsion Limit
🤖
Robot Cell Controller
KUKA KRC5 / FANUC R-30iB+
● AUTO
// Robot-PLC Handshake Protocol CASE RobotState OF 0: // IDLE - Wait for Start IF PLC_StartCmd THEN JobNumber := PLC_JobSelect; ExecuteJob(JobNumber); 1: // RUNNING IF JobComplete() THEN Robot_Done := TRUE; // Zone Management IF Robot1_InZoneA THEN Robot2_ZoneA_Block := TRUE;
SignalTagValueStatus
Current JobR01.JobNumJ042Run
TCP SpeedR01.Speed1.8m/s
Cycle CountR01.Cycles12,458-
Servo TempR01.Temp52°COK
🔒 Zone Interlocks
Zone A Clear Zone B Clear Fixture Clamped Part Present Safe Speed
⚡
Spot Welding
جوش نقطه‌ای
I² × t = Heat (Joules)
Force = f(thickness, material)
Weld Time: 10-20 cycles
Current
8-15 kA
Force
3-6 kN
Tips
Cu-Cr-Zr
Points/Car
4000-5000
⚙️ Adaptive Control
Constant current | Stepper | Expulsion detect
🔥
Arc Welding MIG/MAG
جوش قوسی
V = f(Arc Length)
WFS = Wire Feed Speed
Seam tracking: Laser/Touch
Current
150-300 A
Voltage
18-28 V
Gas
Ar+CO2
Wire
0.8-1.2mm
🎯 Seam Tracking
Laser sensor | Through-arc sensing
💎
Laser Welding
جوش لیزری
Power Density = P / (π×r²)
Keyhole mode > 10⁶ W/cm²
Speed: 2-10 m/min
Power
4-8 kW
Type
Fiber/Disc
Gap
<0.3mm
Class
4 Safety
🔒 Safety Class 4
Enclosure | Interlock | Fume extract
🧪
Adhesive & Sealer
چسب و آب‌بندی
Flow = f(P, Viscosity, Temp)
Bead Width = f(Flow, Speed)
Structural
Epoxy
Sealer
PVC/PU
Pressure
150-250 bar
Temp
40-60°C
📊 Process Control
Flow meter | Pressure | Bead inspect
🔩
Roller Hemming
لبه‌زنی غلتکی
Pre-hem 45° → Final hem 0°
Robot + Force control
Edge detection
Force
2-5 kN
Speed
200-500 mm/s
Parts
Door/Hood
Control
Force FB
🔗
Clinching / SPR
اتصال مکانیکی
Clinch: Cold forming interlock
SPR: Self-Piercing Rivet
FDS: Flow Drill Screw
Force
30-80 kN
Cycle
1-3 sec
Material
Al + Steel
Monitor
Force-Disp
🧠 PLC Logic

منطق کنترل PLC

📋
Station Sequence
توالی ایستگاه
S0: IDLE (Wait for part)
S1: CLAMP (Fixtures close)
S2: WORK (Robot/Tool cycle)
S3: UNCLAMP (Fixtures open)
S4: TRANSFER (Part out) → S0
Cycle
45-60 sec
Steps
20-50
Interlocks
50-100
Mode
Auto/Manual
⚙️ Step Logic
Entry condition + Actions + Exit + Timeout
🛡️
Safety Interlock
اینترلاک ایمنی
Safety PLC (F-CPU) separate
E-Stop → Safe Torque Off (STO)
Light curtain → Safe Speed (SLS)
Guard door → Safe Stop 1 (SS1)
Category
Cat 3/PLd
Response
<100ms
Voting
1oo2
Standard
ISO 13849
🚨 Safe Motion
STO | SS1 | SS2 | SOS | SLS | SDI
🤖
Robot Cell Control
کنترل سلول رباتیک
PLC ↔ Robot (DeviceNet/PNIO)
Handshake: Request→Grant→Complete
Zone management: Collision avoid
PLC→Robot
Start, Job#, Zone
Robot→PLC
Ready, Done, Fault
Zones
Mutual exclusion
Jobs
50-200 per cell
📊 Zone Interlock
IF Robot1 in Zone A THEN Block Robot2
🔧
Fixture Control
کنترل فیکسچر
Part detect → Clamp sequence
Fast approach → Slow clamp
All confirmed → Work enable
Part Detect
Prox/Photo
Clamp Cmd
SOL valve
Clamp FB
Prox sensors
Pressure
Pressure SW
⚠️ Clamp Logic
All part present AND NOT obstruction
⚠️
Error Handling
مدیریت خطا
Info → Warning → Fault → E-Stop
Auto-retry for recoverable
Diagnostic buffer + timestamp
Class A
Stop+Lock
Class B
Stop+Alert
Class C
Continue+Log
Class D
Log only
🎛️
Mode Management
مدیریت حالت
AUTO: Full automatic cycle
SEMI: Step-by-step confirm
MANUAL: Individual actuator
SETUP: Teaching/Adjustment
Selector
Key switch
Transfer
Safe state
AUTO→MAN
Stop safe
MAN→AUTO
Home req
🤖 Robot Control

کنترل ربات

🎯
Motion Control
کنترل حرکت
PTP: Joint interpolation
LIN: Cartesian linear
CIRC: Circular arc
SPLINE: Smooth continuous
Accuracy
±0.05mm
Repeat
±0.03mm
TCP Speed
2m/s
Accel
20m/s²
⚡
Servo Weld Gun
گان جوش سروو
7th axis: Gun open/close
Force control: Pressure reg
Equalization: Tip wear comp
Force
2-6 kN
Stroke
80-150mm
Speed
500mm/s
Equalize
Auto
⚙️ Gun Functions
Squeeze→Weld→Hold→Open | Tip dress
📐
Coordinate Systems
سیستم مختصات
WORLD: Fixed reference
BASE: Robot base
TOOL: TCP reference
USER: Workpiece/Fixture
Calibration
4-point
User Frames
32-64
Tool Data
16-32
Accuracy
0.1mm
🔄
External Axes
محورهای خارجی
Track: Robot on linear rail
Positioner: Rotate workpiece
Coordinated motion
Track
3-15m
Positioner
1-2 axis
Turntable
H/V rotate
Sync
Interpolated
🔧
Tool Control
کنترل ابزار
TCP: Tool Center Point
Auto coupler: Tool change
Payload: Dynamic model
Weld Gun
50-80 kg
Gripper
10-30 kg
Spray Bell
5-10 kg
Tools
8-16/robot
🛡️
Collision Detection
تشخیص برخورد
Torque monitoring per axis
Threshold: Normal + Margin
Response: Stop→Reverse→Alarm
Method
Torque model
Response
<10ms
Sensitivity
Adjustable
Recovery
Manual
👁️ Vision Systems

سیستم‌های بینایی

📷
2D Vision
بینایی دوبعدی
Pattern matching | Edge detect
Blob analysis | OCR/OCV
Output: X, Y, θ offset
Resolution
2-5 MP
Accuracy
±0.1mm
Cycle
50-200ms
FOV
200-500mm
CognexKeyenceSick
🎯
3D Vision
بینایی سه‌بعدی
Structured light | Stereo
Time-of-flight | Triangulation
Output: X,Y,Z,Rx,Ry,Rz
Z Accuracy
±0.05mm
Points
1M+
Cycle
0.5-2s
Range
0.5-3m
🤖 Bin Picking
Random part pick | 6-DOF pose
🎮
Robot Guidance
هدایت ربات
Eye-in-hand: Camera on robot
Eye-to-hand: Fixed camera
Calibration: Hand-eye matrix
Calibration
9-point
Accuracy
±0.2mm
Update
Real-time
Tracking
Conveyor
🔍
Surface Inspection
بازرسی سطح
Deflectometry | Photometric
Detect: Dent, scratch, orange peel
Defect
>0.3mm
Depth
>10μm
Area
Full body
Cycle
30-60s
📏
Dimensional
اندازه‌گیری ابعادی
Gap & Flush measurement
Hole position | GD&T verify
Gap
±0.1mm
Flush
±0.1mm
Points
100-500
SPC
Auto Cp/Cpk
📱
Barcode / RFID
شناسایی قطعه
1D: Code 39, Code 128
2D: DataMatrix, QR
RFID: UHF Gen2
Read Rate
>99.9%
DPM
Laser mark
Verify
ISO 15415
Track
100%
✅ Quality & Material Handling

کیفیت و انتقال مواد

📏
CMM
ماشین اندازه‌گیری
Accuracy
2-5 μm
Volume
5×3×2 m
Points
500-2000
Cycle
15-30 min
ZeissHexagonMitutoyo
🔍
In-Line Measurement
اندازه‌گیری خط
Coverage
100%
Cycle
45-60 sec
Points
100-300
Accuracy
±0.15mm
📊 Closed Loop
Auto-compensation | Trend | Root cause
💧
Leak Test
تست نشتی
Body
Water 4-6min
He detect
1×10⁻⁶
Air decay
1 Pa/s
Pressure
1.5-2 bar
🛷
Skid Conveyor
کانوایر اسکید
Speed
10-30 m/min
Pitch
6-8 m
Load
2000 kg
Drive
VFD
🤖
AGV / AMR
خودروی هدایت خودکار
Load
500-2000 kg
Speed
1-2 m/s
Nav
SLAM
Battery
Li-ion
🛡️ Safety
Laser scanner | Traffic control
⚡
EOL Test
تست عملکردی
ECUs
30-80
Bus
CAN/LIN/ETH
Cycle
3-5 min
Coverage
100%
🔧 Test Items
Lights|Windows|Locks|HVAC|ADAS
📊 Dashboard

Plant Dashboard

🚗 ARG Automotive - Production Control
LIVE
🚗
58
JPH
✅
96.5
FTT %
⚙️
87.2
OEE %
⏱️
62
Takt (sec)
🤖
98.5
Robot %
📦
856
Daily
📈 Hourly Production
🏭 Shop OEE
📈 ROI

Return on Investment

+25%
تولید
-40%
عیوب
+15%
OEE
-30%
توقفات
<18
ماه ROI
100%
Traceability