Production line for truck automatic transmissions with AMR integration
PIA Fact Check
- Integration Interface and Mechanical Adjustments Between Customer and PIA
- An innovative mounting system was implemented directly on the AMR assembly
- The system features four main types, each with different attachments, allowing for more than 100 possible variants
Truck automatic transmissions with industry 4.0 solutions
PIA Automation has once again showcased its innovative strength and technical excellence by successfully commissioning a cutting-edge assembly plant for automatic truck transmissions. Fully integrated into the customer’s control systems and equipped with PIA's digital service applications, this plant offers the customer an "all-inclusive" solution.
PIA Industrial App Suite (piaOptimum, piaAnalyze) enhances the project
The piaOptimum and piaAnalyze software solutions have greatly improved the project by aiding in the evaluation of cycle times, analysis of machining processes, and the recording of message data. With piaAnalyze, we were able to identify correlations in production, optimize settings, and reduce quality losses.
By centrally recording and analyzing cycle times through piaOptimum, we could quickly pinpoint bottlenecks and delays, such as those encountered during material insertion or screwing processes. The software also revealed performance differences between shifts, allowing for targeted improvements.
The systematic recording of fault reports was particularly beneficial, enabling the identification of inefficient steps and the formulation of specific improvements. After technical adjustments or optimizations, we used piaOptimum to directly assess whether the changes had a positive impact on the process.
Overall, the tool provided a solid, data-driven foundation for decision-making, enhancing our understanding of cause-and-effect relationships and enabling targeted optimizations. This significantly supported and expedited project management.
Autonomous mobile robots from PIA for heavy components
The entire assembly process is carried out by specially designed autonomous robots, which meet the highest safety standards for workers, robots, and machines.
With a degree of automation around 35% and the integration of 14 autonomous mobile robots (PIA-AMRs), the system provides a state-of-the-art production solution.
The PIA-AMRs transport the workpieces to the appropriate stations, where processes such as joining, greasing, and screwing are performed. The workpieces remain securely on the AMRs throughout the process and are then transported to the next production step.
PIA successfully addressed the challenges of narrow pathways and the introduction of the AMR system by incorporating a new fleet manager. Through careful planning and the coordination of production assistants, PIA ensures a smooth and efficient production process.
“The complete assembly process on autonomous robots is a first for us and places the highest demands on positioning accuracy and safety. Successfully integrating 14 AMRs into fleet management highlights the performance and flexibility of our solutions.”
Roland Horny, Group Product Manager E-Drive & Powertrain at PIA Automation
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