SHOP4CF stands for Smart Human Oriented Platform for Connected Factories and is...
Product-specific static equilibrium point correction and Technical Support through AR/VR, Big Data and Digital Twins technologies.
Having operations in the durable consumer goods industry with production, marketing and after sales services, Arçelik A.Ş. offers products and services around the world with its 30,000 employees, 23 different production facilities in 9 countries (Turkey, Romania, Russia, China, South Africa, India, Pakistan, Bangladesh) and its 13 brands (Arçelik, Beko, Grundig, Blomberg, Elektrabregenz, Arctic, Leisure, Flavel, Defy, Altus, Dawlance ve Voltas-Beko, Singer) serving products and services in more than 146 countries. The annual production volume of Arçelik is approximately 20 million units. The annual production volume of washing machines produced in Arçelik is around 3-4 million units.
Washing machines consist of two main parts: a rotating and oscillating dynamic part and a static part (cabin). The dynamic part is brought to a static equilibrium with counterweights. The centre of gravity of the dynamic part has a big impact on the dynamic behaviour of the washing machine.
Therefore, product-specific static equilibrium point for washing machine product range is so crucial. Currently, there is no automated tool or control point to check and verify the top and front counterweights which are put on the washing machine at the production station and so static equilibrium of the product during production in the manufacturing lines. The range for mass of counterweights are from 9kg to 12 kg. By the current process in manufacturing lines, the static equilibrium state of products is achieved through manually weighting and defining the centre of gravities of the components. On the other hand, the mass and the centre of mass counterweights shows a dispersion due to variations in the concrete counterweights. Dealing with the mass measurement and balancing of them manually is inefficient, not ergonomic and time-consuming process, while the current manual procedure is labour-intensive.
The weights and centre of gravities will be traced, and data collected in assembly lines will be analysed to define the best counterweight combinations for specific products. The robots will then be able to directly place and screw the verified top and front counterweights on the product, without the need for experimenting with different counterweights or special knowledge to calculate them.
Selecting the most fitting counterweight to assemble on washing machines
A central team of engineering experts could remotely support the local factories through augmented reality (AR) and virtual reality (VR) tools. To this end, the digital twin of the production line and washing machine components will be created. The SHOP4CF augmented reality interface environment using interactive computer monitors and AR/VR glasses will be used. The experts will be able to remotely advise and inspect the local problems. Local engineers would be able to be guided by experts located at the main headquarters which will enable the efficient use of expert human resources to solve technical problems, reduce the efforts (site visiting, equipment transport and travel needs) and reduce the error-rate caused by humans.
Remote support by Istanbul experts to other factories’ maintenance engineers
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