The Need for Traceability

From rolling stock assembly, to MRO, to signalling

First and foremost, as an industry responsible for mass transportation and the management of critical infrastructure, the rail sector’s absolute priority is safety. This permeates across all areas, from rolling stock assembly, MRO (maintenance, repair and overhaul) and signalling. In the transition to a sustainable network, the need for traceability in the manufacturing process and subsequent overhaul operations is also critical.

The Need for Traceability

Securing errors by giving the operator clear feedback on where it happened, so they can correct it

Utilising tool interlock and line control to prevent tools being used on the wrong product

The implementation of

Human-Machine Interfaces (HMIs), which connect an operator to the process they are undertaking.

To achieve zero-fault assembly and maintenance requires the design of processes that prevent errors occurring, or securing an error once detected and correcting it at the source. Error-proofing applies to all manufacturing processes and steps include:

Reducing human error by introducing process control and automation

Historically, the rail industry has been reliant on manual tooling for assembly, requiring further reliance on the operator to record torque values and other quality related information. However, this approach increases the risks related to inconsistency, omissions and errors, so there's been no real control or traceability of the process.

Monitory Key Performance Indicators (KPI)

Visual data displays

Production tracking

Recording and monitoring machine and assembly tool inputs

These interfaces include screens and tablets, as well as warning systems that immediately signal to the operator that an error has occurred.

HMIs can be used in the assembly process for a range of functions, including:

Smart Integrated Assembly

Atlas Copco’s Smart Integrated Assembly concept controls the assembly process via barcode scanning or sending data or PLC signals to inform the tool controller which system or component is being worked on and the corresponding assembly process to be followed. This provides several benefits: Firstly, it eliminates errors due to incorrect program selection. Secondly, it allows variant-specific programmes to be configured, enabling the same tool to be utilised on multiple rolling stock fit-out options and assembly processes, saving money and space during manufacture. And finally, it enables the tool to report results against a unique product ID for traceability and analysis.

Atlas Copco’s ToolsControl system provides an effective solution by enabling a production environment where the tightening tool controller software exists outside the need for any dedicated hardware. ToolsControl is a centralised server-based controller solution, that assigns a specific assembly tool to a virtual station. This is achieved by using channels to establish connections between the tool and a controller. With features such as self-healing, failover, ToolSwap and SingleIP, ToolsControl provides a single point of connection where controller software is run on a single computer or server platform.

By reducing the number of physical controllers in the assembly line or maintenance shed, it not only saves floor space but also materials and resources used for manufacturing the controllers. In addition, the use of centralised and automated administration of the tool controller software reduces the time to install tightening tool controllers from a matter of minutes to just seconds.

Tool Control Systems and Software for Problem-free Assembly and Maintenance

Electric assembly tools are typically equipped with either a physical controller or an integrated controller. Irrespective of how the controller is linked to the tool, they represent an operational challenge that can cost time, money and resources due to the need for multiple controllers, which is time-consuming and repetitive. Also, when existing controllers stop functioning, tools connected to the faulty controllers will stop working, leading to production downtime.

Alongside traceability and quality, flexibility and uptime are key considerations in manufacturing and maintenance operations. Success is in the detail and few matter as much as the tightening process and the associated tool controller and its software that manage this process.

Operating multiple tool types via a single controller also helps manufacturers and maintenance organisations to ensure the correct tool is used for the right application on the same platform. These include applications that are high and low torque safety-critical, as well as those with access demands. Having just one controller also reduces cost and complexity by only needing a single power supply, ethernet connection and IP address, resulting in reduced power consumption and improved space utilisation.

Atlas Copco’s Power Focus 8 platform enables this flexibility by utilising Virtual Stations to connect multiple tools to the customer Manufacturing Execution System (MES) via a single Power Focus controller. Each Virtual Station communicates individually with the MES, allowing a number of tools to be run from just one physical controller.