Assembly line drives in the automotive industry

This case study describes the online condition monitoring of production-critical assembly line drives in the plant of a major UK car manufacturer.

The assembly line conveyor system transports the cars on platforms through the various stages of assembly. The drives operate in very short time cycles, where they start, then clang to a stop every 6-8 seconds. The very short data acquisition window and mechanical disturbances required some optimization to find the best measurement setup for these drives. The system uses post triggers, a relatively high Fmax, and short measuring times to manage these complicating factors.

The assembly line drives are monitored with the Intellinova Compact online system, measuring vibration and shock pulse levels using HD technology. A proximity switch ensures accurate speed, which is essential for SPM HD measurements.

The motors run at 2300 RPM and the output of the helical bevel gearboxes runs between 6 and 18 RPM.

An unplanned stop caused by an equipment failure on the assembly line drive units would cause a loss of production of 35-45 cars per hour.

System.Web.HttpException (0x80004005): Error executing child request for handler 'System.Web.Mvc.HttpHandlerUtil+ServerExecuteHttpHandlerAsyncWrapper'. ---> System.Exception: An error occured when fetching files; Cannot deserialize the current JSON object (e.g. {"name":"value"}) into type 'System.Collections.Generic.List`1[SPM.WebClient.Models.DTO.ExtranetApi.FileGroupCategory]' because the type requires a JSON array (e.g. [1,2,3]) to deserialize correctly.
To fix this error either change the JSON to a JSON array (e.g. [1,2,3]) or change the deserialized type so that it is a normal .NET type (e.g. not a primitive type like integer, not a collection type like an array or List<T>) that can be deserialized from a JSON object. JsonObjectAttribute can also be added to the type to force it to deserialize from a JSON object.
Path 'Message', line 1, position 11.. ---> Newtonsoft.Json.JsonSerializationException: Cannot deserialize the current JSON object (e.g. {"name":"value"}) into type 'System.Collections.Generic.List`1[SPM.WebClient.Models.DTO.ExtranetApi.FileGroupCategory]' because the type requires a JSON array (e.g. [1,2,3]) to deserialize correctly.
To fix this error either change the JSON to a JSON array (e.g. [1,2,3]) or change the deserialized type so that it is a normal .NET type (e.g. not a primitive type like integer, not a collection type like an array or List<T>) that can be deserialized from a JSON object. JsonObjectAttribute can also be added to the type to force it to deserialize from a JSON object.
Path 'Message', line 1, position 11.
   at Newtonsoft.Json.Serialization.JsonSerializerInternalReader.CreateObject(JsonReader reader, Type objectType, JsonContract contract, JsonProperty member, JsonContainerContract containerContract, JsonProperty containerMember, Object existingValue) in /_/Src/Newtonsoft.Json/Serialization/JsonSerializerInternalReader.cs:line 501
   at Newtonsoft.Json.Serialization.JsonSerializerInternalReader.Deserialize(JsonReader reader, Type objectType, Boolean checkAdditionalContent) in /_/Src/Newtonsoft.Json/Serialization/JsonSerializerInternalReader.cs:line 196
   at Newtonsoft.Json.JsonSerializer.DeserializeInternal(JsonReader reader, Type objectType) in /_/Src/Newtonsoft.Json/JsonSerializer.cs:line 907
   at Newtonsoft.Json.JsonConvert.DeserializeObject(String value, Type type, JsonSerializerSettings settings) in /_/Src/Newtonsoft.Json/JsonConvert.cs:line 828
   at Newtonsoft.Json.JsonConvert.DeserializeObject[T](String value, JsonSerializerSettings settings) in /_/Src/Newtonsoft.Json/JsonConvert.cs:line 786
   at RestSharp.RestClient.Deserialize[T](IRestRequest request, IRestResponse raw)
   --- End of inner exception stack trace ---
   at SPM.WebClient.Business.Helpers.ExtranetApiHelper.GetFiles(FilesApiRequest data) in F:\VsOnline\SPM Instrument\v8\App\SPM.WebClient\Business\Helpers\ExtranetApiHelper.cs:line 28
   at SPM.WebClient.Controllers.PartialControllers.DownloadsController.Files(FilesApiRequest data) in F:\VsOnline\SPM Instrument\v8\App\SPM.WebClient\Controllers\PartialControllers\DownloadsController.cs:line 13
   at lambda_method(Closure , ControllerBase , Object[] )
   at System.Web.Mvc.ControllerActionInvoker.InvokeActionMethod(ControllerContext controllerContext, ActionDescriptor actionDescriptor, IDictionary`2 parameters)
   at System.Web.Mvc.Async.AsyncControllerActionInvoker.<>c.<BeginInvokeSynchronousActionMethod>b__9_0(IAsyncResult asyncResult, ActionInvocation innerInvokeState)
   at System.Web.Mvc.Async.AsyncResultWrapper.WrappedAsyncResult`2.CallEndDelegate(IAsyncResult asyncResult)
   at System.Web.Mvc.Async.AsyncControllerActionInvoker.EndInvokeActionMethod(IAsyncResult asyncResult)
   at System.Web.Mvc.Async.AsyncControllerActionInvoker.AsyncInvocationWithFilters.<>c__DisplayClass11_0.<InvokeActionMethodFilterAsynchronouslyRecursive>b__0()
   at System.Web.Mvc.Async.AsyncControllerActionInvoker.AsyncInvocationWithFilters.<>c__DisplayClass11_2.<InvokeActionMethodFilterAsynchronouslyRecursive>b__2()
   at System.Web.Mvc.Async.AsyncControllerActionInvoker.AsyncInvocationWithFilters.<>c__DisplayClass11_2.<InvokeActionMethodFilterAsynchronouslyRecursive>b__2()
   at System.Web.Mvc.Async.AsyncControllerActionInvoker.AsyncInvocationWithFilters.<>c__DisplayClass11_2.<InvokeActionMethodFilterAsynchronouslyRecursive>b__2()
   at System.Web.Mvc.Async.AsyncControllerActionInvoker.AsyncInvocationWithFilters.<>c__DisplayClass11_2.<InvokeActionMethodFilterAsynchronouslyRecursive>b__2()
   at System.Web.Mvc.Async.AsyncControllerActionInvoker.EndInvokeActionMethodWithFilters(IAsyncResult asyncResult)
   at System.Web.Mvc.Async.AsyncControllerActionInvoker.<>c__DisplayClass3_6.<BeginInvokeAction>b__4()
   at System.Web.Mvc.Async.AsyncControllerActionInvoker.<>c__DisplayClass3_1.<BeginInvokeAction>b__1(IAsyncResult asyncResult)
   at System.Web.Mvc.Async.AsyncControllerActionInvoker.EndInvokeAction(IAsyncResult asyncResult)
   at System.Web.Mvc.Controller.<>c.<BeginExecuteCore>b__152_1(IAsyncResult asyncResult, ExecuteCoreState innerState)
   at System.Web.Mvc.Async.AsyncResultWrapper.WrappedAsyncVoid`1.CallEndDelegate(IAsyncResult asyncResult)
   at System.Web.Mvc.Controller.EndExecuteCore(IAsyncResult asyncResult)
   at System.Web.Mvc.Async.AsyncResultWrapper.WrappedAsyncVoid`1.CallEndDelegate(IAsyncResult asyncResult)
   at System.Web.Mvc.Controller.EndExecute(IAsyncResult asyncResult)
   at System.Web.Mvc.MvcHandler.<>c.<BeginProcessRequest>b__20_1(IAsyncResult asyncResult, ProcessRequestState innerState)
   at System.Web.Mvc.Async.AsyncResultWrapper.WrappedAsyncVoid`1.CallEndDelegate(IAsyncResult asyncResult)
   at System.Web.Mvc.MvcHandler.EndProcessRequest(IAsyncResult asyncResult)
   at System.Web.Mvc.HttpHandlerUtil.ServerExecuteHttpHandlerWrapper.<>c__DisplayClass5_0.<Wrap>b__0()
   at System.Web.Mvc.HttpHandlerUtil.ServerExecuteHttpHandlerWrapper.Wrap[TResult](Func`1 func)
   at System.Web.HttpServerUtility.ExecuteInternal(IHttpHandler handler, TextWriter writer, Boolean preserveForm, Boolean setPreviousPage, VirtualPath path, VirtualPath filePath, String physPath, Exception error, String queryStringOverride)
   at System.Web.HttpServerUtility.ExecuteInternal(IHttpHandler handler, TextWriter writer, Boolean preserveForm, Boolean setPreviousPage, VirtualPath path, VirtualPath filePath, String physPath, Exception error, String queryStringOverride)
   at System.Web.HttpServerUtility.Execute(IHttpHandler handler, TextWriter writer, Boolean preserveForm, Boolean setPreviousPage)
   at System.Web.HttpServerUtility.Execute(IHttpHandler handler, TextWriter writer, Boolean preserveForm)
   at System.Web.Mvc.Html.ChildActionExtensions.ActionHelper(HtmlHelper htmlHelper, String actionName, String controllerName, RouteValueDictionary routeValues, TextWriter textWriter)
   at System.Web.Mvc.Html.ChildActionExtensions.Action(HtmlHelper htmlHelper, String actionName, String controllerName, RouteValueDictionary routeValues)
   at ASP._Page_app_plugins_furillo_grid_spmdownloads_editor_cshtml.Execute() in C:\inetpub\spminstrument.co.uk\www\app_plugins\furillo\grid\spmdownloads\editor.cshtml:line 37
   at System.Web.WebPages.WebPageBase.ExecutePageHierarchy()
   at System.Web.Mvc.WebViewPage.ExecutePageHierarchy()
   at System.Web.WebPages.WebPageBase.ExecutePageHierarchy(WebPageContext pageContext, TextWriter writer, WebPageRenderingBase startPage)
   at Umbraco.Web.Mvc.ProfilingView.Render(ViewContext viewContext, TextWriter writer) in D:\a\1\s\src\Umbraco.Web\Mvc\ProfilingView.cs:line 25
   at System.Web.Mvc.Html.PartialExtensions.Partial(HtmlHelper htmlHelper, String partialViewName, Object model, ViewDataDictionary viewData)
   at ASP._Page_Views_Partials_grid_editors_Base_cshtml.Execute() in C:\inetpub\spminstrument.co.uk\www\Views\Partials\grid\editors\Base.cshtml:line 20

Solutions for the automotive industry

SPM offers efficient condition monitoring solutions for the automotive industry, enabling high-level availability in the production lines.

Intellinova Family

The Intellinova online systems combine HD measurement technologies with high-performance digital hardware to ensure the earliest possible warning of deteriorating mechanical condition.

HD Technologies

Condition monitoring with High Definition (HD) technologies provides extremely long pre-warning times, thus maximizing the planning horizon for maintenance and repairs.