The Problem
Delphi approached PTP with a requirement for a custom test rig. This was needed for a production line to ensure that a particular type of fuel injector was performing precisely to specification. The following critical requirements were identified at the start of the project:
Speed was of the essence
- There was a need to achieve a specific throughput of a part every 20 seconds
- Extremely fast ‘pick and place’ operations were required – 40 operations in 18.5 seconds
- Parallel processing of components was needed in order to achieve the required throughput
A complex situation
- A wide range of hardware from a number of different manufacturers would need to be integrated as part of the system
- PTP would need to liaise with other contractors to integrate different components of the system
- Extensive project management was required as PTP was asked to project manage all aspects of the project
- Complex sequencing would be required allowing each hardware component to perform its individual task whilst higher level sequencing would be needed to bring all the relevant component parts of the rig back together at the required time
Extensive connectivity
- The rig would need to have 120 digital input channels, 72 digital output channels and multiple analogue channels
- It would also need to make use of TCP and Profibus communications protocols
A wide range of software languages would be required
- It was identified that PTP would need to work in a number of languages ranging from proprietary languages to communicate with the intelligent video camera through to Microsoft .Net C#