Operation Manual

335 Connie Crescent
Vaughan, ON. L4K 5R2

Tel. 905.669.2302
Fax. 905.669.1848
www.ulamatic.com
ULA-Matic Project No. 15106

Customer: APT
CHRYSLER ETOP BEV & PHEV

WATER PUMP ASSEMBLY SYSTEM
OPERATION MANUAL
ULA-Matic – Project 15106 February-2016 Page 1

Table of Contents
1. PROPRIETARY INFORMATION ................................................................................................................................ 5
2. INTRODUCTION .......................................................................................................................................................... 5
3. Machine Description .................................................................................................................................................... 6
3.1 System .......................................................................................................................................................................... 6
3.2 Stations equipment .......................................................................................................................................................... 8
3.3 HMI Screens ................................................................................................................................................................... 8
3.3.1 General Description ..................................................................................................................................................... 8
4. Safety Features ................................................................................................................................................................ 9
4.1 Lockout Locations....................................................................................................................................................... 9
4.2 Emergency Stop (E-Stop) ......................................................................................................................................... 10
4.3 Safety Light Curtain .................................................................................................................................................. 11
4.4 Power-up Procedure .................................................................................................................................................. 12
4.5 Indicator Lights ......................................................................................................................................................... 12
4.6 Dome Lights.............................................................................................................................................................. 13
4.7 HMI Screen Description ............................................................................................................................................... 14
4.7.1 Main Operation Screen .............................................................................................................................................. 15
4.7.2 Alarm/Fault Screen .................................................................................................................................................... 16
4.7.3 Manual Mode Operation Screen ................................................................................................................................ 17
4.7.4 Setup Screen for when Values need to be changed .................................................................................................... 18
4.7.5 Data Screen ................................................................................................................................................................ 19
4.7.6 I/O Screen (Flex I/O, Armor point, and Valvebank).................................................................................................. 20
5 STATION OPERATION ................................................................................................................................................. 21
5.1 PC Cabinet .................................................................................................................................................................... 21
5.1.1 PC Computer .............................................................................................................................................................. 21
5.2 Station 10 Marking Station ........................................................................................................................................... 22
5.2.1 Start up the machine................................................................................................................................................... 22
5.2.2 Part style selection ..................................................................................................................................................... 22
5.2.3 Start Laser Marking ................................................................................................................................................... 23
5.2.4 Trouble shooting ........................................................................................................................................................ 24
5.2.5 PLC Sequence Steps Station 10 ................................................................................................................................. 24

5.3 STATION 20: Inner G Rotor Shaft Press ..................................................................................................................... 25
5.3.1 Description ................................................................................................................................................................. 25
5.3.2 Part Style Selection .................................................................................................................................................... 25
5.4 STATION 35: MARPOSS INNER ROTOR HEIGHT ................................................................................................ 27
5.4.1 Description ................................................................................................................................................................. 27
5.5 Station 30: Mag Rotor Install ........................................................................................................................................ 29
5.5.1 Description ................................................................................................................................................................. 29
5.6 Station 40: Magnetize Mag Rotor ................................................................................................................................ 32
5.6.1 Description ................................................................................................................................................................. 32
5.6.2 Troubleshooting ......................................................................................................................................................... 32
5.7 Station 50: Wet Sleeve Install ....................................................................................................................................... 33
5.7.1 Description ................................................................................................................................................................. 33
5.8 Station 70: Motor Pump Assembly ............................................................................................................................... 35
5.8.1 Description ................................................................................................................................................................. 35
5.9 Station 80: Motor Pump Assembly Leak Test (Wet and Dry) ...................................................................................... 38
5.9.1 Description ................................................................................................................................................................. 38
5.10 Station 85: Pin Weld (PHEV) .................................................................................................................................... 40
5.10.1 Description ............................................................................................................................................................... 40
5.10.2 Troubleshooting ....................................................................................................................................................... 42
5.10.3 PLC Sequence Steps Station 85 ............................................................................................................................... 44

5.11 Station 90: Final Assembly ......................................................................................................................................... 45
5.11.1 Description ............................................................................................................................................................... 45
5.11.2 Part Style Selection .................................................................................................................................................. 46
5.11.3 PLC Sequence Step Station 90................................................................................................................................. 47
5.12 Station 95: Plasma....................................................................................................................................................... 48
5.12.1 Description ............................................................................................................................................................... 48
5.12.2 PLC Sequence Steps Station 95 ............................................................................................................................... 49
5.13 Station 120: Plotting System ....................................................................................................................................... 50
5.13.1 Description ............................................................................................................................................................... 50
5.13.3 PLC Sequence Steps Station 120 ............................................................................................................................. 51
5.14 Station 130: Connector insert ...................................................................................................................................... 52
5.14.1 Description ............................................................................................................................................................... 52
5.15 Station 135: Connector Leak Test ............................................................................................................................... 54
5.15.1 Description ............................................................................................................................................................... 54
5.16 Station 100: Performance Test .................................................................................................................................... 56
5.16.1 Description ............................................................................................................................................................... 56
5.17 Station 110: CIC Check .............................................................................................................................................. 62
5.17.1 Description ............................................................................................................................................................... 62
5.18 Station 140: Final Leak Test and Capping .................................................................................................................. 64
5.18.1 Description ............................................................................................................................................................... 64

5.19 Station 150 Final Inspection and packaging ............................................................................................................... 66
5.19.1 Description ................................................................................................................................................................. 66
6 Fixture rack ........................................................................................................................................................................ 67
1. PROPRIETARY INFORMATION
The Contents of this document are confidential and proprietary to ULA Matic Inc.
The contents of this manual are not to be copied or distributed without the written consent of ULA Matic Inc.
2. INTRODUCTION
The purpose of this manual is to inform users and operators how to optimally and safely operate the machine.
If the information and instructions in the manual are not followed, all guarantees and supplier warranties are
void.
The number one priority is safety. The safety guidelines must be adhered to, not only during operation, but also
during any other activity, such as trouble shooting or performing routine maintenance.
Hence the safety guidelines described in this manual must always be unconditionally followed.
ULA Matic Inc. assumes no responsibility whatsoever if proprietary and other safety procedures such as
OSHA’s and your company’s own safety rules are not followed.
This machine has been specifically designed with safety as the foremost feature and is a safe piece of equipment
to maintain and operate, provided the instructions in this and the auxiliary manuals are followed.
It is an assumption, and a pre-requisite for the validity of all warranties given by ULA-Matic Inc. that all
personnel operating and/or maintaining the equipment possess the necessary competency, skills and experience
to do so in a safe and correct way.
Please contact ULA Matic Inc if there are any questions regarding the operation, safety procedures or
maintenance of the line. Do not proceed with an operation of the line if you are not fully clear on how to
perform that operation.

3. Machine Description
3.1 System
This eTOP low Volume pump assembly line can build Chrysler PHEV/BEV. It has 16 Stations and most of the stations
are semi-automatic. All stations are standalone and they are communicating with PC for tracking the part using its 2D
barcode.
Figure 1: eTOP Pump Assembly Layout

Operation Description Station
Engrave Pump/Motor Housing 1-010
Inner G Rotor Shaft Press 1-020

The eTOP Line assembly system has 16 stations and a PC unit
that collects the data for each Pump. Only 5 Stations have a U
Magnetized Rotor Assembly 1-030
shape light curtain: Stations.
Marposs Gauge Inner Rotor 1-035
- 20 (Inner G Rotor Shaft Press).
- 30-35 (Magnetized Rotor assembly and Marposs Gauge
Magnetize Rotor 1-040
Inner rotor).
- 40 (Magnetize rotor).
Wet Sleeve Installation 1-050 - 100 (Performance test).
- 140 (Final leak test).
Motor Pump Assembly 1-070
General description of the eTOP line: Parts are marked with a
Motor Pump Assembly Leak Test
2D barcode matrix and the data is created in the PC for each
1-080 individual barcode. Each station will read the barcode and
(Dry/Wet)
request the status of the part from the PC, if the part is good
Pin weld (PHEV) 1-085 (pass) the stations will allow to process the part and the result is
stored in PC for the stations. If the part is failed, the station will
Rotor Gauge Final Assembly 1-090 stop and will need a supervisor to clear the fault to continue.
The process will be repeated through the 16 stations and all

Plasma Treating 1-095 results are stored in the PC.
Plotting System 1-120
Connector Insert 1-130
Connector Leak Test 1-135
Performance Test 1-100
CIC Check 1-110
Final Leak Test 1-140
Packing 1-150

3.2 Stations equipment
In general each station will have the following equipment:
- Control Panel with Allen Bradley Panel View Plus 600

- HMI Panel View Plus 600
- Digi force
- Cleco
- U shape light curtain (Keyence)
- Keyence barcode reader
- IFM vision for detecting part
- E-stop/Control power push button
- Main air supply with lock out
- Stack lights and Dome lights
- Overhead light
3.3 HMI Screens
3.3.1 General Description

There are 8 HMIs on this assembly line,
HMI # 1 STN:10, 20
HMI # 2 STN:30-35
HMI # 3 STN:40
HMI # 4 STN:50, 70, 80
HMI # 5 STN:85, 90, 95
HMI # 6 STN:120, 130-135
HMI # 7 STN:100
HMI # 8 STN:110, 140
Each HMI has a couple of screens that pertain to all stations in the MENU screen (bottom right corner). The
station-specific screens are repeated from station to station and differ only in controls that pertain to the individual station.
The following general station-specific screen list is followed:
- Main Operation Screen

- Alarm/Fault Screen
- Manual Mode Operation Screen(Manual button must be pressed)
- Setup Screen for when Values need to be changed
- Data Screen (not all Stations need data to be displayed)
- I/O Screen (Flex I/O, Armor point, and Valvebank)
4. Safety Features
________________________________________________________________________A
! Failure to observe the following safety procedures can cause injury that may result in death.
Always follow these safety procedures:
1. All maintenance and troubleshooting tasks are to be performed by qualified maintenance personnel.
2. The main disconnect must be turned off before performing any maintenance task on this equipment. Always lock-
out the machine, following plant lock-out procedures that are in place.
3. Do not remove a lock if it does not belong to you. Always find the person who installed the lock before re-starting
the machine.
4. Do not try to access the machine by climbing over any guarding.
5. Keep hands and loose clothing away from moving parts at all times.
6. Do not work alone. Always have a co-worker with you.
7. Follow all posted safety rules.
8. Use common sense.
9. Ask if you are unsure, if you need help or if you need instruction.
4.1 Lockout Locations
Any electrical panel that should be locked-out before any electrical maintenance is performed. A lock should be
attached to the handle and removed only when the work is complete.
The main air supply for the assembly line can also be locked-out, to prevent unauthorized personnel from
operating the machinery. Turn the lever to the right to release the air and insert lock into the hole. Service units located on
the stations may also be locked-out individually for localized maintenance work, if the main air supply is left unlocked.
LOCK-OUT
LOCATIONS
Figure 2: (a) Electrical Panel and Main Air for locking out

4.2 Emergency Stop (E-Stop)
Each station will have one Emergency Stop button mounted at the machine on the right in front of the
operator.
Cycle Start Fault Reset System Start/
Power ON
Power On
Figure 3: Emergency Stop Buttons
When the E-Stop button is pressed, the main air will turn off and all moving cylinders will come to a stop.
The station circuitry removes all power to the valves.
To Reset the E-Stop:
- Pull the E-Stop button till it pops up and press the amber button beside it to re-engage the air and circuitry.

4.3 Safety Light Curtain
Stations 20, 30-35, 40, 100, 140 have a light curtain installed. When the light curtain is blocked the main
control relay will be de-energized and main air will turn off, all moving equipment will come to a stop.
E-Stop PB and
Cycle Start / Reset Light Power on
Light Curtain Curtain Button
Figure 4: U-Shape Light Curtain
When the light curtain is blocked the machine sequence cycle will stop, to reset the light curtain swipe your
hand on the cycle start button. When the light curtain is broken a red message at the top of the HMI will be
displayed and the “Light Curtain” indicator on the HMI will turn yellow. You can also go to the HMI under
MENUalarms you can see the light curtain alarm will show.

4.4 Power-up Procedure
To power up the station the following steps should be followed.
1. Ensure that all locks are removed from the line, disconnected switches and air service units.
2. Turn the main Distribution panel disconnect to ON position first.
3. Turn on all distribution switches, all PLC panel disconnect to ON position.
4. Turn ON the main air service unit, then ensure that all station service units are in the ON position too.
Check that air pressure reaches the required level.
5. Check and ensure that all SAFTEY DOORS are closed.
6. Release all E-Stops on all stations.
7. Press POWER ON at all stations.
8. On the line PC start the eTOP program for data collection.
9. Use the assembly line, following this manual’s instructions.
CAUTION: Do not start the eTOP program until all stations are turned on, if this happens the station
will not record data and will either fault out or fail all proceeding parts.
4.5 Indicator Lights
All stations on the assembly line are equipped with a beacon stack, for indicating machine status. The Beacon
stack has three colors: Red, Amber, and Green. The following table summarizes the various light configurations.
Indicator State Machine Status

Light
Green Solid Auto Mode Active
Green Flashing Step Mode Active
Amber Solid Manual Mode Active
Amber Flashing Operator Request (Warning)
Red Solid Emergency Stop Active
Red Flashing Fault Present
Figure 5: Stack Lights

4.6 Dome Lights
Figure 6: Done Lights (Green, Yellow, Red)
All stations on the assembly line are equipped with a dome light, for indicating machine status. The Dome light
has three colors: red, amber, green. The following table summarizes the various light configurations:
Solid Green: Pass Part/ Load New Part
Flashing Green: Part passed Do not remove part, load next component/ finish the next step.
Solid Amber:
Flashing Amber: The machine is currently running (leak test, oil dispensing, sealant dispensing, robot in operation)
Solid Red: Part failed.
Flashing Red: Step Failed

4.7 HMI Screen Description
Each stations HMI screen allows the operator to control the station; all stations have dual or triple stations and are
controlled from one HMI.
Home
Figure 7: HMI
To navigate the HMI Press the MENU Button to get the following options:
- Main Operation Screen

- Alarm/Fault Screen
- Manual Mode Operation Screen(Manual button must be pressed)
- Setup Screen for when Values need to be changed
- Data Screen (not all Stations need data to be displayed)
- I/O Screen (Flex I/O, Armor point, and Valvebank)

4.7.1 Main Operation Screen
Here on the main operation screen you are able to begin building your parts. By pressing the AUTO button it will
turn bright green and you may being by loading your part and proceed through the shown steps on screen. If AUTO mode
button does not light up then STEP or MANUAL mode buttons are selected. To deselect them just press them again to
turn off their selected light.
Yellow --- Green--- the

machine is in part/operation is
operation (if Light good/present
curtain is yellow it
need to be reset)
Current Step
Red--- the
Stop/Home button (hold for
part/operation
X seconds for reset)
has failed
Change Screens
Auto Mode
Step Mode Manual Mode
Figure 8: Main Screen

4.7.2 Alarm/Fault Screen
Here on the Fault/Alarm screen you can see current and Past Faults/Alarms. You CAN NOT clear the fault that the Blue
background is selecting you will need your Super Visor to come and clear the Faults before you can continue.
If the Back ground color is

Blue then it’s the one the
Arrow keys are currently
selecting
If Text is in RED then the

fault is not cleared If the Text is in Yellow then
the Fault is still active
If the Text is in White then Arrows to scroll up or down

the Fault is cleared
Figure 9: Fault Screen

4.7.3 Manual Mode Operation Screen
Here on the Manual screen you are able to active any locks, presses, and fluids that are part of the PLC’s step order. In
order for this screen to work you must have manual button selected for anything on this page to work. If you go against
the PLC’s step order some buttons will turn red for unsafe to move because something else might be in the way that could
get damaged.
Safe (Green)
Unsafe (Red)
Press buttons to
activate
Manual button is
pressed and
highlighted
Figure 10: Manual Screen

4.7.4 Setup Screen for when Values need to be changed
Here on the Setup screen you will be able to change any values on the HMI. This screen is password protected. To
change the values press the value you want to change and a screen will pop up allowing you to enter the new value, and
once you press enter key the value will be changed.
Values
Figure 11: Setup Screen

4.7.5 Data Screen
The Data screen will show select data to be displayed (not all Station have data to be displayed).
Figure 12: Data Screen

4.7.6 I/O Screen (Flex I/O, Armor point, and Valvebank)
The I/O Screen will allow you to monitor what sensors are active. Press Flex I/O, Armor Point, or Valvebank and the next
screen will show what sensor is active (highlighted yellow) or no not active (Gray)
I/O screen
selection
Figure 13: I/O Screen

5 STATION OPERATION
5.1 PC Cabinet
5.1.1 PC Computer
This line has 3 computers. The top PC will be the main PLC and tester, the middle will be for Digi force and the bottom
on will be for the SQL Database. Both PC must be on and the Data collection program (file Name: eTOP, shortcut located
on top computer on the desktop) is running.
Figure 14: Computer Cabinet
WARNING !!!!! Do not run data collection program before you power up all PLC’s
To Start, turn on computer and monitor (there is only one keyboard and mouse) and start program eTOP on the desktop to
make sure data collection software is running.

5.2 Station 10 Marking Station
This station will mark/engrave the part with a 2D matrix barcode for Chrysler BEV/PHEV water Pump. The
operator will load the part into the fixture, clamp the part down and closed the door to cycle start
Fume
Extraction
Unit
Keyence Laser
Marking Unit
Figure 15: Station 10
5.2.1 Start up the machine

- Turn on Keyence laser Marking unit
- Turn on Fume Extraction unit
- Turn on PLC and PC cabinet
5.2.2 Part style selection

- Place desired fixture into the drawer and style will change automatically.
- To acknowledge any faults press the red fault bar on the top left of the HMI
- To reset back to step 0 press and hold the HOME button for 5 seconds on the HMI
- Make sure Keyence Laser unit did not have any error lights when turning the key to laser ON position
- If any faults/error light exists, close the drawer and press the stations reset.

Off, Power ON, Laser ON
Power,
Laser,
Ready,
Error
Figure 16: Keyence laser
5.2.3 Start Laser Marking

- Select Auto Mode on HMI
- Place in correct fixture
- Place Part in nesting and clamp down
- Close the drawer, the dome green light will become a flashing yellow light indicating station is in use
- When marking is done, the dome light will turn solid green.
- Remove the part and repeat.

5.2.4 Trouble shooting
Laser marking did not start:
- Check to see if the laser marking unit is on (green light on the top laser unit).
- Check to see if the laser marking unit did not have any fault/errors (HMI and marking unit PC with key).
- If the red led is turned on, close the drawer and reset the station from the HMI
- If fault is still active close laser drawer, turn the key to the OFF position, wait 5-10 seconds and then turn key all
the back to Laser ON.
- Check if data collection program eTOP is working.
- Check eTOP program to see what part number in saved on STN 10 and its status.
- If the marking/part fails a supervisor is needed to release the part.
5.2.5 PLC Sequence Steps Station 10

The following steps describe how the PLC program running the sequences. When the PLC is stop at certain step, the
correspondent messages will be display on the HMI screen.
Station 010 operational sequence
Step Description
0 Home
1 Drawer lock to work
2 Create Part Record in Database
3 Laser Marking Start
4 Laser Marking Complete
5 Check Marking
6 Update Part Status in Database
7 Drawer Lock to Home
8 Drawer Open and Part Removed

5.3 STATION 20: Inner G Rotor Shaft Press
5.3.1 Description
This station will press the Shaft into the Inner G rotor. Operator unloads finished part and loads a new shaft into
press cavity and places rotor on top (PHEV dot faces up, BEV no dot), initiate cycle start, the press will press shaft into
rotor. Green dome list is on indicating a good part, Red when part fails, an arm will pick up the part and drop it into fail
bin.
PHEV/BEV
Block
5.3.2 Part Style Selection

Station 20 has only 1 fixture that works with both PHEV and BEV. There are 2 Blocks that are labeled PHEV or
BEV, this blocks is inserted under the press with a long lock pin. To Change to PHEV or BEV you will need to Change
STN 30 fixture because they are linked by G rotor type.

Steps Description
0 Home
1 Spare Step
2 Press Down to Intensify
3 Press Intensify
4 Thru-Hole Presence Check
5 Press to Home Position
6 Press Enable Off and Check Process Results (OK go to End)
7 Horizontal Reject Slide to Work (Advance)
8 Vertical Reject Slide to Work (Down)
9 Reject Gripper Close, Pick Part
10 Vertical Reject Slide to Home (Up)
11 Horizontal Reject Slide to Home (Retract)
12 Vertical Reject Slide to Work (Down)
13 Reject Gripper Open, Drop Part into Reject Bin
14 Vertical Reject Slide to Home (Up)
15 Spare step
16 END

5.4 STATION 35: MARPOSS INNER ROTOR HEIGHT
5.4.1 Description
This Station will take the engraved pump housing from STN 10 and the pressed G Rotor. The G Rotor will be
placed into the pump housing and it will be measured using the Marposs gauge to check if inner rotor height is good.
STN 30 STN 35

- To change Fixtures simply remove 2 lock pins and exchange to new fixture and re-insert pins.

Steps Description
0 HOME
1 Read Barcode and Lookup Part Data
2 Spare Step
3 Operator Removes Marposs From Dock
4 Operator Gauges G-Rotor Height
5 Operator Returns Marposs to Dock
6 Update Part Status and Save to Database
7 Spare Step
8 END

5.5 Station 30: Mag Rotor Install
5.5.1 Description
This station will install a Magnetized rotor from Station 40 and the Gauged G-Rotor and pump from Station 35
together, by pressing the G-Rotor into the Mag Rotor. The Operator will take the Magnetized Rotor from Station 40 and
insert it into the middle on the fixture making sure the four dots are facing up. Then the pump and G-Rotor from Station
35 will be taken and placed on top of the Mag Rotor, and initiate cycle start.
STN 30 STN 35

1. To change Fixtures simply remove 2 lock pins and exchange to new fixture and re-insert pins.
2. When changing Fixtures you need to also change oil.
3. First remove the air using the quick disconnect.
4. Then bleed the remaining air with the orange tab.
5. Once the air has been bleed open the four tabs and removed the lid.
6. Removed the empty oil container and wipe down the tubes so the oils don’t mix.
7. Place a rag or Cup in front of station 30 nozzle.
8. On the station nozzle there is a screw underneath, unscrew it a little and let the oil bleed out on a rag or in a cup.
9. Place the new oil into the bin and place the lid on top and screw the four tabs back on and attach the quick
disconnect.
10. Once the oil has been changed, go to the HMI and press the MANUAL button and go to the Manual screen.
11. Once a rag or cup is placed on the Manual screen press the Oil Priming OFF/ON and allow the oil to purge.
12. The oil will change to the new oil which should either be Clear and colorless or reddish/pink.
13. Press the Oil Priming OFF/ON again to finish.
Bleed air
(Orange tab)
Quick disconnect
4 Tabs
Figure 20: oil bin

Steps Description
0 HOME
1 Read Barcode & Get Data
2 Spare Step
3 Spare Step
4 Check Part Presence

5 Lube Cylinder to Work
6 Enable Lubricant
7 Lube Cylinder to Home
8 Press Fast Down to Approach Position

9 Press Shaft into Mag Rotor
10 Press Complete
11 Update Status & Save Part Data
12 Spare Step
13 Spare Step
14 Press Retract
15 END

5.6 Station 40: Magnetize Mag Rotor
5.6.1 Description
This station will magnetize a mag rotor to be used in station 30. The operator will load the mag rotor into the fixture slot
(with the 4 holes facing up to prevent confusion) and will initiate cycle start with the whisker.
5.6.2 Troubleshooting
- If the part finished and the flux number is low, you will get a fail part but do not throw this part out.
- If the part fails press the fault reset, and spin the part slightly and try again.
- The 4 holes facing up give you 4 chances to re-magnetize for a good flux number.
- If all 4 try’s failed then dispose of the part into the reject chute, and use the next part.

5.7 Station 50: Wet Sleeve Install
5.7.1 Description
This Station will install a protective sleeve over the Mag rotor as well as an inner and outer O-ring. The Operator will take
the finished part from Station 30 and attach one inner and one outer O-ring to the production part. Once the rings are
installed the Operator will slide a wet sleeve up into the press and then place the part into the fixture. The part will be
scanned with a barcode reader and a censor to detect the O-rings. The Operation then pulls the handle down to push the
wet sleeve onto the Mag rotor.

- Change O-Rings depending on PHEV or BEV

Steps Description
0 HOME
2 Press Sleeve into Housing
3 Press Complete
5 Release Press Lock
6 Press to Home Position
7 END

5.8 Station 70: Motor Pump Assembly
5.8.1 Description
This Station will assemble the pump housing that just finished at Station 50 and a Motor housing build elsewhere. The
operator will take the Motor Housing and inset it into the fixture then will place a spring inside the motor housing from
the nearby spring holder. The operator will then compress the spring with the spring hold lever(s) so the mag rotor does
not magnetically attract the spring. The Pump housing is placed onto the Motor housing and its barcode will be read. The
operator will then slide the press forward and compress the spring. Once the spring is compressed the operator will then
spin the fixture and insert 3 screws for the smart arm to screw them in. The operator then spins the fixture back and the
fixture will release the compressed part.

- The E-Stop button needs to be pressed down to cut off the air supply
- Remove the air tube attached to the top left side of the fixture
- Remove the 2 lock pins from both fixtures
- Spin the fixture slowly half way around so the fixture points up
- With both hands carefully remove the fixture
- Exchange fixtures
- With the new fixture slide the back hooks on first and spin back to original position
- Take 2 pins from both fixtures and re-insert them
- Take the air line and re-insert it into the new fixture
- Pull the E-Stop up and the push the POWER ON button to cycle the air.

Steps Description
0 HOME
1 Spare Step
2 Read PHEV Motor Barcode
3 Operator Advances Spring Hold Lever
4 Check Spring Presence
5 Level in Position
6 Read Barcode on Pump Housing
7 Release Slide Lock – Operator Pulls Press Slide to Press Position
8 Engage Slide
9 Operator Presses Arbor Press, Compressing the Spring
10 Engage Rode Locks
11 Operator Raises Press
12 Releases Slide Locks
13 Operator Returns Press Slide to Home
14 Operator Rotates Fixture to Bolting Position
15 Read BEV Motor Barcodes
16 Enabled Fastening of First Bolt
17 Fastening of the First Bolt Complete
18 Enabled Fastening of Second Bolt
19 Fastening of Second Bolt Complete
20 Enable Fastening of Third Bolt
21 Fastening of Third Bolt Complete
23 Operator Rotate Fixture to Home Position
24 Release Rod Locks
25 END

5.9 Station 80: Motor Pump Assembly Leak Test (Wet and Dry)
5.9.1 Description
This Station will perform a Wet and Dry Leak Test. The operator will take the finished part from Station 70 and load it
into Station 80’s Fixture. The operator will then push the fixture in and it will lock in place allowing the press to be pulled
down onto the fixture to begin the tests. If the part is BEV the operator will need to place an O-ring on the outer ring of
the G-rotor for the leak test.
Dry test
Wet test

- Disconnect hose line on fixture and on press (there is a small button on it to disconnect)
- Lift and exchange fixtures
- On the press pull, the small pin up to release press head and exchange to the new head (Labeled PHEV and BEV)
- Re-attach both lines

Steps Description
0 HOME
2 Fixture Lock to Work Position
3 Release Arbor Press Lock
4 Operator Manually Sends Arbor Press Down to Work
5 Engage Arbor Press Lock
6 Seal Cylinder to Work
7 Begin Wet Test
8 Wet Leak test Complete
9 Begin Dry Leak Test
10 Dry Leak Test Complete
11 Seal Cylinder to Home
13 Spar Step
14 Release Arbor Press Lock
15 Arbor Press Up to Home
16 Release Fixture Lock
17 Fixture to Home Position
18 END

5.10 Station 85: Pin Weld (PHEV)
5.10.1 Description
This Station will ONLY weld PHEV top pins. The operator will load the PHEV part into fixture and press the outer start
button to cycle start.
Outer Start
Button
Figure 25: (a) Station 85

OPERATE
MODE
PRG.NO
CURSOR
ARROW KEYS ENTER READY ORIGIN ( ORG )
Figure 26: (a) Station 85 weld controllers

5.10.2 Troubleshooting
- If the middle console is off/sleep mode and the top four buttons are green and cycling through, press the
OPERATE button to remove the console from sleep and allow it to start up.
- If the station gets a Fault, and the welder is closed and holding the pins press the ORIGIN ( ORG ) button to open
the pins and release the part and press the supervisor reset button on the HMI.
- If the station does not cycle check the hand held controller and see if it says “program 3” in the top right corner.
Press MODE and use CURSOR / ARROW KEYS to select EXTERNAL MODE for the PLC program to control
the welder. If SWITCH RUN MODE is on then the operator will need to manually trigger each pin.
- If E’Stop is pressed or the hand held Controller says “no program selected”, press PROGRAM NUMBER
“PRG.NO” and input “3” on the number pad to select program 3 then press ENTER.
- When the electrode tips reach their set threshold on the HMI, the tips will need to be changed by using the “setup
tool” and extra tips from the spare electrodes. Take an Allen key and unscrew one side (left or right), exchange
the tips and using the “setup tool” align the new tip in the correct position and tighten the screws. Repeat for the
other tip.
SETUP
REMOVE
TOOL
ONE TIP
AND LINE
IT UP. ADD
NEW TIP.
SPARE
REPEAT
ELECTRODE
FOR OTHER
TIPS
Figure 27: (a) Station 85 electrode change

WARNING
EXTREMELY HOT
DO NOT TOUCH
Figure 28: (a) Station 85 Warning Hot Surface

Steps Description
0 HOME
2 Operator Setup for Weld #1
3 Operator Perform Weld #1
8 Spare Step
9 Spare Step
10 Spare Step
11 Spare Step
13 Welding Sequence ENABLE
14 END

5.11 Station 90: Final Assembly
5.11.1 Description
This Station will assemble the final parts of the PHEV or BEV. The operator will place the housing into the left
fixture and the mating plate will get an 8 ring inserted and placed into the right fixture. The operator will clamp down the
leak test for the mating plate and initiate the cycle start to begin the leak test. In the left fixture the operator will use the
Marposs gauge to measure the inner rotor with Marposs #1, then the outer ring will be placed around the inner rotor and
Marposs #2 will be used to measure the outer ring. If the Part is a BEV an O-ring will be placed around the outer rotor. If
the part is a PHEV no O-ring is needed. The operator then pulls the oil dispenser forward which will lock in place and
dispense oil (be careful the oil may spray you if you are standing too close).once oil is done dispensing move oil back and
the mating plate leak test should be done. If leak test is good remove the plate and place on top of the housing. Place 2
screws into the top and bottom holes and using the smart arm screws them in.

1. Remove hose from leak test on right side (there is a small button on it to disconnect).
2. Remove 2 lock pins and exchange fixture.
3. Re-insert 2 lock pins and attach hose.
4. When changing Fixtures you need to also change oil.
5. First remove the air using the quick disconnect.
6. Then bleed the remaining air with the orange tab.
7. Once the air has been bleed open the four tabs and removed the lid.
8. Removed the empty oil container and wipe down the tubes so the oils don’t mix.
9. Place a rag or Cup in front of station 90 nozzle.
10. On the station nozzle there is a screw underneath, unscrew it a little and let the oil bleed out on a rag or in a cup.
11. Place the new oil into the bin and place the lid on top and screw the four tabs back on and attach the quick
disconnect.
12. Once the oil has been changed, go to the HMI and press the MANUAL button and go to the Manual screen.
13. Once a rag or cup is placed on the Manual screen press the Oil Priming OFF/ON and allow the oil to purge.
14. The oil will change to the new oil which should either be Green or red.
15. Press the Oil Priming OFF/ON again to finish.
Bleed air
(Orange tab)
Quick disconnect
4 Tabs
Figure 30: Oil Bin

5.11.3 PLC Sequence Step Station 90
Steps Description
0 HOME
1 Spare Step
3 Wait for Marposs Measurement
4 Spare Step
5 Spare Step
6 Operator Advance Oil Dispensing Slide to Work
7 Lock Oil Dispensing Slide
8 Advance Oil Dispensing Cylinder
9 Enable Oil Air Blow Valve
10 Retract Oil Dispensing Cylinder
11 Unlock Oil Dispensing Slide
12 Operator Returns Oil Dispensing Slide to Home Position
13 Spare Step
14 Spare Step
15 Wait for Mating Plate Leak test Complete
16 Operator Releases Mating Plate Toggle Clamp and Loads Mating Plate onto Pump Housing
17 Enable Fastening of Screw #1
18 Screw #1 Fastening Complete
19 Reset Nutrunner
20 Enable Fastening of Screw #2
21 Screw #2 Fastening Complete
22 Spare Step
24 END

5.12 Station 95: Plasma
5.12.1 Description
This station will heat treat the top areas of PHEV and BEV and caps that will be inserted later on. The operator will insert
PHEV or BEV and cap stand with cap inserted into the fixture (one fixture for all parts). Operator will make sure the side
vacuum is turned on. Operator will close the screen and initiate cycle start. If the cap has fallen on the floor or just needs
to be heat treated again just place the cap and cap stand inside go to HMI and go to “setup” and select “Cap Insert” and
initiate cycle start. The “Cap Insert” will only be active for the ONE run, it will need to be reactivated each time a cap
needs to be heat treated again.
STN 95 Vacuum

Steps Description
0 HOME
1 Read barcode and Lookup Part Data
2 Spare Step
3 Select Plasma Treating Program
4 Enable Plasma Generator
5 Begin Plasma treating
6 Waiting for Plasma Treating Complete
7 Spare Step
8 Spare Step
9 Spare Step
10 Spare Step
11 Spare Step
13 Operator Open Robot Door
14 END

5.13 Station 120: Plotting System
5.13.1 Description
This Station applies sealant with UV pigments. The operator is to place the housing onto the scale and zero the weight.
Once weight is zeroed the operator places housing into fixture and pushes the sealant dispenser down to cycle start. When
the cycle finishes the operator will place the housing on the scale again to see if the weight is 0.60g (+ or - .05g).


Steps Description
0 HOME
2 Operator Lower Dispensing Slide
3 Spare Step
4 Engage Slide Lock Shot Pin
5 Vertical Slide to Work
6 Dispense Loctite
7 After Dispense delay
8 Vertical Slide to Home
9 Spare Step
10 Horizontal Slide to Work
11 Vertical Slide to Work
12 Dispense Loctite
13 After Dispense Delay
14 Vertical Slide to Home
15 Spare Step
16 Horizontal Slide to Home
18 Release Slide Lock Shot Pin
19 Operator Return Slide to Raised Position
20 END

5.14 Station 130: Connector insert
5.14.1 Description
This station will press the plasma treated cap into the part housing. The operator will press the cycle button to make sure
air is running. Once air is running the operator takes the cap and mounts it to the suction cap. Operator then places
housing into the fixture and initiates cycle start to press the cap into the housing.
STN 135 STN 130

- On the HMI put STN 130 into manual mode and go to MANUEL screen
- Press to lower the guard and for the vertical change and press to go to “1”
- Once the press is down, raise the guard and disconnect the air line and remove the pin, exchange the press parts
and re-insert the pin and air hose (both BEV and PHEV only fit in one way so the pin can be re-inserted).
- Lower the guard and press “go to home” on the vertical press screen and raise the guard.

Steps Description
0 HOME
2 Close Servo Cover
3 Servo Press to Approach Position
4 Servo Press to Cap Insert Position
5 Disable Vacuum, Servo Dwell Time
6 Servo to Home Position
7 Check Cap Present
9 Raise Servo Cover
10 END

5.15 Station 135: Connector Leak Test
5.15.1 Description
This Station will perform a leak set for the recently inserted cap from Station 130. The operator will place housing into the
fixture and pull the handle to cycle start.
Dry leak
test
STN 135 STN 130


Steps Description
0 HOME
2 Operator Engage Arbor Press
3 Engage Press
4 Waiting for Leak Tester Ready
5 Begin Leak test
6 Leak test Running, Waiting for Complete
7 Spare Step
9 Release Press Lock
10 END

5.16 Station 100: Performance Test
5.16.1 Description
This Station runs a performance test checking various aspects suck as high and low voltages, RPM, etc. The operator
places the housing into the fixture and initiates cycle start.

- Remove the 2 lock pins and remove the fixture.
- Physically push up and spin the circular plate from underneath to the BEV or PHEV.
- Place new fixture and re-insert pins.

Steps Description
0 HOME
2 Spare Step
3 Lower Top Tooling
4 Engage Pogo Cylinder
5 Zero Test System Analog Values
6 Performance Test
7 Retract Pogo Cylinder
9 Raise Top Tooling
10 END

GM BEV eTOP
EOL Test Sequence
Step Description PWM/LIM Voltage Conditions Acceptance
1 Reverse polarity test OFF -16Vdc Motor shut down, reverse polarity Current < 100 μA
applied to power pins
2 Power and ground OFF 16Vdc Motor shut down, correct polarity 0 < V_EMC Init < 1 V
circuit test applied to power pins, continuity test
connected between pin 6 and motor
housing
The motor housing connected to 3 < V_EMC Charged < 8
VBATT via 510kΩ V
3 Quiescent current OFF 14Vdc Motor shut down, VBAT connected, Vbatt Quiescent
test VCONT disconnected Current < 100 μA
4 Idle current test 15% 9Vdc Motor enabled but not running after Diagnostic = cycle 8% -
application of valid PWM in 92% @100Hz
command. Speed = 0 rpm
Current_VCONT ≤ 50 mA
5 Minimum (Low) 25% 9Vdc Motor starts and runs at minimum Diagnostic = cycle 8% -
Speed Test speed 800 rpm 92% @132Hz
700 < rpm < 900
Current < 0.5A
6 Maximum (High) 90% 12Vdc Motor accelerates and runs at Diagnostic = cycle 8% -
Speed Test with no maximum speed (4600 rpm nominal), 92% @284Hz
pump ports open 4370 < rpm < 4830
load
Current < 5A
7 Shutdown motor 5% or 0% and 12Vdc Pump stops, shuts down and remains Diagnostic = cycle 8% -
using PWM 95% or 100% shut down with alternative shutdown 92% @100Hz
command. Speed = 0 rpm
command
Current_VCONT ≤ 50 mA
8 Switch controller LIN read 12Vdc Pump controller reports major and Correct software version is
mode from PWM to command minor software version. reported
LIN mode
9 Maximum speed LIN speed 12Vdc Pump is started and running with the 4370 < rpm < 4830
with pump outlet command (4600 high speed command in LIN mode 1.0 < Current < 7.0
and then the outlet port is blocked Pressure_Outlet (psi) > 2.5
blocked rpm) and pressure is measured.
10 Maximum speed LIN speed 12Vdc Pump is running at the high speed 4370 < rpm < 4830
with pump inlet command (4600 command in LIN mode with the inlet 1.0 < Current < 3.0
port blocked (outlet port open) and Pressure_Inlet (psi) > 2.0
blocked rpm) vacuum is measured. Power is shut
off at the end of this test.
11 Shutdown LIN speed 12Vdc Pumps shut down Speed = 0
command
(0rpm)

GM BEV eTOP
EOL Test Parameters

Chrysler PHEV eTOP
EOL Test Sequence
Step Description LIN COM Voltage Conditions Acceptance
1 Reverse polarity test OFF -16Vdc Motor shut down, reverse Current < 100 μA
polarity applied to power
pins
2 Power and ground OFF 16Vdc Motor shut down, correct 0 < V_EMC Init
circuit test polarity applied to power <1V
pins, continuity test
connected between pin 6
and motor housing
The motor housing 3 < V_EMC
connected to VBATT via Charged < 8 V
510kΩ,
3 Idle current test OFF 13.5Vdcv Motor enabled and waiting Speed = 0 RPM
for LIN command. Current_VCONT
≤ 50 mA
4 Read software version LIN read 13.5Vdc Pump controller reports Correct software
command major and minor software version is
version. reported
5 Minimum (Low) Speed LIN speed command 13.5Vdc Motor starts and runs at 700 < rpm < 900
Test 800 rpm minimum speed 800 rpm 0.2A<Current <
0.55A
6 Maximum (High) Speed LIN speed command 13.5Vdc Motor accelerates and runs 4600< rpm <5250
Test with no load 5000 rpm at maximum speed (4600 1.2A<Current <
rpm nominal), pump ports 2.5A
open
7 Maximum speed with LIN speed command 13.5Vdc Pump is started and 4460< rpm <4940
pump outlet blocked 4700 rpm running with the high 1.5A<Current <
speed command in LIN 3.0A Outlet (psig)
mode and then the outlet > 2.5
port is blocked and
pressure is measured.
8 Maximum speed with LIN speed command 13.5Vdc Pump is running at the high 4460< rpm <4940
pump inlet blocked 4700 rpm speed command in LIN 1.25A<Current <
mode with the inlet port 2.2A
blocked (outlet port open) Inlet (psiv)>3.7
and vacuum is measured.
Power is shut off at the end
of this test.
9 Shutdown LIN speed command Pumps shut down Speed = 0
0 rpm

Chrysler PHEV eOP
EOL Test Parameters

5.17 Station 110: CIC Check
5.17.1 Description
This Station will do a vision check to see if the pins have the correct height and position relative to the outer rim. The
operator will load the part on the screw height check(right side of table), if screw height passes place housing into fixture
and pull slide towards housing and initiate cycle start. If part passes slide is unlocked and part is able to be removed, if red
part is locked until supervisor arrives to unlock.
Monitor to see
results
Keyence
vision system
4 cameras


Steps Description
0 HOME
1 Reset Gauges Result
2 Gauging Screw Height Collection Data
3 Operator Remove Part from Gauging Fixture
4 Operator Load Part to Camera Fixture
5 Read Barcode and Lockup Part data
6 Operator Engage Fixture Slide
7 Engage Slide Lock
8 Wait for Operator to Cycle Vision
9 Perform Vision Check
11 Release Slide Lock
12 Operator Return Slide and Remove Part
13 END

5.18 Station 140: Final Leak Test and Capping
5.18.1 Description
This Station will perform the final leak test and caps will be inserted to prevent dust or damage. The Operator will place
the Housing into the fixture and initiate cycle start. Once the cycle is finished the operator will insert the bottom tab and
top/side tab then cycle start. When the part passes or fails it will go onto its respected conveyor belt, either so be rejected
or to be sent to Station 150 for packaging.


Steps Description
0 HOME
2 P&P Vertical Down to Approach Position
3 P&P Vertical Down to Hold Part
4 Start Leak test
5 Leak test Completing, Waiting for Results
6 P&P Vertical Up to Home Position
7 P&P Horizontal Shift to Pick up Position
8 P&P Vertical Down to Pick Approach Position
9 P&P Vertical Down to Pump Pick Position & Update Part Status and Save to Database
10 P&P Gripper Close
11 P&P Vertical Up to Home Position
30 Move to Cap Check Position and Check Top/Bottom Cap Presence
12 (REJECT) P&P Horizontal Shift to Reject Conveyor Position
13 (REJECT) P&P Vertical Down to Reject Conveyor Position
14 (REJECT) P&P Gripper Open
15 (REJECT) P&P Vertical Up to Home Position
16 (GOOD) P&P Horizontal Shift to Good Part Conveyor Position
17 (GOOD) P&P Vertical Down to OK Parts Conveyor Position
18 (GOOD) P&P Gripper Open
19 (GOOD) P&P Vertical Up to Home Position
20 (GOOD) P&P Horizontal Shift to Home Position
21 END

5.19 Station 150 Final Inspection and packaging
5.19.1 Description
This station will inspect the finished housings and print a label for packaging. The operation will take the finished
housings from station 140’s GOOD conveyor and do one last inspection. The housing will then be placed on the base
fixture and the operator will cycle start to scan the housings barcode which will be later printed out on the shipping label
(each box contains 12 parts).
Keyence scanner
and base fixture
Shipping label printer
Figure 38: (a) Station 150

6 Fixture rack
The fixture rack will hold every fixture so they do not get missed placed. Each rack is labeled with a station number.
Move the fixture rack to the middle area of the whole line to swap all fixtures if the whole line is being used, if not then
take and replace the fixture you need.
Figure 39: (a) Fixture Rack

Operation Manual

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335 Connie Crescent

Vaughan, ON. L4K 5R2

ULA-Matic Project No. 15106

CHRYSLER ETOP BEV & PHEV

ULA-Matic – Project 15106 February-2016 Page 1

ULA-Matic – Project 15106 February-2016 Page 2

ULA-Matic – Project 15106 February-2016 Page 3

ULA-Matic – Project 15106 February-2016 Page 4

ULA-Matic – Project 15106 February-2016 Page 5

Figure 1: eTOP Pump Assembly Layout

ULA-Matic – Project 15106 February-2016 Page 6

Inner G Rotor Shaft Press 1-020

The process will be repeated through the 16 stations and all

Plotting System 1-120

Connector Insert 1-130

Connector Leak Test 1-135

Performance Test 1-100

CIC Check 1-110

Final Leak Test 1-140

ULA-Matic – Project 15106 February-2016 Page 7

In general each station will have the following equipment:

- Control Panel with Allen Bradley Panel View Plus 600

3.3 HMI Screens

3.3.1 General Description

- Main Operation Screen

Always follow these safety procedures:

4.1 Lockout Locations

ULA-Matic – Project 15106 February-2016 Page 9

Figure 3: Emergency Stop Buttons

To Reset the E-Stop:

ULA-Matic – Project 15106 February-2016 Page 10

Figure 4: U-Shape Light Curtain

ULA-Matic – Project 15106 February-2016 Page 11

4.5 Indicator Lights

Indicator State Machine Status

Figure 5: Stack Lights

ULA-Matic – Project 15106 February-2016 Page 12

Figure 6: Done Lights (Green, Yellow, Red)

Solid Green: Pass Part/ Load New Part

Solid Red: Part failed.

Flashing Red: Step Failed

ULA-Matic – Project 15106 February-2016 Page 13

- Main Operation Screen

ULA-Matic – Project 15106 February-2016 Page 14

Yellow --- Green--- the

Step Mode Manual Mode

Figure 8: Main Screen

ULA-Matic – Project 15106 February-2016 Page 15

If the Back ground color is

If Text is in RED then the

If the Text is in White then Arrows to scroll up or down

Figure 9: Fault Screen

ULA-Matic – Project 15106 February-2016 Page 16

Figure 10: Manual Screen

ULA-Matic – Project 15106 February-2016 Page 17

Figure 11: Setup Screen

ULA-Matic – Project 15106 February-2016 Page 18

Figure 12: Data Screen

ULA-Matic – Project 15106 February-2016 Page 19

Figure 13: I/O Screen

ULA-Matic – Project 15106 February-2016 Page 20

Figure 14: Computer Cabinet

ULA-Matic – Project 15106 February-2016 Page 21