JLR HALEWOOD FRONT AXLE SLAVE TOOLING ROBOT CELLS
End User Jaguar Land Rover
Project Engine Platen Tooling Storage & Retrieval
Sales Value £ 800,000
Control Media: Rockwell GuardLogix
Standards: JLR DCP
Networks Ethernet: IP Project
Duration: September 2017 – December 2018
Jaguar Land Rover Limited is a British multinational automotive company with its headquarters in Whitley, Coventry,
United Kingdom, and a subsidiary of Indian automotive company Tata Motors. The principal activity of Jaguar Land
Rover Limited is the design, development, manufacture and sale of vehicles bearing the Jaguar and Land Rover
Both marques have long and complex histories and are manufactured in the UK, Europe and Asia. There are multiple
manufacturing sites in the UK with this project being at the Halewood plant on Merseyside, which was formerly a
To supply a turnkey electrical and software solution (project management, design, supply, install, program and
commission) for the Integration of the Robots and conveyors within their environment including the following:
- Project Management
- Electrical Design
- PLC Software Design
- Electrical & Functional Commissioning
- A2 Control Panel with Plug & Sockets
- Point I/O and Safety I/O Allocation
- Operator Push-button Station
- Cable Installation Materials
- Installation Labour & Supervision
- Standby and Training
Vehicle engines are assembled on a number of platens which are conveyed along the production line. Each platen is
configured according to the vehicle variant called from the build schedule. This facility provides storage and tracking
of the platen tooling and the ability to reconfigure the tooling on the platen in order to match the build schedule.
It consists of 2 robots, and 2 exchange stations. The engine platen is conveyed on a twin chain conveyor. The platen
is presented in sequence to each of the exchange stations. At these stations, it is accurately clamped and the tooling
is unlocked. The robot then proceeds to the exchange procedure where one set of tooling
Tool with Barcode Identification
There are 6 different tools, with 76 variants, so requiring a total of 456 tool storage locations.
24 places are reserved for manual input and output of tooling. In addition, there are 24 locations for damaged or out
of service tooling.
The functionality delivered included-
- Robot automatic and recovery cycles.
- Cell HMI functionality using the JLR standard CMU.
- Tool store map definition, HMI and management.
- Tool selection and interchange criteria and sequencing.
- RFID readers interface and integration.
- Gripper part detection scenarios and operations.
- Gripper barcode reader interface and sequencing.
- Platen conveyor motor control and sequencing.
- Safety device interfacing and annunciation.
- MES interface.
- End user training.
The control system was delivered as a turnkey solution with full project documentation and fully compliant to JLR
project book requirements and using DCP programming protocols. Rockwell 1734 series PLC I/O hardware on
Ethernet was supplied throughout.
We undertook the contract knowing we could meet the demanding specifications and timescales of the customer.
The design, procurement of parts, and build of the Control Panels and Desks took place concurrently. The installation
started prior to the arrival of the Control Panel, Control Desks, and other elements on-site and we coordinated the
commissioning activities of all parties.
The facility was completed on schedule and within the client’s budget with trials and full production taking place
within the timescale agreed at project kick-off.
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