E-check station I from steering Wheel assembly line

Description steering wheel assembly line

Scope of this line is to ensure the correct assembly of the steering wheel which is used on KIA Ceed cars. The entire line is controlled by a Siemens PLC CPU312, which is mounted in a general electrical cabinet. All stations have a Siemens IM ET200S without CPU, and are connected at mai cabinet.
Setup of the entire line is done by TRACE system, from the TRACE computer.
The line is also equipped with racks for components and a pick by light system is integrated.
Concept of process, mechanical design, electrical concept and design and PLC programming in STEP7 were done completely by Metrom Trading.


Purpose of the e-check station is to check that all swithces, the heating system, the vibration motor and the illumination of the SW are working well.
First step of the process is to fix the SW in the nest.
After the component is fixed, the 2D datamatrix is scanned.
If everything goes OK, the operator will press each switch from the SW and the PLC check the resistance or the current from each switch to confirm that all are ok.
The order of pressing is given by the PLC and shown on the HMI.
After swithces are checked the operator press the start button, and the drawer goes inside the station.
In the station the motor starts and with a converter is checked the frequency of it.
Next step is to check the illumination. This is done with a vision system.
Last step is to check the horn function. A cylinder comes from above and touch the 4 rivets.
The plate is equipped with 4 INGUN pins and with this concept the continuity of the current is checked.
If all checks are OK, the drawer push the SW outside, and a label is realised from the printer.
The label is applied manually and another scanner will check this.
If the scanning comes OK from PLC than the SW is realised from station.
For safety reasons station is equipped with 2-hand start buttons from Captron.

Equipment used

  • Cognex Insigth camera system
  • Ziegler Muller relays for resistance and tension
  • Zebra printer
  • Ulcos converted for frequency
  • Captron 2-hand buttons
  • Keyence optical fibers
  • Cognex dataman scanner
  • Datalogic Gryphon scanner
  • Festo pneumatics
  • Proface HMI
  • Siemens ET200S IM with modules