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SAE TECHNICAL 2007-01-2742

PAPER SERIES E

Torque Management System

Yuri Surzynskyj
T-Systems do Brasil Ltda.

Jorge Luiz Tomaz de Brito

T-Systems do Brasil Ltda.

FILIADA À
XVI Congresso e Exposição Internacionais
da Tecnologia da Mobilidade
São Paulo, Brasil
28 a 30 de novembro de 2007

AV. PAULISTA, 2073 - HORSA II - CJ. 1003 - CEP 01311-940 - SÃO PAULO – SP
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 Downloaded from SAE International by Imperial College London, Thursday, August 09, 2018

2007-01-2742

Torque Management System

Yuri Surzynskyj
T-Systems do Brasil Ltda.

Copyright © 2007 SAE International

ABSTRACT independently and granting security of data. Although the

Looking for a continuous improvement and the
satisfaction of customers, the automotive industry needs
each time more help from IT systems to improve its
productive processes. This necessity points to development
of specific systems such as Torque Management System
that use a real-time monitoring of shop floor to generate
quality and error control reports of nut lock processes.
system provides only support for nut lock process and it
must be adaptable to your process generating results that
you can trust to make decisions.
See below a hypothetical process deviation curve to
be analyzed by the system, the first picture tells about
uncontrolled process and the second about controlled
process:

A MOTIVATION, AN IDEA

What will happen if one truck lost one wheel on the

road? And be evidenced that one of the nuts of the wheel
came unlocked from factory?

Following this idea and quality control we had a

motivation to develop a system capable of generate
Effective Control of Locks and quality/error reports
although permits tracking for each one product that was
assembled.

These reports must be used by production leaders or

production planning to control the quality of processes and
quality of its processes under Statistical Process Control
(SPC) concepts although grants the tracking.

EXPLORING THE IDEIA

The SPC standards apply an extensive use of

Statistics to generate results, all the time, based on samples
of data. In our case the idea is Effective control, not
statistical control because we have all the data, where some
statistical procedures not run ok.

The most important concept is the analyses of

Deviation Curve to make decisions. These analyses permit
a rapid detection of failures from processes growing-up the
quality and reducing costs of rework to lower-levels.
Now thinking about the system, many companies
have a structure based on independent production lines or
cost centers that need its own reports, results and strategies
then the system needs provide information sector-by-sector
DEFINING THE MAIN ROLES OF SYSTEM
To generate effective results the system must be own
all data from nut lock processes and have a powerful
processing and data consolidating engine capable of give
results in a few minutes or according to the necessity of

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your production system. Joining the ideas we define that
the system must be:

Owner of all the data from locking processes

Capable to do Deviation Curve Analysis

Capable to generate results into time window of
your processes.

Capable to generate custom reports

Capable to generate SPC Cards and Graphics

Flexible and adaptable to your nut lock processes
generating trusted information.

Flexible to support your company structure
granting the security of data sector-by-sector

Scalable, Available, Fast and Downtime-Less

Flexible to adapt the various protocols of
machines
TECHNOLOGY POWERING RESULTS
Today we have the technology of Electric Nut Runner
s that turns possible the collect of lock data to make
analysis. Many Nut Runners supports computer-network
connections, other machines do not have this support but
we can apply a PLC or any signal converter, using
automation, into the machine to enable the network support
and data delivery. Some processes use Electro-Pneumatic
machines to execute locks and this machines also can be
network enabled using specific-designed devices that can
share lock data over networks.
Nowadays the SERIAL networks have your use
tending to local applications, like barcode scanner, and not
supports an enterprise network, then we consider the best
way the use of TCP/IP networks to transfer data between
machines and computers/servers reaching speeds up to 100
Mbps granting fast delivery of information to control
system.
PASSING BY THE CHALLENGE OF
INTEGRATION
The main challenge to develop a system that supports
this structure is the level of interoperability with machines
and other systems that it integrates.
If you have a diversity of machine types, during the
integration, you will find a big confusion with protocols
generating a scenario like “Tower of Babel” because each
device communicates in one specific protocol. You must
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implement each protocol and delivery your data to other
structure. This second structure is known by your system
and you can work only with this structure to do a
conversation with devices and collect the data of locks.
Certainly this phase of system project is the most important
because it will define the big part of performance of
system.
If you develop low-quality integration the system will
consume more resources and time to process the
information, what can be a problem in the future and you
will spend more time to develop new integrations until the
system turns disorganized with failures and low stability.
See below the best way to implement and run
multiple protocols concurrently.
THE CONCEPT AND THE REALITY
This concept tells about an enterprise integration of
nut runners and we had full applied it for one of our
customers and we passed by many technical and
management challenges during the project.
As this concept was extracted from the practice you
not will find big differences between concept and reality. In
this case, during the first phase of the project, we had
integrated approximately 100 machines/devices from 9
different suppliers to a central system where the users from
any part of the network can access its information to make
decisions or simply to track the production using a website.
THE SYSTEM MAINTENANCE
As the system was designed in many modules we can
do changes and maintenance using hot-swap concepts to
reduce the down-time of solution where the continuous
capture of the data is granted.
The hot-swap concept tells about design that permit
the system receive changes with it running and executing
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its tasks normally, without operation stops to grant the used Is MS-SQL 2000.
integrity of data and availability of the system.

The costs of support are low and the start-up is very

fast comparing to other enterprise systems considering that
you have the same machines that system was enabled, but if
your machine is new for the system, we can create new
protocol interfaces to do the communication in a short time
window.

SYSTEM DESIGN

The system was designed using the OOP (Object

Oriented Programming) concept and structured in four
layers. Each layer is a package of classes and other
implementations that serves the upper layer and consumes
the lower layer services. The layers are CORE, BIZCORE,
SERVICE and WEB.

1 - Core: This layer contains common controls of

system and services such as Data Providers, Ethernet
Connectors and IO Interfaces.

2 - BizCore: This layer consumes the major part of
Core controls and its responsibility is the transformation of
collected data to internal structure of the system and
provides the consolidated data for upper layer, the user
interface. This layer implements also the drivers for each
one protocol that the system supports.
3 - Service: It’s the most important layer and the heart
of the system because it’s responsible to generate
consolidation of data, pre-processing of statistics and
process deviation curve analysis although the control of
data collect and data integrity check. It needs grant the
correct input of data into the system and the interoperability
with the legacy systems and/or with devices over the
network.
4 – Web: This layer is responsible only by provides
user interface, administration of the system and Generation
of runtime reports.
PLATFORM:
As the design of the system is OO you can implement
it in many commercial platforms like MS-Windows or
UNIX/LINUX with JAVA. In the cases of MS-Windows
you can use .Net Platform too.
The physical platform must be able to support cluster
services using the “Failover” concept to grant the
availability and we recommend that you use two equal
servers at least to implements the system.
THE SYSTEM AND THE NEW PROCESS OF
LOCKING AND QUALITY CONTROL
With the system processing the lock data, the quality
team of our customer doesn’t will spend many hours
calculating and filling SPC cards with results or drawing
graphics as in the past. They only will click in buttons and
get the processed data with respective graphics in a few
seconds. The other part of time will spend only to analysis
the results getting decisions and solving the problems off
processes/products.
We also implement a special report that, at the end of
production, will be generated for each assembled product
where an operator do the check of all locks from product
and, if necessary, grant the revision of items NOK.
Certainly the productivity of quality teams grows-up
and the quality of products too, resulting in a security and
satisfaction of the final customers. We can observe that the
cost with rework was really reduced after the problematic
processes receive more attention and solutions to its fails.
THE FIRST PLATFORM THAT WE USED TO
IMPLEMENT THE SYSTEM
The TMS was designed and implemented using
Microsoft .Net Platform with C#.net and ASP.Net for the
website. The system runs over two machines equipped with
16GB of RAM and four Intel Core 2 Quad Xeon processors
with 2.4 GHz clock each one granting the speed that our
customer needs to its process timing.

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The data storage system used is IBM DS8100
partition. The logical platform applied uses MS Windows
2003 as operational system and the MS-SQL Server 2000
as Database Server. The web application is served by
IIS(Internet Information Services) from MS too.
THE PAST AND THE FUTURE OF OUR
IMPLEMENTATION
ABOUT THE AUTOR
He work at T-Systems Brazil as Engineering
Technician and is student of Computational Engineering.
He is 20 years old and develops enterprise systems since
2004; nowadays he is dedicated to develop automotive
embedded systems and manufacturing automation systems
for TSBR customers.

We spent about eight months for develop and test the Contact e-mail : yuri.surzynskyj@t-systems.com.br.
core of the system to be capable to support the demand of
data processing and consolidating. The results of applied
tests grant that the data comes into the system and is
processed successfully. Now we totalize about 1,200 hours

The same customer and our team still designing the

changes to the system be able to support new production
lines where we will integrate more 40 machines/devices to
the system and totalizing 520,000 locks/month completing
the first phase of the project.

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© Copyright 2007 Society of Automotive Engineers, Inc.

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