Jaguar Land Rover

Manufacturing Equipment Standard

Plastic Man-rider Mechanical Standard

Approved for use in BIW Yes 11/03/2019

Approved for use in T&F Yes 23.05.2018

Approved for use in Paint No

Plastic Man-rider Carrier Advanced Revision Engineering Conveyor System Mechanical Version: Date: Page 1 of 33 Standards, Controls & Joining Standard Manufacturing Engineering JLR-MEES-TD-151 -009 22.06.2018 V1.1

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Jaguar Land Rover

Manufacturing Equipment Engineering Standard

Revision History

Date Name Issue Change Description

10/05/2017 Paul Morgan V0.1 New base line for standard

15/05/2017 Paul Morgan V0.2 Internal updates

28/06/2017 Aaron Tivey V0.4 Acronym change

03/07/2017 Aaron Tivey V0.4 Insert “Drive inverter location” section

04/08/2017 Paul Morgan V0.5 Format updates

18/10/2017 M Lishman V0.6 Format updates / List of figures

23/05/2018 Rodica Mirea V1.0 Updated MEES Format

22/06/2018 D.Olver V1.1 Removed reference to air requirements

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Manufacturing Equipment Engineering Standard

Table of Contents 1 INTRODUCTION ...... 5

1.1 ACRONYMS AND ABBREVIATIONS ...... 5 2 DESIGN GUIDELINES ...... 6

2.1 REGULATORY COMPLIANCE ...... 6 2.2 DESIGN STANDARDISATION ...... 6 2.3 ASSOCIATED JLR STANDARDS ...... 7 3 DESIGN REQUIREMENTS ...... 8

3.1 SYSTEM DESCRIPTION ...... 10 3.1.1 Function ...... 10 3.1.2 System Boundary ...... 11 3.1.2.1 Interfaces ...... 11 3.1.2.2 Drive inverter location ...... 11 3.1.2.3 Constraints: ...... 11 3.1.3 Exclusions ...... 12 3.1.4 Sequence of operations ...... 12 3.2 FUNCTIONAL DETAIL ...... 13 3.2.1 Common items ...... 13 3.2.1.1 Specifications ...... 13 3.2.1.2 Capacity ...... 13 3.2.1.3 Conveying line ...... 13 3.2.1.4 Plastic mat top conveyor ...... 13 3.2.1.5 Plastic mat chains ...... 15 3.2.1.6 Wear plates ...... 16 3.2.1.7 Side guides ...... 17 3.2.1.8 Return rollers ...... 17 3.2.1.9 Intermediate frame ...... 18 3.2.1.10 Processing stations ...... 18 3.2.1.11 Inspection pits ...... 18 3.2.1.12 Idler Brake drive and Tensioner Frame ...... 18 3.2.1.13 Drive & Control Frame ...... 22 3.2.1.14 Catenary sag ...... 27 3.2.1.15 Speed and Position Sensing ...... 28 3.2.1.16 Dimensional and geometrical tolerances, repeatability, measurement points and datum features ...... 28 3.2.1.17 Maintenance requirements ...... 28 3.2.1.18 Visual requirements ...... 29 3.2.1.19 Fixing requirements ...... 30 3.2.1.20 Performance requirements ...... 30 4 EQUIPMENT RFQ REQUIREMENTS ...... 32

4.1 OVERVIEW ...... 32 4.2 WORKPIECE CHARACTERISTICS ...... 32 4.3 PRODUCTION REQUIREMENTS ...... 32 4.4 ENVIRONMENTAL CHARACTERISTICS ...... 33 4.5 USER CHARACTERISTICS ...... 33

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Manufacturing Equipment Engineering Standard

Table of Figures

FIGURE 1 – EXAMPLE OF A MAN-RIDER CONVEYOR SYSTEM > 10M LONG ...... 8 FIGURE 2 – EXAMPLE OF MAN-RIDER CONVEYOR SYSTEM < 10M LONG ...... 8 FIGURE 3 – EXAMPLE OF MAN-RIDER CONVEYOR LINE (MAIN CONVEYOR REMOVED FOR CLARITY) ...... 9 FIGURE 4 - EXAMPLE MAN-RIDER CONVEYOR SYSTEM (TYPE SHOWN FLOOR LEVEL) ...... 10 FIGURE 5 - MOVIFIT INVERTER MOUNTED ON A ROLLER BED...... 11 FIGURE 6 - MOVIPRO INVERTER MOUNTED ON A DROP SECTION ...... 11 FIGURE 7 – EXAMPLE OF MAN-RIDER CONVEYOR ALONGSIDE A MAIN CONVEYOR LINE ...... 13 FIGURE 8 – EXAMPLE SECTION THROUGH A MAN-RIDER PLASTIC MAT TOP CONVEYOR ...... 14 FIGURE 9 – EXAMPLE OF PLASTIC MAT SECTIONS FIXING ...... 15 FIGURE 10 – PLASTIC MAT TOP CONVEYOR SELECTION CRITERIA ...... 15 FIGURE 11 – EXAMPLE OF SPROCKET POCKETS ...... 16 FIGURE 12 - EXAMPLE OF PIT EDGE TO MAT EDGE GAP ...... 16 FIGURE 13 – EXAMPLE OF A DRIP TRAY BETWEEN THE UPPER ROLLERS AND RETURN CHAIN ...... 17 FIGURE 14 - EXAMPLE OF A MAN-RIDER IDLER BRAKE GEARED MOTOR AND TENSION FRAME...... 19 FIGURE 15 – EXAMPLE OF A MAN-RIDER IDLER BRAKE GEARED MOTOR AND TENSION FRAME (CHAIN REMOVED FOR CLARITY ...... 20 FIGURE 15 – EXAMPLE OF A MAN-RIDER IDLER BRAKE GEARED MOTOR AND TENSION FRAME (CHAIN REMOVED FOR CLARITY) ...... 20 FIGURE 16 - EXAMPLE OF A DEBRIS COLLECTOR UNIT ...... 22 FIGURE 17 – EXAMPLE LAYOUT OF MAIN DRIVE AND CONTROL FRAME ...... 24 FIGURE 18 – EXAMPLE LAYOUT OF THE MAIN DRIVE AND CONTROL FRAME ...... 25 FIGURE 19 – EXAMPLE LAYOUT OF THE MAIN DRIVE AND CONTROL FRAME ...... 25 FIGURE 20 – EXAMPLE OF CATENARY SAG ...... 27 FIGURE 21 – EXAMPLE OF MAIN DRIVE SPROCKET ...... 28 FIGURE 22 – EXAMPLE LIFTING CAPABILITY ...... 29

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Manufacturing Equipment Engineering Standard

1 Introduction This standard is owned, controlled and shall be modified by the Jaguar Land Rover (JLR) Global Standards and Control department (GSC).

Deviations from this standard shall require agreement from the JLR GSC in addition to the nominated Advanced Manufacturing Engineering department (AME) facilities project engineer.

This document outlines the expectations that JLR has of its suppliers with regards to the system described. Specific elements of the equipment described in this document shall be dependent upon the project specific requirements.

Project specific requirements, not covered in this standard, shall be detailed in the Request For Quotation (RFQ) which will accompany this standard. 1.1 Acronyms and Abbreviations Common acronym list, not all acronyms AC Alternating Current shall be used within this standard AME Advanced Manufacturing Engineering department AMEDOCS Advanced Manufacturing Engineering Documents BSPT British Standard Pipe Thread CE European Conformity DC Direct Current DCP Diagnostic Control Program DFMEA Design Failure Mode and Effect Analysis DoC Declaration of Conformity DoI Declaration of Incorporation ECPL Energy Control and Power Lockout EHSR Essential Health and Safety Requirements EMC Electromagnetic compatibility EMS Electrified Monorail System FFL Factory Floor Level GSC Global Standards and Controls department HMI Human-Machine Interface I/O Input/ Output JLR Jaguar Land Rover MSDS Material Safety Data Sheet MTBF Mean Time Between Failure MTTR Mean Time To Repair NEPT New Equipment Procurement Team OEM Original Equipment Manufacturer OHC Overhead Conveyor PBQ Paint Body Quality PED Pressure Equipment Directive PFMEA Process Failure Mode and Effect Analysis RPL Required Performance Level RFQ Request For Quotation S&C Standards and Controls SE Simultaneous Engineering UK United Kingdom

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2 Design Guidelines

2.1 Regulatory Compliance

All equipment must comply with the relevant European Conformity (CE) marking directives and be supplied with a Declaration of Conformity (DoC) or Declaration of Incorporation (DoI), as appropriate, stating compliance to the relevant Essential Health and Safety Requirement Requirements (EHSR) of the applicable European Directives, including but not limited to;  The Machinery Directive 2006/42/EC;  The Low Voltage Directive 2014/35/EU;  The EMC Directive 2014/30/EU;  The Pressure Equipment Directive 2014/68/EU;  ATEX Equipment Directive 2014/34/EU;  ATEX Workplace Directive 99/92/EC (ATEX 137); Relevant harmonised standards include, but are not limited to;  BS EN 14238:2004+A1:2009 - Cranes. Manually controlled load manipulating devices;  BS-EN1494:2000+A1:2008 - Mobile or movable jacks and associated lifting equipment;  BS EN ISO 14120:2015 - Safety of machinery. Guards.

Safety equipment shall address both the JLR Global Standards and Controls safety standards; and EN62061 safety risk assessment of the equipment function and associated production processes, performed by the supplier.

Risk assessments shall be supplied to JLR when requested and at pre-agreed milestones.

All Civil and structural designs and specifications shall be compliant with the applicable Eurocodes EN 1990 – EN1999.

2.2 Design Standardisation

The supplier shall supply equipment that maximises the commonality of components and design philosophies, whilst working to the current JLR standards.

Purchased components and sub-assemblies shall be sourced from the approved JLR purchased parts list. Any deviation from this list shall require agreement with the nominated JLR project manager. The adoption of a non-standard purchased component or sub-assembly shall only be applicable to the specific project in question.

The system must comply with critical design requirements specified as a result of conducting Design Failure Mode and Effect Analysis (DFMEA) and Process Failure Mode and Effect Analysis Plastic Man-rider Carrier Advanced Manufacturing Revision Engineering Conveyor System Mechanical Version: Date: Page 6 of 33 Standards, Controls & Joining Standard Manufacturing Engineering JLR-MEES-TD-151 -009 22.06.2018 V1.1

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Manufacturing Equipment Engineering Standard

(PFMEA) through the design and delivery lifecycle to ensure the specified level of reliability, operation and safety in the specified operating environment: Wet, Humid, hot or dry.

The design solutions, where possible, shall have a maintenance interval of more than 6 months. Where this is not possible, then systems such as automated lubrication will be used for regular preventative maintenance tasks.

The solution shall have passive provision for data gathering devices that support JLRs 4.0 strategy, for example condition monitoring sensors. Specific requirements shall be agreed with the JLR AME representative, or will be defined in the project RFQ.

2.3 Associated JLR Standards

Relevant United Kingdom (UK) and European Normalised standards, the JLR General Pan Project Rules and individual specific JLR standards shall be applied to the design, build and installation of all equipment. Controls standards refer to;  The JLR DCP Standard Workbook;  The JLR Ethernet Workbook;  The Rockwell Project Workbook;  Festo Project Workbook. Switching standard refer to;  JLR IFM Project Workbook. Drives information refer to;  JLR SEW Project Workbook. Guarding Standards refer to;  JLR Mechanical Specification 22 – Machine Guarding and Access;  The Bosch Guarding Project Workbook.

For all other standards refer to applicable JLR Trim and Final Standards at the following web address;

https://us.sso.covisint.com

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Manufacturing Equipment Engineering Standard

3 Design Requirements

This document describes two types of man-rider systems < 10m and > 10m;  Man-rider system > 10m long (Figure 1); Length > 10m

Idler brake gearmotor Plastic mat top Main drive geared motor and and tensioner unit conveyor chain control unit frame frame

Man-rider conveying line intermediate frame

Section A-A Figure 1 – Example of a man-rider conveyor system > 10m long  Man-rider system < 10m long (Figure 2). Length < 10m

Idler frame Plastic mat top Main drive geared motor and conveyor chain control unit frame

Man-rider conveying line intermediate frame

Section A-A Figure 2 – Example of man-rider conveyor system < 10m long

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Manufacturing Equipment Engineering Standard

The man-rider conveyor line (Figure 3) shall be considered to only include the following sub-sections;

 Conveying line;

 Idler brake geared motor or tensioner frame;

 Main drive geared motor and control frame;

 Catenary sag.

Manrider conveyors

Figure 3 – Example of man-rider conveyor line (main conveyor removed for clarity)

The man-rider conveyor shall function with the following features;  The upper conveyor chain shall be under tension, creating a moving stable platform to transfer JLR associates towards the head of the conveyor;  The conveyor chain is guided and supported on wear strips (included in the intermediate frame) and moved through a series of processing stations at a nominally constant speed (variable speed control shall be provided to allow for specific production conditions such as, but not limited to, new model introduction or parts shortages);  The conveyor chain is fed on the wear strip deck into the main drive geared motor and control unit frame;  The chain shall engage with and be driven by the sprocket mounted on the main drive shaft;  The conveyor chain is rotated around the sprocket set and fed onto the return carrier rollers on the underside of the intermediate frame;  The conveyor chain shall be returned in the lower section of the intermediate frame on rollers in the direction of the idler brake geared motor and tensioner unit frame for conveyors > 10m and the Idler unit for conveyors < 10m;  The conveyor chain is moved along the return rollers by the main drive geared motor and control unit;  The conveyor chain is fed from the return rollers into the idler brake geared motor and tensioner unit for conveyors > 10m and the idler unit for conveyors < 10m.

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Manufacturing Equipment Engineering Standard

• The conveyor chain engages with the sprocket set mounted on the idler shaft;

• The conveyor chain shall be rotated on the sprocket set and tensioned;

• The conveyor chain engages with the sprocket set mounted on the tensioner unit;

• The conveyor chain is rotated on the sprocket set and tensioned;

• The conveyor chain tension or slack shall be detected and adjusted to the specified catenary sag on the return prior, to the tensioner unit.

3.1 System Description

3.1.1 Function The function of the man-rider conveyor is to convey JLR associates through a series of processing stations that may incorporate ancillary equipment synchronised with the movement of the plastic or steel slat conveyor shown in Figure 4.

A

A Slat conveyor

Manrider conveyor chain

Idler brake motor and tensioner unit Main drive gear motor

Manrider conveyor support frame Conveyor pit

Section A-A Figure 4 - Example man-rider conveyor system (type shown floor level)

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3.1.2 System Boundary The man-rider shall be installed within the main building structure; its size and location dictated by the local production facilities and the size, weight and shape of the load. These details shall be included within the individual equipment RFQ.

3.1.2.1 Interfaces

The man-rider shall be electrically supplied, for details of the supply refer to JLR electrical installation standard and the individual RFQ.

Electrical Input/ Output (I/O) provision shall be included for interfacing with associated safety components, i.e. interlocked safety fencing and light curtains. This may require the allowance to mount cabinets, switch’s or cables to the equipment.

The design of the man-rider shall include where required mechanical connections to the load handling technology and building infrastructure; specific detail shall be contained within the RFQ.

3.1.2.2 Drive inverter location

MOVIFIT (Figure 5) and MOVIPRO (Figure 6) drive inverters shall be mounted next to the equipment/drive unit that it is controlling.

Figure 5 - MOVIFIT Inverter mounted on a Figure 6 - MOVIPRO Inverter mounted on roller bed a Drop Section

3.1.2.3 Constraints: The design shall be dependent upon the permitted loading on the building structure, as well as the profile of the facility; refer to the RFQ for project-specific data.

The man-rider shall be self-supporting and shall not be suspended from a building structure. Bracing between the building structure and the man-rider may be allowed for reaction against lateral loads. All requested connections to the building structure require the approval of the responsible JLR AME construction engineer. Drilling or welding into/onto the building structure is not permitted, clamping onto the building structure may be allowed, but shall be approved by JLR. Plastic Man-rider Carrier Advanced Manufacturing Revision Engineering Conveyor System Mechanical Version: Date: Page 11 of 33 Standards, Controls & Joining Standard Manufacturing Engineering JLR-MEES-TD-151 -009 22.06.2018 V1.1

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The position of the man-rider shall take into account the location of expansion joints in the supporting floor.

3.1.3 Exclusions The following features and/or equipment are excluded from this standard and are included either within their own standard or the individual RFQ;  Control system and electrical interfaces with the connecting technologies;  Handling equipment; o Drop sections; o Turntables; o Cam lifters; o Workpiece, including skids and pallets.  Electrical supply information;  Load size and mass.

3.1.4 Sequence of operations

The man-rider conveyor shall act as a continuously recirculating moving chain and as such does not have a sequence of operation.

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3.2 Functional Detail

3.2.1 Common items

3.2.1.1 Specifications The dimensions of the man-rider conveyor shall be designed with reference to the load data supplied and detailed in the RFQ. The supplier shall gain approval from the designated JLR engineer for the type of plastic mat to be used. The supplier shall demonstrate durability and suitability of the belt for the equipment application.

3.2.1.2 Capacity The capacity of the system shall be designed with reference to the requirement data to include but not limited to mass, size and takt time detailed in the RFQ.

3.2.1.3 Conveying line The conveying line consists of a long pit housing the conveyor and framework. All parts of the conveyor (control/ drive unit, idler brake and tensioner unit) outside of the belt area shall be fully covered. The conveyor shall transfer associates through a series of processing stations alongside the main conveyor (Figure 7) that may incorporate ancillary equipment. The man-rider conveyor shall be synchronised with the movement of the main conveyor line. All material finishes shall be in accordance with JLR standards.

Figure 7 – Example of man-rider conveyor alongside a main conveyor line

3.2.1.4 Plastic mat top conveyor The plastic mat top conveyor shall include plastic mat chains, wear strips and return rollers to recirculate the plastic mat chain. A plastic mat top conveyor system shown in Figure 8 (not all items shown) consists of; • One row of plastic mat slats (option to be both sides of main conveyor);

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• Intermediate frame; • Return rollers; • Wear strips; • The control and drive unit; • Idler brake drive and tensioner unit; • Detection, safety and lubrication systems.

Side guide Plastic mat Wear strips strips A Pit

Return Roller

Intermediate Frame

Detail view ‘A’

Figure 8 – Example section through a man-rider plastic mat top conveyor

The plastic mat top conveyor shall allow for the incorporation of proximity sensors that track the position of the conveyor and process station pitch controlled via the DCP process station equipment. Plastic mat top conveyors shall be equipped with side guide strips. The conveyor shall comprise of plastic mat sections fixed together in series to form a chain (Figure 9). The upper face of the conveyor shall be the flat surface of the plastic mat section.

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Figure 9 – Example of plastic mat sections fixing Details of the loads to be transported, the width and length of the conveyor, along with the plastic mat location features shall be specified in the individual equipment RFQ.

The chart shown below (Figure 10) shall be used to aid the selection of the type of plastic mat top conveyor system to be used, when considered against the area of application. This chart shall be used as an aid but further criteria may need consideration.

Operating Slat Conveyor Total Below FFL Factory Floor Level (FFL) Process Trim & Final Process applications Environment chain length (m) Process Type Conveyor type Slat material Final Final No. Workpiece only - Pit -Ex: Under Engine/ Workpiece + Associate Assembly Inspection Water Wet Dry <120m >120m Automated (Ex: Workpiece Suspension Associate only lines - lines - test lines Water test line) inspection Assembly line Wheels on. Wheels on a WIDE- Single Plastic Mat Top Conveyor Plastic x x x x x x x b Narrow - Single Plastic Mat Top Conveyor Plastic x x x x x x c Twin Plastic Mat Top Conveyor Plastic x x x x x x x x Figure 10 – Plastic mat top conveyor selection criteria

3.2.1.5 Plastic mat chains The plastic mat chains shall;  Be moulded to the required width specified in the RFQ (each conveyor section shall be the full width of the conveyor without joints);  Have an anti-slip surface suitable for standing on;  Suitable for both wet and dry applications, being resistant to chemicals such as washer detergents or any other vehicle fluids so that they do not corrode or degrade. The list of potential chemicals within the environment shall be included within the RFQ. The supplier shall issue a certificate of conformity of the plastic mat selected;  Provide a smooth (no juddering) interaction between the chain sprocket pockets and the sprockets so as to minimise the friction created, see Figure 11 for an example of sprocket pockets;

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Sprocket pockets

Plastic mat top chain

Figure 11 – Example of sprocket pockets  Not have gaps large enough to cause a trap hazard between the links when the chain is wrapped around the sprockets;  Be self-lubricating;  Incorporate visual markings, including, but not limited to; o Conveyor edge markers. If the conveyor is used within an ATEX environment then the chains shall be of an antistatic material. The centreline of the conveyor shall be aligned vertically with the mid-point of the mat; the conveyor line shall incorporate features to enable vertical adjustment of the mat. The plastic mat chain structural integrity shall be designed to achieve the JLR occupancy level requirements detailed in the RFQ. Horizontal flooring edge to mat edge gap shall be consistent and have a gap ≤ 5mm along the whole of the conveyor line (Figure 12).

Figure 12 - Example of pit edge to mat edge gap

3.2.1.6 Wear plates The wear plates shall support the chain over the entire width and length of the conveyor. Plastic Man-rider Carrier Advanced Manufacturing Revision Engineering Conveyor System Mechanical Version: Date: Page 16 of 33 Standards, Controls & Joining Standard Manufacturing Engineering JLR-MEES-TD-151 -009 22.06.2018 V1.1

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The specification inclusive of material type, surface finish and pattern of the wear plates shall be detailed by the equipment supplier to meet the requirements of the application detailed in the RFQ and approved by the AME JLR engineer. In general the wear plates shall be;  Plastic for dry production processes;  Cold rolled stainless steel plates for wet or humid production processes. The design of the wear plate surface shall not include dirt or debris traps and shall prevent damage to the plastic mat top chain. Instead they shall provide a path for dirt and debris to be removed to a collection tray. For dry processes, a drip tray (Figure 13) between the upper rollers and return chain shall be included to safely collect and remove pollutant vehicle fluids. For wet and humid processes a stainless steel drip tray shall be included to collect and remove fluids and debris to prevent the premature wear of the sprocket teeth and chain.

Figure 13 – Example of a drip tray between the upper rollers and return chain

3.2.1.7 Side guides In general the plastic mat top chains shall be guided with Polyethylene wear strips. The clearance between the chain and the guide shall;  Take account of the thermal expansion of the chain;  Be specified using the chains maximum width (tolerance + expansion) + 10mm (5mm clearance each side of the plastic mat).

3.2.1.8 Return rollers The rollers shall be;  Equally spaced at between 1m and 2m;  Able to freely spin to prevent premature wear on top of the chain;  Rigid to prevent bowing (the supplier to demonstrate capability).

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It shall be possible to remove and replace the return rollers without the requirement to disassemble the plastic mat or other conveyor components. This shall be demonstrated to the AME JLR engineer at;  Concept and detailed design stage, by using a 3D simulation model;  Equipment buy off stage, by removing and replacing a roller. 3.2.1.9 Intermediate frame The intermediate frame shall support the upper plastic mat top conveyor chain and transported load on fixed wear strips attached to the frame. Side guides to maintain the correct alignment of the Plastic mat top chain shall also be attached to the intermediate frame. 3.2.1.10 Processing stations The quantity, dimensions and use shall be described in the RFQ. 3.2.1.11 Inspection pits Inspection pits shall be process dependant and outlined in the RFQ if required. 3.2.1.12 Idler Brake drive and Tensioner Frame The idler brake geared motor and tensioner frame shall be specified for man-rider conveyor lengths > 10m. Conveyor lengths < 10m shall be specified with an adjustable idler shaft only. The idler brake drive and tension frame (Figures 14 and 15) shall be used so the upper section of plastic mat conveyor maintains a tensioned state and the return section of plastic mat conveyor takes up any slack. The idler brake drive and tensioner frame shall be located at the start of the conveyor at the point where the associate steps onto the plastic mat top conveyor. The frame shall be fixed to pit floor and walls with appropriately sized and quantity of chemical anchors. The idler shaft shall be mounted and secured at each end in sealed bearing housings. The idler shaft assembly shall be mounted on an adjustable carriage, the amount of adjustment shall be included within the RFQ.

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Plastic mat top conveyor Idler shaft

Control wheel

Sprocket

Idler brake Adjustment geared motor unit

Frame

Figure 14 - Example of a man-rider idler brake geared motor and tension frame

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Brake geared motor Plastic mat unit top chain

Control wheel

Drive chain Frame

Figure 15 – Example of a man-rider idler brake geared motor and tension frame (chain removed for clarity)

Idler shaft

Sprocket Set

Section A-A Figure 15 – Example of a man-rider idler brake geared motor and tension frame (chain removed for clarity

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 Key Design Features The equipment shall consist of; . Idler shaft The idler shaft shall be mounted and secured at each end in sealed bearing housings. . Sprockets Sprockets shall be attached to the tension shaft, and located by means of a shoulder in the shaft, spacers and retaining rings. There shall be a set of sprockets equal to the number of sprocket pockets across the width of the chain. . Drive control encoder The drive control shall use an incremental encoder for precise control of the conveyor. The encoder shall be assembled directly to the motor shaft. . Idler brake and gearbox reducer unit An idler brake and gearbox reducer unit shall be described in detail in the SEW project book. An idler brake and gearbox reducer unit shall be installed at each end of the Idler shaft. The idler brake drive capacity shall be calculated at 20% of the main drive and control unit at the head of the conveyor. The motor shall be a 3-phase synchronous type with variable speed controller. The motor shall provide direct drive to the gearbox reducer input shaft. The motor shall be mounted on an adjustable plate to allow for belt tension between the Idler Brake unit assembly and the control wheel which can be adjusted and calibrated. The gearbox reducer output shaft shall be linked via a drive chain to a control wheel at each end of the Idler shaft. An adjustable torque limiter shall be positioned on the reducer output shaft and equipped with a pulley and detection disk to the electric motor transmission. The motor shall be sized by the supplier and is directly linked to the tensile load and maximum speed of the slat conveyor. . Drive Gear The drive gear is meshed with a drive chain to the control wheel that is keyed and locked onto the main idler shaft containing keyed and locked sprockets. . Control Wheel A control wheel shall be mounted on both ends of the idler shaft.

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The control wheel shall rotate the idler shaft and the sprocket set assembly to engage and move the plastic mat top chain. . Debris collection tray An angled debris deflector plate and removable collection tray (Figure 16) shall be included to collect any debris captured between and on the slats. The angle shall be large enough such that debris falls into the collection tray. The design of the collection tray shall include safe and ergonomic access to be maintained and cleaned.

Debris deflector plate and collector

Figure 16 - Example of a debris collector unit 3.2.1.13 Drive & Control Frame The drive and control frame shall be located at the head of the conveyor and in the direction of travel. The drive and control unit shall be assembled onto a framework (Figures 17, 18 and 19) structure that is fixed to the pit floor and walls using appropriately sized and quantity of chemical anchors. The drive and control frame shall provide the guided movement of the plastic mat chain in forward and return. The control frame shall include an adjustable roller to maintain the specified tension and catenary sag of the chain during the return movement. The position of this roller shall be detected with switches so that if the plastic mat conveyor was to be snagged the conveyor would stop without causing damage to the equipment. The control unit shall include a standby and duty electric motor and reducer gearbox linked with a V-drive belt. Plastic Man-rider Carrier Advanced Manufacturing Revision Engineering Conveyor System Mechanical Version: Date: Page 22 of 33 Standards, Controls & Joining Standard Manufacturing Engineering JLR-MEES-TD-151 -009 22.06.2018 V1.1

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Each electric motor and reducer gearbox unit will be independently synchronised and engaged with the drive gear. The counter driver shaft assembly shall be linked and meshed at each end with a drive chain to a drive control sprocket wheel that is keyed and locked onto the main drive shaft containing a keyed sprocket set. Generally for narrow plastic mat top conveyors the drive gear will be connected and meshed with a drive chain to a control sprocket wheel mounted and keyed in the main drive shaft. The main drive shaft shall be mounted and secured at each end in a sealed bearing. On the main drive shaft will be a keyed sprocket set that are aligned and mesh with the plastic mat top chain sprocket pocket locations. The control unit shall use an incremental encoder for precise positioning of the slat conveyor. The encoder shall be assembled either directly or via a remote drive shaft with transmission to the main drive shaft, or at the electric motor or gear transmission. The drive and control frame equipment shall be located in a pit;  Covered with checker plates set in a structural framework to provide; o A floor loading that facilitates the loading of support vehicles or vehicle movers (Stringo); o Safe access to conduct maintenance and inspection activities; o Interlocked pit access to prevent conveyor operation during maintenance activities.

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Plastic chain Sprocket set Main drive shaft

Plastic chain return, tensioning unit and Main drive chain adjustment

Duty drive

Counter drive shaft

Adjustable bearings (set screw alignment) Torque limiter Counter drive chain

Counter drive shaft control wheel

Standby drive

Main drive chain

Figure 17 – Example layout of main drive and control frame

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Main drive gear

Duty and standby drive motor and gearbox reducer

Figure 18 – Example layout of the main drive and control frame

Duty drive motor and gearbox reducer Main drive chain

Figure 19 – Example layout of the main drive and control frame  Key Design Features The equipment shall consist of; . Duty and Stand-by Motor The motor type shall be described in detail in the SEW project book. The motor shall be a 3-phase synchronous type with variable speed controller. The motor shall be mounted on an adjustable plate to allow for belt tension between the motor and the gear transmission to be adjusted and calibrated. The motor shall be sized and specified by the supplier. . Gearbox reducer The gearbox shall be a gear train meshed to a final reducer output shaft.

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An adjustable torque limiter shall be positioned on the reducer output shaft and equipped with a pulley and detection disk to the electric motor transmission. . Drive Gear The drive gear shall be capable of being engaged by either the duty or stand-by reducer output shafts. It is meshed with a drive chain to a control wheel that is keyed and locked onto the main drive shaft containing 2 keyed and locked sprockets. . Counter Drive shaft The counter drive shaft shall be mounted and secured at each end in sealed bearing housings. . Counter Drive shaft Control Wheel The drive gear shall be linked and meshed with a drive chain to a control wheel on the counter drive shaft. . Main Drive shaft Control wheel The main drive shaft control wheel shall be linked and meshed with a drive chain to a control wheel on the main drive shaft. . Drive Shaft The main drive shaft shall be mounted and secured at each end in sealed bearing housings. In general the main drive shaft shall be a square bore shaft. . Sprocket set In general the sprocket set shall be square bore. The centre sprockets shall be locked onto the shaft using set collars and other sprockets should float axially. . Return Plastic mat top chain tensioner unit. The plastic mat top chain shall not be run tight. The return tensioner shall be specified by the supplier. In general the specified tension of the return plastic mat top chain shall be maintained by catenary sag or a tension unit close to the drive unit. The supplier shall provide tension adjustment visual aids and maintenance procedures displayed at the point of use. Any slack in the conveyor must be managed on the underside of the conveyor; any slack greater than ½ the pitch must have a mechanism to cope.

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. Position control The control unit uses an incremental encoder for precise positioning of the slat conveyor. The encoder can be assembled either direct or via a remote drive shaft with transmission to the main drive shaft or at the electric motor or gear transmission. . Debris collection tray An angled debris deflector plate and removable collection tray shall be included to collect any debris captured between and on the slats. The angle shall be large enough such that debris falls into the collection tray. The design of the collection tray shall include safe and ergonomic access to be maintained and cleaned. 3.2.1.14 Catenary sag The plastic mat top chains shall function without the requirement to tension them in the intermediate frame. The chain and sprockets shall be designed to work with a catenary sag in the return section, created by the weight of the chain with allowance for excess chain to accumulate. The control frame shall include an adjustable roller (Figure 20) to maintain the specified tension and catenary sag of the chain during the return of the chain. The position of this roller shall be detected with switches so that if the plastic mat conveyor was to be snagged the conveyor would stop without causing damage to the equipment. The catenary sag shall be adjusted by removing links to achieve the specified sag. The catenary sag shall be located close to the main drive unit between the 1st and 2nd return rollers.

Idler roller Drive roller

Adjustable roller

Sensor Figure 20 – Example of catenary sag

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3.2.1.15 Speed and Position Sensing The speed and position of the plastic mat top conveyor shall be maintained by closed loop control, described in the DCP standard. The position of the conveyor referenced to the processing station pitch shall be sensed, generally by a proximity sensor detecting a robust feature designed into or assembled on to the plastic mat top. The processing station pitch point markers (Pitch = 1 processing station length) shall be visually marked and identified on the upper and lower surface of the plastic mat top chain. 3.2.1.16 Dimensional and geometrical tolerances, repeatability, measurement points and datum features If the tolerance or position of any major mechanical assembly will have an effect on secondary equipment mounting or workpiece transfer. Then there shall be a requirement that the major mechanical assembles are provided with datum features and a checking fixture to check and confirm location. The meshing of the plastic mat top conveyor chain on the sprocket set shall be tangential to the horizontal as indicated in Figure 21.

Horizontal Tangent

Sprocket set

Main drive shaft centre point

Figure 21 – Example of main drive sprocket

3.2.1.17 Maintenance requirements Equipment needs to be designed so it can be maintained easily and safely without the need of dis- assembly. Where possible sealed for life bearings shall be used. Provision for automatic greasing systems or accessible greasing points shall be provided where non-sealed bearing are used. All lubrication points shall be labelled in accordance with JLR Visual management standard and colour coded as specified in the JLR lubrication standard that cross references lubrication type against colour code.

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Jacking points shall be incorporated into the system, identified and labelled with lift instructions. The lift jacking points and instructions shall be standardised across all lifts to reduce training and increase safety. There shall be clear labelling of the weight of all large assemblies e.g. carriage, motor/gearboxes, counter weights etc. This shall help maintenance select the correct equipment should these ever need to be removed. All assemblies with a mass ≥ 15kg shall be labelled. Lifting eyes attached to the motor and gearbox assemblies shall be able to take the combined mass of the units. The vendor must lubricate all parts of the system prior to start up. Lifting capability is required to be installed (Figure 22) above the drive and control frame, brake driver and tensioner frame pits to facilitate the installation and removal of heavy equipment details of the lifting hoist and beam to be included within the JLR rail and lifting standard.

Rail

Hoist

Space outside of conveyor line (put down area)

Drives and controls

Figure 22 – Example lifting capability The changeover of standby drives shall be detailed in the maintenance manual including the process steps required to engage the conveyor in the reverse direction. The changeover of full width rollers shall be detailed in the maintenance manual including the process steps required to remove / replace the rollers where access is limited. Drive mechanisms shall be visible at all times. If safety fencing prevents this then vision / access panels shall be fitted. 3.2.1.18 Visual requirements All equipment must adhere to the requirements of the JLR Visual Management Standard. Equipment colour coding must comply with the JLR Visual Management Standard Plastic Man-rider Carrier Advanced Manufacturing Revision Engineering Conveyor System Mechanical Version: Date: Page 29 of 33 Standards, Controls & Joining Standard Manufacturing Engineering JLR-MEES-TD-151 -009 22.06.2018 V1.1

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All load bearing equipment must adhere to the requirements of the JLR Weight Marking Standard. Match marking shall adhere to the JLR Visual Management Standard and shall be specified for;  Load Bearing Fasteners;  Fasteners that are subject to dynamic load and/or vibration;  Fasteners with a specified torque. Name plates should include (but not limited to) (refer to requirements of nameplate EU directive);  Manufacturer;  Model number;  Serial number;  Power rating: voltage, current, supply frequency;  Speed (rpm);  Weight;  Date of manufacture;  Batch number (if applicable);  Capacity eg. Load, volume, power, pressure, flow rate etc.;  Dimensions (L, H, W), volume (if applicable).

3.2.1.19 Fixing requirements All floor mounted mechanical elements that are under dynamic or lateral loads such as, but not limited to, friction drive assemblies shall be fixed in place using appropriately sized chemical anchors with reference to concrete condition. All fixings used by the equipment suppliers shall be installed in accordance with the fixings manufacturer’s recommended installation procedure. A damping system shall be installed between any connections from the equipment attached to the building. The type of damping to be approved by JLR.

3.2.1.20 Performance requirements  Availability The equipment’s operational availability shall be ≥ 99.5% as measured by JLRs Facility Monitoring system.  Mean Time to Repair (MTTR) The MTTR for the supplied system shall be no greater than 15 minutes. Vendors to demonstrate / prove that this requirement is satisfied; any requested deviation from this requirement to be agreed with JLR.  Takt time The installed equipment shall be validated to demonstrate achievement of the required takt time as per the equipment RFQ and timing diagram.

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 Expected Life The mechanical features shall have a service life of 15 years; takt time, number of shifts/operations per year shall be included within the equipment RFQ.  Operational validation The supplier shall abuse test the system and provide a report to verify that it meets the requirements of the JLR acceptance tests (check sheets available from JLR). This abuse testing shall be demonstrable to JLR on request or during equipment buy-off and shall include function, safety and recovery methods are operational.

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4 Equipment RFQ Requirements

4.1 Overview

This section lists out some of the requirements that shall be included within the project specific RFQ. This list is indicative and is not exhaustive.

4.2 Workpiece characteristics

• Workpiece variant / Model type • Workpiece / work holder geometry / envelope, including but not limited to:- o Height o Width o Length o Centre of gravity position • Workpiece / work holder / lifting points o This equipment o Previous equipment transferred from o Next equipment transferred to • Workpiece / work holder weight o Minimum and maximum during build / transfer o Weight distribution and contact points • Workpiece pallet / skids / rails o Length o Width o Height o Weight o Manufacturing tolerances

4.3 Production requirements

• Takt time • Number of shifts/ operations per year • Permissible model change time if required • Build station geometry / envelope o Length o Width o Height o Lineside parts storage restrictions

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• JLR Associates access • Workpiece / equipment interface and controls logic • Entry / exit interface requirements • Inspection Access • Maximum load capacity • Transition change • Lineside parts storage

4.4 Environmental Characteristics

• Environmental conditions • Preferred equipment material specifications • Protection requirements / chemical resistance with relevant material safety data sheets (MSDS) • Noise Level

4.5 User characteristics

• Factory floor level (FFL) inspection/production functional process requirements • In-process inspection and asset care requirements • FFL and pit Maintenance and access requirements • Infrastructure restrictions: o Foundation surface condition and material o Truss positions o Volume available • Equipment characteristics: o Variant / model type o Geometry / space envelope, including but not limited to: . Height x Width x Length (HxWxL) o Weight . Weight distribution and contact points . Centre of gravity o Static and dynamic loading on building structure o Lifting points o Dimensional and geometrical tolerances of the equipment o Clearance and play between the side guides and workpiece

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