GM has a "smart bolt" that mounts the embedded RFID device on the bolts to maintain the accuracy of the production process.
We often hear about smartphones and smart watches, but have anyone heard of "smart bolts"? GM's Tonawanda engine assembly plant in New York, USA, has a bolt that mounts an embedded RFID device on a bolt to maintain the accuracy of the production process. This method was used to produce a universal 5th generation V8 small cylinder engine.
These "smart bolts" look the same as ordinary bolts, but the interior is hollow and replaced by a radio frequency identification device and a wire antenna. Each bolt can store 2048 kilobytes of data and is attached to the engine block throughout the production process.
In the fifth generation of small-cylinder engine production, GM tagged engine parts. The entire process light engine block contains 29 production steps, and the engine head also contains 11 processes. Once the two parts have been assembled separately, the final assembly will be carried out to become a complete engine.
The assembled engine is fixed to a dedicated pallet. Each cylinder head of each engine has an RFID tag integrated into the bolt and corresponds to the serial number of the engine block and head. The data collected by the tag is uploaded to a central server for easy retrieval of each engine.
On the production line, RFID tags transmit and receive data at 50 different locations, ensuring the correspondence between each component and the engine. A wireless identification scanning device is arranged along the production line. Before each process starts, the data of the tag in the bolt is read, and after the process is completed, another radio frequency identification signal transmitting device inputs new data into the tag. If the engine on any of the production lines does not meet the predetermined production standards, it will be detected by the RFID scanner before it enters the next process. The engine will be transported to another location via another special “shunt line†that will be inspected by a dedicated inspector.
When the cylinder head is fully ground, a dedicated machine combines it with the engine block by simultaneously drilling 20 bolts. Here, the RFID tracking technology works again to "tell" the worker if each bolt is successfully installed. Because each bolt has its standard tolerance class, and the number of turns it must rotate, the slight difference will affect its tightening torque, which will affect the engine's tightness. In the previous traditional process, the accuracy of the worker could only be controlled, so the parameters could not be completely unified, and the sealing of the engine was obviously not as good as it is now.
The quality control process in the production process also needs to rely on the radio frequency identification system. When the supplier informs the assembly plant that there is a problem with the quality of a batch of parts, the RFID system can retrieve the engine batch with the defective parts in a short time by matching the parts to the serial number of the engine.
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