Sorion Electronics can provide solutions in the following areas

Sorion can provide you with the spectrum of solutions from simple hand held production and test aids through to complete assembly line process control and test.

Sorion can use our existing platforms together with feedback from you in a staged approach to develop a final solution , including full specifications and documentation

Click on a picture to find about more about each product area.
 

Production line process control, data capture and electrical / electronic test for sub-assemblies and complete vehicles.

Electrical / Electronic assembly aids.

Duracon^TM Ruggedised Industrial connectors and harnesses.

End of line Hot & Cold engine test facilities.

Batch build of Electrical / Electronic systems  and harnesses.

Assembly Process and Test Systems

Sorion offer a comprehensive range of assembly process control and test systems.  The main areas that are covered in the Sorion system are detailed below:

	Interface to build scheduling systems
	Component type validation against build specification
	Component ID data capture and validation
	Assembly process control (Textual and Graphic representations)
	Interface and control of ancillary systems (Torque tooling, conveyor systems, etc.)
	Intrusive Electrical test of assemblies
	Serial Diagnostics to ECUs  for programming, control and diagnostics
	Database systems for system integration and results storage / archiving

Hardware

Sorion use a range of commercially available industrial computing and control hardware (ensuring continued availability and second sourcing opportunities).  In addition to this hardware Sorion manufacture a range of specialist test interfaces to provide flexible and reliable systems.

The hardware packaging can be configured to suit the application, this typically consists of ruggedised PC enclosures or command arm style systems with panel PCs.

Software

Shop floor software is derived from Sorion's comprehensive range of software modules written in Visual Basic running under the industry standard Microsoft Windows NT4, 2000 or XP that can be readily configured to suit your exacting requirements.

The screen shots above are a small example of a build specification, part number checking and a graphical process control screen.

In server based solutions Sorion has developed its Orion^TM database system that is fully web based.  For further information on Orion^TM click here.

Ongoing Maintenance and Support

Sorion can offer a comprehensive range of support services including remote access links can be setup and supported to provide a greater level of support at reduced costs (reducing the need for expensive dedicated site engineers).

Click here for further information on the support services we can offer.

Download the Assembly Process & Test Systems Flyer (507kb pdf)

Sorion your Partner for Electronic Test | Sorion Electronics Site

Orion^TM Database System Overview

Sorion has developed a wholly new factory database system Orion^TM. This is now providing valuable reports on customer sites and is offering a robust failure tolerant solution. Data is collected from a wide range of factory systems (both Sorion delivered and from other facilities suppliers) using a networked robust XML transfer process and stored in an expert designed MS SQL database.

The user interface is web based and provides not only reporting and real time status monitoring of the connected factory system, but also web based maintenance tools allowing the user to carry out day-to-day tasks and also the tools necessary in maintaining such a system following the inevitable factory system or network outages that occur from time to time.

Sorion have recently developed a cost effective yet fully functional door test unit for Land Rover to use on the Freelander door assembly lines.

The door test units are based on Sorion's experience of producing Assembly aids and is extended into an compact but yet effective sub assembly test unit.

Each test unit tests the door or doors from one side of the Freelander.  The unit capable of testing left and right hand drivers doors (both 3 and 5 door versions), front and rear passenger doors.  Sorion's engineering analysis of the door design has significantly reduced the interconnection count and the overall test complexity, saving Land Rover both financially in the initial capital investment and the ongoing man power requirements.

Testing of a pair of door typical takes less that 60 seconds including connection / disconnection, manual inspection and the electrical function tests.

The door test unit carries out the following functions;

	Electric mirror movements
	Heater mirror current draw
	Power fold mirror movements
	Front window lift / lower
	Rear window lift / lower
	Front and rear door speaker test
	Front door central locking test
	Rear door central locking test
	Lock mechanism key and latch status

The Central locking tests are fully microprocessor controlled and are carried out in a matter of seconds without operator intervention.

The speakers are tested (again under microprocessor control) for correct connection of base/mid range unit and tweeter.  The test is carried out using induction measurements against tightly defined limits.  The test is carried out almost instantaneously without producing any sound.

The unit is suspended from an overhead catenary system (also providing the 12 volts supply) that allows the unit to travel with the doors as they are tested.

The total project from order placement to delivery of the first unit was 6 weeks, including the provision of the test harnesses and bespoke Duracon^TM ruggedised connectors.

Sorion your Partner for Electronic Test | Sorion Electronics Site

Assembly Aids

Sorion Assembly Aids are designed to survive the harsh environment of the vehicle assembly shop

They are ergonomically designed with functionality and durability of paramount consideration

The units are custom made and vary in the level of complexity from a simple switchable power source using industry standard Bosch power tool batteries and charging facilities, to units with integrated electronics and remote wireless communication

	Electrical Test:-      Test with Pass / Fail Indication
	Functional Test:-    To check the operation of                                  a moving part
	Mechanical Test:-  Used to check mechanical                                  properties
	Optical Test:-         The use of optics to detect                                  presence or correct fit

Sorion can design you an assembly aid to meet your exact requirements, without compromise.

Download the Assembly Aids Flyer (70

4kb pdf)

Duracon^TM Ruggedised Connectors

Sorion's Duracon^TM ruggedised connectors are ergonomically designed with functionality and durability of paramount consideration to survive the harsh environment of the vehicle assembly shop.

There is a vast range of connectors available to suit most connectors used in automotive manufacture, new connectors are being added continuously to the range.  Sorion will make Duracon^TM connectors to suit virtually any harness or unit connector (subject to evaluation).

Duracon^TM connectors are non-intrusive and don't effect the guaranteed life of the mating connector on the product under test.

Duracon^TM connectors utilise replaceable gold plated spring loaded pins with current ratings of up to 45Amps at 12Vdc. Life expectancy of the pins is in the order of 80,000 - 100,000 insertions, to further improve uptime the pins are easily replaced with the aid of a simple tool.

Duracon^TM connectors can be supplied loose in quantities as low as 1 off's or complete with a harness for connection to your assembly / test equipment.

Complex multipart Duracon^TM connectors can be supplied and an example of these is shown below
 

J1962 - OBD Connectors

Duracon Selector Guide

Sorion your Partner for Electronic Test | Sorion Electronics Site

Engine Test Systems

Sorion offer a comprehensive range of Engine Harness (static engine), Cold (engine cranked, but not fired up) or Hot (engine running) end of line engine test systems.  The engine test systems build upon Sorion's core electrical test system, however this is expanded on to provide for the full control of, acquisition of data from the engine under test:

	Interface to build scheduling systems
	Test control (Textual and Graphic representations)
	Interface and control of test bed systems
	Intrusive Electrical test of assemblies
	Serial Diagnostics to ECU's  for engine control and diagnostics
	Database systems for system integration and results storage / archiving

Hardware

Sorion use a range of commercially available industrial computing and control hardware (ensuring continued availably and second sourcing opportunities).  In addition to this hardware Sorion manufacture a range of specialist test interfaces to provide flexible and reliable systems.

Interfacing to AC and DC servo drive systems for Engine cranking / power absorbtion, fuel meters and ignition measurement systems.

Software

Sorion has a comprehensive range of software modules written in Visual Basic running under the industry standard Microsoft Windows NT4, 2000 or XP that can be readily configured to suit your exacting requirements.

The screen shots above are a small example of a Calibration screen, Trace Screen and a  process control screen at a barcode entry prompt.

The following pages provide more information on the differing philosophies.

	Engine Harness Testing
	Engine Cold Testing
	Engine Hot Testing

Ongoing Maintenance and Support

Sorion can offer a comprehensive range of support services including remote access links can be setup and supported to provide a greater level of support at reduced costs (reducing the need for expensive dedicated site engineers).

Click here for further information on the support services we can offer.

Sorion your Partner for Electronic Test | Sorion Electronics Site

Standard Products

Click on the picture to take you to the product information

Rigel Processors
Industrial Automation and Communication

Mintaka Low Cost Data Capture

Ruggedised J1962 - OBD connector

Serial / Digital I/O Adaptor

Ruggedised Crocodile Clips

Sorion your Partner for Electronic Test | Sorion Electronics Site

Prototype and Low Volume Electronic Manufacturing

Sorion can also offer both pre and full production of the products in our low volume manufacturing facility. Capabilities include prototype build using both "Vero-board" and through hole plated printed circuit boards.

Batch build of PCB's, including enclosures, cabling and test.

Manufacture of harnesses utilising standard connectors or Sorion's own Duracon^TM ruggedised industrial connectors using a range of standard and special purpose cabling and protection systems.

Sorion your Partner for Electronic Test | Sorion Electronics Site