Esys is a leading global supplier of tire and wheel automation solutions, with an installation base of over 60 locations globally. We offer cost effective modular solutions that address all phases of the tire and wheel assembly process. This includes tire pressure monitoring system (TPMS), automated weight apply for wheel balancing (AutoW8t), tire and wheel vision systems as well as product track and trace. Custom assembly solutions, including infrastructure general contracting are also available for both OEM and tier suppliers.

Esys provides turnkey services for modular and custom solutions, from planning and simulation to commissioning and support. We combine equipment from a wide variety of leading suppliers with Esys developed components in order to deliver superior solutions at competitive prices. Upgrades or enhancements to existing tire and wheel assembly solutions are also available.

From planning and design all the way to installation and support
our team will help you every step of the way!

What to Expect
– Project Management –

AutoW8t

AutoW8t is a patented innovative solution for dispensing, cutting and applying the revolutionary 3M™ Wheel Weight System in high speed tire assembly operations.

This automated precision wheel balance system represents a leap forward in tire and wheel assembly technology, dramatically improving the speed, quality and cost of OEM high-speed tire balancing processes. AutoW8t eliminates the most troublesome bottleneck in tire and wheel assembly operations: weight application. It is the first machine of its kind and was designed to be simple, maintenance-free and extraordinarily reliable.

AutoW8t is available in two different fashions. The first being a semi-automated system designed to replace bin picking and enable your team members to quickly perform their job with greatly increased accuracy. The second is a fully automated system that can accurately apply the weights in half the time it typically takes to apply weights.

Esys and 3M were named Automotive News PACE Award Winners for 2012. The PACE awards are recognized around the world as the industry benchmark for innovation. Esys, together with 3M, helped initiate a leap forward in tire and wheel assembly technology, dramatically improving the speed, quality and cost of the OEM high-speed tire balancing processes. This innovation has made wheel balancing easier and faster than ever, while reducing inventory and freeing up valuable manufacturing floor space. Click here to read the full press release.

Auto Weight Apply System

Auto Weight Apply System

The Auto Weight Apply (AWA) Machine is a fully automatic breakthrough that has forever change tire and wheel assembly processes. Designed to have a very small footprint, the AWA machine is typically installed immediately after a balancer. The 3M™ Wheel Weight Material is fed to the machine from a convenient material handling location where it is cut and applied with precision to both the curb side and car side planes of the wheel. Esys has streamlined and proven this sequence, making it cost effective while also improving quality and efficiency throughout the entire process.

Multi-Weight Apply

Multi-Weight Apply

The next generation of automatic weight apply is here.  Combing all of the functionality of the traditional AWA this machine is also capable of applying weight to flanges.  The Multi-Weight Apply (MWA) Machine applies the traditional 3M™ Wheel Weight Material and the new 3M™ Mechanical Replacement (MR) Wheel Weight Material.  This new technology allows for 100% automation of the weight apply process even in plants where steel wheels are predominant.  Just like the AWA, this machine is typically installed immediately after a balancer. Both types of weight material are fed to the machine from a convenient material handling location where it is cut and applied with precision to curb or car planes or flanges as needed.  This cost effective solution allows 100% automation and takes up an extremely small footprint..
Dispense & Cut System

Dispense & Cut System

The Esys Dispense and Cut System (DCS) is a machine designed for dispensing and cutting 3M™ weight coil stock for use in the balancing of automotive wheels. Esys combines the Wheel Weight Technology of 3M™ with its proprietary Dispense and Cut System to eliminate the use of lead weights, reduce inventory of clip on weights, eradicate waste and correct imbalances by dispensing precise weights on demand.The DCS is utilized in a manual weight apply station in place of traditional bins and weight picking. This proven system is designed to easily install and maintain into an existing weight apply station, delivering a precision cut weight directly to the team member applying the weight. We also can provide press tools to meet your needs or modify your existing tools.

Tire Pressure Monitoring Systems

Since 2001, Esys Automation has been helping to pioneer antenna technology for communicating with tire pressure monitoring systems (TPMS) in the manufacturing environment. In 2002, Esys helped integrate some of the first TPMS equipment installed in major auto plants. Customer response since then has been tremendous. Today, the Esys TPMS is employed in a large percentage of tire assembly operations around the globe.

In 2012 we set out to develop a solution that overcomes the issues manufacturers have when dealing with multiple TPMS sensors & suppliers. Our Gen 2 TPMS equipment has been specifically created to handle this challenge.

Data Marriage Systems

Data Marriage Systems

The primary function of a TPMS Data Marriage System is to gather the serial numbers of each TPMS stem after assemblies have been mounted on a vehicle. The vehicle requires the TPMS stem serial numbers in order to operate its on-board TPMS system. Our proven and reliable Esys Data Marriage System, provides the highest read rates on the market while also operating in some of the most demanding production environments. The Data Marriage System is made up of three primary components:

  • Main Control Panel that houses power distribution, control equipment, PLC, and HMI interfaces to operate the system.
  • Two TPMS receiving antennas staged on opposite sides of the line and triggered by the presence of a vehicle in station.
  • Back-up station – A TPMS Hand Held Reader and small control panel with an HMI interface provide back-up should the main station antennas fail to read or are damaged.
Handheld Readers

Handheld Readers

Esys Handheld Readers are typically used in conjunction with our on-line TPM Antenna Systems. This wireless reader can update the plant system with the correct data to program the vehicle, should data integrity become corrupt or a tire assembly require replacing. Some of our customers also use the Handheld Readers in very low production environments.Our readers are fully cordless and come with a rugged industrial case. They utilize a powerful Low Frequency wake-up signal and offer an optional integrated barcode scanner for reading vehicle ID#s. Multiple TPM frequencies and modulation decoding occurs in the same unit. Each unit stores TPM data for up to 50 vehicles and is supplied with a docking station for data transfer and battery charging.

Track & Trace

Track & Trace

TPMS antenna equipment is no longer limited to validating stem sensor functionality or programing the sensor ID to the vehicle. Today, many of our customers are using our state of the art equipment to track and trace their products. Our antennas can be used as an excellent RFID device to track products and associate critical process data to sensor IDs and ultimately vehicles. They can work in conjunction with the Tracker system provided by Esys or can be easily integrated into their own manufacturing execution system (MES) if one is already in place.

Verification Station

Verification Station

TPMS Verification Antennas are commonly installed in the tire and wheel assembly process prior to vehicle mount for quality and error proofing purposes. This ideal product will test the TPMS sensor in order to ensure that a correct stem is installed and that the tire has proper inflation. It also helps to track rejects and repairs, capture traceability data (weights, build parameters, inflation) as well as verify orders for proper sequence prior to shipment.We offer standard LF and RF receiver modules, which are mounted on a 730mm (29”) square antenna board for the activation and reading of TPMS devices in tire and wheel assemblies. This application is typically performed in a stop station on a conveyor system. TPMS Verification Antenna applications include:

  • Testing a TPMS sensor prior to assembly process
  • Error-proofing to ensure that correct stem is installed
  • Testing an assembly for proper inflation
  • Tracking rejects and repairs
  • Verifying the proper assembly order
  • Traceability data (weights, build parameters, inflation values, vehicle ID)
  • Confirm shipment and adjust inventory

Tire & Wheel Vision

Esys Tire and Wheel ID are capable of verifying or identifying up to 99 individual tire/wheel styles. The pre-integrated design is compatible with all other Esys-developed Tire and Wheel assembly solutions.

Operator Interface Benefits:

  • Teach new product with point and click features
  • Operator configurable — easily change, delete, or update styles
  • Real-time operator feedback on production status and failure modes

System Highlights:

  • Uses the power of Cognex VisionPro with PatMax
  • Interfaces with the plant database or tracking system to receive an anticipated tire/wheel style and provide a pass or fail status
  • Can operate in code detect mode to match the tire/wheel to the best possible option in the dictionary without the use of a tracking system

Having Problems Keeping up with Constant Product Changes?

Tire Vision System

Tire Vision System

The Tire Vision System utilizes two cameras and an optical beam array in combination to perform five means of tire differentiation:

  • Tread Identification
  • Color Stripe Detection
  • Side Wall Raised White Letter Identification
  • Color Label or Paint Dot Detection
  • Tire Height Detection (Beam Array)
Wheel Vision System

Wheel Vision System

The Wheel Vision System utilizes one camera to perform three means of wheel differentiation:

  • Pattern Identification
  • Finish Detection
  • Color Detection

Tracker Solutions

The Tire and Wheel Tracker Solution provided by Esys Automation, is the industry’s only comprehensive scheduling, tracking and traceability application designed specifically around Tire and Wheel assembly operations. It has proven capabilities such as its Program Logic Controller (PLC)-based architecture, which offers extreme reliability and high-speed data communications. The application provides a single point of operator control to disseminate and compile detailed part information across a distributed system of assembly machines.

Other capabilities include:

  • High speed production – can deliver data to equipment in less than 125m seconds
  • Increases data accuracy – eliminates need for shift registers
  • Minimizes production interruptions – 2 to 4 hour buffer from the upper level broadcast system
  • Convenient – a single point to insert or remove assemblies definitions from production system
  • Customizable – PLC-based design

Flexibility by Design

The Tracker database synchronizes production equipment according to a “build manifest”, rather than traditional FIFO/shift register methods. Operators can manually adjust build data via a local user-friendly interface, eliminating the need to remove and reload parts into the system to capture the correct data. This approach allows production to continue even when an individual piece of equipment malfunctions and has fallen out of the sequence. Avoiding direct impact to the rest of the assembly process results in substantial production throughput and cost savings.

Scheduling

Scheduling

The Esys Tracker provides faster and easier scheduling by supporting the download of master production requirements as well as manual inputs to generate a dynamic build queue for tire and wheel assembly production lines. It provides a single interface in order to add, edit, and review production work orders and data. It then marries this information to individual machines in order to assure accurate build sequences.A user-editable “dictionary” provides convenient, single point management of production build parameters to improve system accuracy. For example, even if the plant’s data system only provides for a single tire code, operators can define related style-based tire diameter and load ratings to feed assembly equipment. Simplifying all system dictionaries into a single interface, allows for easier management of constantly changing wheel styles as well as increases in productivity and simplification in machine setup.

Tracking, Traceability, Genealogy

Tracking, Traceability, Genealogy

Esys understands that product identification is an important enabler of traceability and Error-Proofing operations. The Esys Tracker not only feeds build parameters to assembly equipment, it also collects production information in real time from tire pressure monitoring, vision, balancing, and other sources. This data can then be integrated with master production records, and is correlated with the product “as-built” histories.

Turnkey Tire & Wheel Assembly

Esys is a leading global supplier of tire and wheel automation solutions, with an installation base of over 60 locations globally. Esys has integrated Turnkey Tire and Wheel systems for OEMs and Tier one suppliers. Our ability to coordinate multiple suppliers is the key. Our strength is being flexible with supplier selection to get the best fit possible.

An Esys team of professionals can lead your project from the early planning stages up through planning and simulation to commissioning and support, performing all the trade disciplines required. Coordination is mandatory for a tire and wheel process to come together to provide years of reliable efficiency. Our project managers will ensure your project is executed properly.

Error Proofing

Error Proofing

Esys provides several solutions for error-proofing Tire & Wheel Assemblies in your manufacturing processes. We offer Vision systems, TPMS, Torque monitoring, pick to light as well as barcode reading. Let our team of experts demonstrate how our solutions can assist your business.

Process Planning & Simulation

Process Planning & Simulation

Let the Esys team of engineers assist your business with the planning of your tire and wheel assembly operation. From an entirely new process to simple improvement efforts, Esys will provide the right professionals with the capacity and expert understanding required to achieve all of your performance goals and objectives.

Roller & Belt Conveyor Systems

Roller & Belt Conveyor Systems

Esys is an experienced and reliable provider of roller and belt conveyors for our customers. Our services start from the conceptual phase right up through commissioning and eventual full-production capacity. We will assign a team of qualified individuals to design, fabricate, test, and mount devices for control. If required, we can set-up and replicate your conveyor to run just as it will in your facility before it is actually shipped to your facility. In addition to providing complete control systems for conveyors, we can also integrate tracking and traceability systems into your application.

Wheel & Tire Load Processing

Wheel & Tire Load Processing

Esys provides all the required equipment for tire and wheel handling in the load and unload process. We recognize that every customer’s needs are unique when it comes to these processes. Therefore, our team of experts will custom design the right system, specifically for the processes of your business such as Lift assists, lift table, material racks, dun-age removal, barcode printing, error-proofing, scheduling systems and marquees for assisting workers. Let us demonstrate how we can help address all of your system’s challenges.

Balancing - Key Providers

Balancing - Key Providers

Esys integrates complete time rooms by working with many different reliable Balancer Companies, who are key industry providers. These companies may include but are not limited to: Kokusai, Micropoise, Schenck Ro Tec and others.

Mount & Inflate - Key Providers

Mount & Inflate - Key Providers

Esys integrates complete tire rooms by working with many different reliable Mount and Inflate companies, who are key industry providers. These companies may include but are not limited to: SchenckRotec, Dominion Technologies, Fori Automation, Burke E Porter, Nissan Altia, etc.