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Sorion Electronics

The Sorion Group's logo

Contact Sorion

Sorion
Magreal Industrial Estate,
Freeth Street, Birmingham,
West Midlands, UK.
B16 OQZ

Tel: 0121 454 8966
Fax: 0121 454 8970
Email Sorion

Sorion Menu

The links below go to the individual page. To browse the Sorion Electronics site with full frames and graphics click on the Home link below or at the bottom of every page.
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Sorion Product Overview

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.
 

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

A selection of Assembly Aids ranging from a simple battery supply box to component fuction control boxes
Electrical / Electronic assembly aids.

Duracon Ruggedised Industrial Connectors
DuraconTM Ruggedised Industrial connectors and harnesses.

Land Rover TD5 Engine Test - Land Rover
End of line Hot & Cold engine test facilities.

Examples of batch build
Batch build of Electrical / Electronic systems  and harnesses.

Sorion your Partner for Electronic Test | Sorion Electronics Site


Electrical Test Systems

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:

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

      Flat Panel Display installed in a Rittal enclosure                 Data Capture Station

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.

Build Specifcation  Part Number Check

Graphic Part Editor

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 OrionTM database system that is fully web based.  For further information on OrionTM 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 Database System

OrionTM Database System Overview

Sorion has developed a wholly new factory database system OrionTM. 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.

Benefits
  • Enhanced Product Traceability
  • Complete build system data capture, storage and analysis
  • Analysis tools to support process and product improvement
  • Flexibility to receive data from a wide range of sources
  • Easy to use web based monitoring and reporting

    Features
  • Windows 2000, XP compatible
  • Runs on any hardware platform running Windows
  • Uses industry standard OBDC compliant database (SQL server)
  • Powerful yet flexible database schema handles data for most applications
  • Scalable design for small to corporate deployment

    Applications

    The OrionTM system is targeted at high volume manufacturing where component traceability and data analysis is required, examples of such industries are shown below:

    Automotive - Final Assembly

    • Engines, Gearboxes, Chassis
    • Steering and Suspension
    • Braking Systems
    • Electrical and Electronic systems
    • Fastening data (DC tooling)
    • Fluid Fill data (Brakes, Aircon, Oils Suspension, etc.)
    • Airbag

    Automotive - Tier One / Sub-assembly

    • Interior trim
    • Heater / Aircon assembly
    • Cockpit assembly
    • Airbag build
    • Rotary coupler assembly

    Other Industries

    • Household Appliances
    • Hand Tools
    • Garden Tools
    • Industrial and Marine engines and equipment

    The following are the major elements that make up OrionTM and the hardware requirements of an OrionTM installation.

    • Orion QTS - Quality & Traceability System (Shop Floor Element)
    • Orion NET - Orion Client Network Interface Component
    • Orion PDM - Process Definition and Management (Editing Tools & Parts Definition)
    • Orion QTR - Quality & Traceability Reporting - ( Web Based Analysis )
    • Orion SMT - System Maintenance Tool - ( Web Based Monitoring )

    Sorion offer customisation of our core products engineered to suit your requirements. For more information please contact Sorion.

    Sorion your Partner for Electronic Test | Sorion Electronics Site


  • Sub-assembly test solutions

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

    Freelander Door Test (actual size 360mm x 200mm x 150mm)  The multi cavity connector used to connect to the front door main harness

    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;

    bullet

    Electric mirror movements

    bullet

    Heater mirror current draw

    bullet

    Power fold mirror movements

    bullet

    Front window lift / lower

    bullet

    Rear window lift / lower

    bullet

    Front and rear door speaker test

    bullet

    Front door central locking test

    bullet

    Rear door central locking test

    bullet

    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 DuraconTM ruggedised connectors.

    Sorion your Partner for Electronic Test | Sorion Electronics Site


    Assembly Aids

    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.

    Power Folding Mirror Setting / Test Unit

    Vehcile Electrical Test Body Connection Set


    Download the Assembly Aids Flyer (70

    Sorion your Partner for Electronic Test | Sorion Electronics Site

    4kb pdf)


    Ruggedised Connectors

    DuraconTM Ruggedised Connectors

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

    Examples of Simple Duracon Connectors

    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 DuraconTM connectors to suit virtually any harness or unit connector (subject to evaluation).

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

    DuraconTM 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.

    Examples of the Gold Plated Spring Loaded Pins Used

    DuraconTM 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.

    Sorion can provide fully built up harness assemblies as well as connectors

    Complex multipart DuraconTM connectors can be supplied and an example of these is shown below
     

    Multi-connector and a mating pair of machine connectors

    J1962 - OBD Connectors

    Duracon Selector Guide

    Sorion your Partner for Electronic Test | Sorion Electronics Site


    Engine Test Systems

    Engine Test Systems

    Land Rover TD5 Cold Test

    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.

    Cold Engine Test       Hot Engine Test

    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.

      Calibration Screen

    Engine Data Capture Screen  Oil Pressure Trace

     

    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

    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

    Sorion's J1962 Compliant ruggedised connectors are specifically designed for harsh manufacturing environments

    Serial / Digital I/O Adaptor

    Ruggedised Crocodile Clips

    01M28A Ruggedised Crocodile Clips for Automotive Assembly

    Sorion your Partner for Electronic Test | Sorion Electronics Site


    Prototype and Low Volume Electronic Assembly

    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.

    Vero board prototypes and finished PCB assemblies

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

    Various batch built PCBs and Assemblies

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

    Batch built harnesses

    Sorion your Partner for Electronic Test | Sorion Electronics Site


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