Desenvolvimento e implementação de uma arquitetura padronizada de controle para bancadas automatizadas em processos de montagem automotiva: um estudo de caso

Abstract

The present study brings as its theme, the development and implementation of standardized technological architectures as factors that imply the competitiveness of systemist industries, among them, those that belong to the current automotive sector. It is based on the premise of presenting a case study developed at Alfa Componentes Automotivos, with the objective of designing and implementing modular hardware and software control architecture for automated assembly benches of optical assemblies. The method was based on a mixed approach (quali-quantitative) and of an applied nature, based on participant observation procedures, field diaries, and documentary analysis of technical reports collected between months of January and February 2026. The results showed that the replacement of permanent conjugated electrical wiring by disconnect able multipolar industrial outlets optimized corrective maintenance routines. From the software's perspective, the automation of the loading of sensor, torque, and angle parameters via structured Excel spreadsheets eliminated typing errors and reduced to zero the 400 hours of outsourced external programming required in the old model (valued at the technical rate of R$ 130.00/h in 2025). From an ergonomic point of view, the rigid attachment of interfaces and controls to the anthropometric elevation of 1,200 mm eliminated the chronic history of articulated monitor breakages due to collisions with machine objects and mitigated the operators' postural fatigue. Important divergences were found in relation to academic literature, such as the rejection of digital encoders due to electromagnetic noise, requiring the return to traditional analog feedback from 0 to 10 V for table leveling, and the superiority of physical plastering over the flexibility of adjustable ergonomic adjustments. It was concluded that the dimensional standardization (1,200 mm/1,500 mm) shielded the company's assets against the obsolescence of products commanded by the automakers, limiting the future investment strictly to the development of internal fixation devices (R$ 40,000.00 to R$ 50,000.00) in replacement of the acquisition of new complete benches (R$ 220,000.00).