MSI MS-1A91 Industrial Panel PC Enables Real-Time Press-Fit Monitoring for a European Automotive Measurement Systems Manufacturer
An European manufacturer of automotive measurement systems deployed the MSI MS-1A91 Industrial Panel PC as an HMI and process monitoring terminal at its press-fit and assembly workstations.
Overview
In automotive manufacturing and assembly, press-fitting is widely used to install bearings, bushings, gears, and other powertrain components.
Press-fit quality depends not only on whether a component reaches its final position, but also on how force changes throughout the insertion process. Insufficient force, excessive pressure, component misalignment, or dimensional variation may affect assembly quality, structural integrity, and long-term reliability.
In this case, a European manufacturer of automotive measurement equipment needed a more intuitive way to monitor press-fit processes in real time. The company selected the MSI MS-1A91, a 10.1-inch fanless Industrial Panel PC, as a standalone HMI dashboard installed beside the assembly workstation.
By integrating the panel PC with press-fit equipment, programmable logic controllers (PLCs), and measurement systems, the solution converts raw force and displacement data into real-time curves, Pass/Fail results, and abnormality alerts.
Operators can quickly understand the status of each press-fit cycle without having to interpret large volumes of raw data.
Application Challenges
Limited Visibility into the Complete Press-Fit Cycle
Traditional press-fit equipment may display only the final insertion position, maximum force, or a single measurement result.
This does not provide a complete picture of how force and displacement change throughout the process. Even when the final position appears correct, abnormal force patterns, component binding, misalignment, or excessive compression may still occur.
Quality Decisions Relied on Manual Interpretatio
When operators must manually review measurement values or rely on personal experience, quality standards may vary between employees and production shifts.
Manual evaluation also increases the workload for shop-floor personnel and may delay the detection of process deviations.
Nonconforming Parts Could Enter Downstream Operations
If a press-fit abnormality is not detected immediately, a defective component may continue into subsequent assembly or testing stages.
This can result in additional disassembly, rework, scrap, production delays, and quality investigation costs.
Commercial Computers Were Unsuitable for Shop-Floor Deployment
Automotive assembly environments may expose equipment to dust, oil, liquid splashes, and extended operating hours.
When standard commercial computers are installed next to production machinery, cooling fans may accumulate dust, cleaning can become difficult, and maintenance requirements may increase.
Existing Equipment and Limited Installation Space
The new monitoring solution had to exchange data with existing press-fit machines, PLCs, and measurement equipment while fitting into a space-constrained workstation.
The customer therefore required a compact Industrial Panel PC with flexible connectivity and installation options.
Application Benefits
Real-Time Force-Displacement Curve Visualization
The monitoring system continuously receives data from press-fit machines, PLCs, or measurement equipment and converts each operation into an easy-to-understand force-displacement curve.
Operators can immediately see whether the component was inserted correctly and whether any abnormal changes occurred during the process.
Automated Pass/Fail Quality Evaluation
The application software compares each press-fit result against predefined acceptance criteria.
If the force, displacement, or curve characteristics fall outside the permitted range, the dashboard displays a Fail or NG result. This allows operators to inspect or isolate the affected part before it enters the next production stage.
Immediate Displacement and Process Alerts
When the system detects an incorrect insertion position, insufficient force, excessive force, or another process deviation, it can notify operators through on-screen messages, warning lights, or audible alarms.
Early detection allows personnel to inspect the component, tooling, fixture, or machine condition before the same issue affects additional parts.
Consistent Quality Standards Across Production Shifts
Quality evaluation is performed according to predefined process limits rather than individual operator judgment.
This provides a consistent inspection standard across different employees, workstations, and production shifts.
Clear Visualization of Complex Measurement Data
The standalone dashboard transforms raw measurement data into curves, numerical values, quality results, and alerts that are easier for operators to understand.
Process engineers can also use the curve data to compare normal and abnormal press-fit cycles and investigate possible issues involving components, tooling, or equipment.
Easier Integration with Existing Production Equipment
The Industrial Panel PC provides Ethernet, USB, and serial communication interfaces for integration with PLCs, machine controllers, and measurement devices.
In many applications, manufacturers can retain their existing press-fit equipment while adding real-time visualization, quality evaluation, and alarm functions.
Features and Benefits
Conclusion
Automotive press-fit quality cannot be evaluated solely by checking the final insertion position or a single measurement value. Manufacturers must understand the complete relationship between force and displacement throughout the process.
By deploying the MSI MS-1A91 Industrial Panel PC, the European measurement systems manufacturer created a standalone monitoring dashboard for automotive press-fit and assembly workstations.
The solution converts complex measurement data into clear force-displacement curves, Pass/Fail results, and displacement alerts. This allows operators to identify process deviations earlier and address nonconforming parts before they enter downstream operations.
The MS-1A91 provides a fanless design, an IP65-rated front panel, a 10.1-inch touchscreen, flexible communication interfaces, and a compact form factor. These features provide a reliable hardware foundation for shop-floor operation, existing equipment integration, and flexible workstation installation.
For automotive measurement equipment manufacturers, system integrators, and component suppliers, real-time force-displacement monitoring can improve process visibility, reduce quality risks, and support the continued pursuit of higher production yields and zero-defect manufacturing.
Product Information:
https://ipc.msi.com/product_detail/Industrial-Panel-PC/Front-IP65/MS-1A91
FAQ
Q1: Is the Industrial Panel PC suitable for demanding production environments?
Yes. Its fanless design and IP65-rated front panel help reduce the risk of dust and liquid splashes entering the system from the front. The fanless architecture also minimizes dust buildup and fan-related maintenance, making it suitable for long-term deployment on the shop floor.
Q2: Can operators use the touchscreen while wearing work gloves?
Yes. The 5-wire resistive touchscreen supports pressure-based operation, allowing operators to navigate screens, confirm results, and acknowledge alarms while wearing work gloves. Actual performance may vary depending on glove thickness and material, so on-site testing is recommended.
Q3: Is the display easy to read in a factory environment?
Yes. The 10.1-inch, 500-nit display provides clear visibility of force-displacement curves, Pass/Fail results, and warning messages, helping operators quickly understand process status and respond to abnormalities on the production floor.
Q4: Can a Real-Time Monitoring System Be Integrated with Existing Press-Fit Machines?
Yes, provided that the available communication interfaces and data formats of the existing equipment are confirmed in advance.
An Industrial Panel PC can exchange data with PLCs, machine controllers, and measurement equipment through Ethernet, USB, or serial communication. In many projects, the existing press-fit machine can be retained while visualization, quality evaluation, and alarm functions are added.
Q5: What Should Manufacturers Consider When Selecting an Industrial Panel PC for an Automotive Assembly Line?
Key considerations include display size and brightness, touch technology, fanless operation, front-panel protection, power input range, mounting options, and the communication interfaces required for existing equipment.
Manufacturers should also confirm that the operating temperature, available installation space, and environmental conditions comply with the selected system’s specifications.