3. Key technology of engine agile flexible automatic line

(1) Digital design of the production line The design of a new generation of flexible automatic line production line requires the use of co-simulation technology in accordance with the lean and agile concept, enabling users to select technical and economically optimized solutions. Automakers using this digital manufacturing technology have increased their product-to-market speed by 30%, redesigned designs by 65%, and production planning processes by 40%. Its successful application abroad has set a good example for our independent innovation.

(2) High-speed machining center RMT with reconfigurable module as the core technology of the new generation of machining cylinder and cylinder head production line. It is characterized by modularization, high speed, and dry cutting. Only modularity can achieve reconfigurability, and only modularity can significantly reduce manufacturing and usage costs.

(3) On-line detection of online testing equipment for the quality of the engine block/cylinder head joint surface. In order to realize on-line precision detection under high-volume and high-productivity conditions of automobile engines, the resolution of the detection equipment is required to be 1 μm, and the measurement period of the entire measurement shape is within several tens of seconds, and the measurement points reach several million or more. At present, it is totally dependent on imports, and it is urgent to make breakthroughs through innovation.

(4) Flexible fixtures Flexible fixtures are the soft underbelly of Chinese manufacturing companies and need to be proficient in engine manufacturing processes. Foreign engine production line suppliers are mastering the engine manufacturing process, and their flexible fixture prices are approaching machine prices. For example, when an engine company in China imports a German engine production line, the other party proposes 50,000 euros per station flexible fixture, and the domestic price is 6000 yuan per station.

(5) The logistics system is regarded as “the second type of production”, including automatic loading and unloading, workpiece transfer storage and transportation, and real-time factory logistics system. Will greatly improve the efficiency and reliability of modern engine production. Zero stock availability is possible. Advanced plant logistics systems are key to achieving lean and agile modern engine production. The latest development in automatic loading and unloading is the automatic loading and unloading of robots (manipulators) to increase versatility and flexibility.

(6) Information system automatic line CNC control system must control the process equipment system (including machine tools, flexible fixtures, intelligent tools, online detection systems, etc.), but also control the logistics system. The essence belongs to the category of factory automation. Its complexity is not just comparable to controlling a single machine. There are only a few top companies in the world that have this ability, and China is currently blank.

(7) The automatic line reliability technology needs to meet the requirements of the entire automatic line process capability index Cpk value ≥ 1.67, and the average trouble-free working time MTBF ≥ 3000h. Therefore, the process equipment system (machine tool, flexible fixture, intelligent tool, online inspection system, etc.), logistics system (automatic loading and unloading, workpiece transfer storage and transportation, real-time factory logistics system, etc.) are required, and the engineering capability index of the automatic line CNC control system is required. Meet Cmk, MTBF value.

4. Typical high speed machining center with reconfigurable modules

A number of Japanese companies have introduced a new solution for solving large-scale complex parts of large-scale production and processing of automobiles, which is composed of multiple modules to form a production line. These three modules are essentially compact vertical machining centers, horizontal machining centers and vertical turning centers, as shown in Figure 1. Take Mori Seiki's products as an example (the same below), the machine width is only 680mm, so it is "compact", in order to save the area of ​​the production line. Moreover, the widths of the three modules are strictly consistent, and the lengths are consistently about 2130 mm, that is, the required floor space is the same, that is, the positions are interchangeable, and the length of the production line is not changed when the replacement is performed. In this way, the production line is easy to reconstruct, so it is called "reconfigurable". The three modular worktables (the turning center is the chuck spindle centerline) are fixed (ie the three-axis motion is on the main shaft, as in the three-axis unit that appeared before), and the height from the ground is strictly the same, the top surface, The front and side spaces are open, all of which are designed to facilitate the automatic transfer of workpieces.

At present, these parts are generally machined by special machine tools. The purpose of innovating this line is to replace the special machine tools with high concentration of processes with process-dispersed production lines. The new idea is that in terms of productivity and floor space, this line is likely to be less than a dedicated machine. However, in the era of diversification, the design of parts has changed frequently. Once the design changes, the dedicated machine needs to be discontinued and even reinvented. This line is flexible and reconfigurable, allowing it to quickly adapt to frequent changes in the design of the workpiece.

Special machine tools are difficult to design and manufacture, and the cycle is long, resulting in high cost and high price. The three modules of this production line have a large degree of generalization, small difficulty in design and manufacture, short cycle and low price.

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