On April 21st, the first experience officer of the first enjoyment plan will lead you into the Changan UNI-T production and manufacturing base, in the form of live broadcasting, the whole process of visualization, leading users to visit the intelligent production process of UNI-T, explaining the production story behind UNI-T, technical difficulties and advanced technology. Behind the visible intelligent interaction, there are more invisible intelligent processes to escort the high quality of UNI-T.
Changan Automobile's UNI-T production base, with a total investment of 2.5 billion yuan, covers an area of 475,000 square meters, and has a design capacity of 260,000 vehicles/year, and was officially put into operation on May 15, 2018, after 14.2 months of construction and development.
Changan Automobile UNI-T production base mainly produces SUV, MPV and other models, the production line adopts advanced technology and equipment. Stamping workshop for the fully enclosed high-speed dual-arm mechanical production line, the production beat of 15 times / min, low noise and environmental protection, while the use of synchronous control, CNC hydraulic pad, fully automatic mold change and other key technologies. Welding for the first time using 4 models of flexible line, automation rate of 50%. Paint shop for water-based 3C1B + VOC end incineration process, using the bottom of the rubber extrusion, bottom sealing, spraying robot. Final assembly workshop adopts liftable large skateboard, intelligent adaptation to the operating height, chassis automatic assembly AGV, glass automatic extrusion, torque control system. At the same time, with the logistics concept of "shorter time, lower cost, less inventory, less space", we strive to build a first-class modern factory.
Stamping Workshop
The stamping workshop has a total floor area of 25,820 square meters, with two 2400T double-arm automatic high-speed closed stamping production lines, with the highest production beat of 15 (punches)/minute, and the maximum annual capacity of the workshop reaches 7 million (punches), which represents the most advanced large-scale complete set of stamping equipment in the international production level. In accordance with the lean, agile, flexible production concept, the use of synchronous control, fully automatic die change, energy-saving CNC tensioning pads, all-digital monitoring and other key technologies, mainly responsible for the production of large-scale external coverings of Changan Automobile models stamping tasks.
Stamping production line: It is an advanced intelligent system production line, which adopts fast and efficient automatic die change system, and it takes only 3 minutes to change the die successfully, which improves the production efficiency of the automated line and the safety of the equipment, and it is more in line with the requirement of flexible production of the automated line, and it meets the actual production needs of the modernized automobile and stamping factories.
Totally enclosed stamping: the stamping workshop adopts advanced hydraulic pad technology, the sheet molding process can be controlled by the parameters, which ensures good molding and rigidity of the parts. Stamping workshop adopts fully enclosed large stamping equipment, dust and noise reduction can effectively reduce the noise decibel to the national standard of 85 decibels or less.
Traveling crane spreader: In the improvement of improvement, the workshop staff fully use their own wisdom and talent, make full use of the existing resources, design and produce their own traveling crane spreader, installed in the production line traveling crane, reduce the time of stamping production line die change, according to the production of 200 days a year, it can save about 200 hours a year, greatly improve the efficiency of die change, and reduce the labor intensity of the operators.
Multi-functional three-dimensional warehouse: stamping workshop storage end pickup multi-functional three-dimensional warehouse, can realize the end pickup in and out of the warehouse management automation, data maintenance query, inventory analysis, print reports and other functions, can be completed in less than 90 seconds end pickup automatic access, saving area of 1800 square feet, in line with the requirements of the modernization of the workshop agility production.
Welding shop
Welding shop covers a total area of 42,000 square meters, mainly consists of a flexible main line and a rigid main line and body storage and transportation line, the design capacity of 260,000 units/year, the maximum production capacity of 390,000 units/year. In order to emphasize the leading capability of intelligent welding quality, the workshop is equipped with 336 sets of fully automated equipments with international first-class quality.
Body-in-white precision of 98.9%: Since the start of production, the number of batch quality accidents has been "0", and the body-in-white precision has so far climbed to 98.9%, which is ranked the first among all manufacturing bases of Chang'an Automobile.
Precision Cultivation Center: It is just like a super large X-ray detector, through 2 sets of cantilevered CMM (Hexagon CMM imported from Switzerland, the maximum load capacity ≥ 8000Kg, to meet the needs of large SUVs, MPVs measurement; single-arm mode spatial measurement accuracy MPEE ≤ 70um, double-arm mode spatial measurement accuracy MPEE ≤ 90um), 2 sets of high-precision laser tracking instrument, 12 sets of high-precision laser tracking instrument, 12 sets of high precision laser tracking instrument, and 12 sets of high precision laser tracking instrument, the precision of the white body has increased to 98.9% so far, ranking the first in each manufacturing base of Chang'an Automobile. The whole process of vehicle welding and main assembly is monitored by 100% dead-end monitoring of parts and components, jigs and fixtures testing, mold precision and process control, and logical correlation analysis and data integration are carried out for abnormalities, so that abnormalities generated in the body-in-white welding process are invisible, and problems within the tolerance range of 0.8-1.2mm can be monitored by 100% of the whole process. All the problems within the tolerance range of 0.8-1.2mm can be avoided by 100%, and the precision monitoring of body-in-white can be improved by 50% compared with the conventional one. This kind of model is unique and leading in the whole industry.
Visual Inspection System: The most basic automatic production line for the lower body (chassis) of the whole vehicle welding. In order to ensure the sealing effect of the chassis, the Cognex Eagle Eye from Germany was introduced at the beginning of the design. --? The visual inspection system can verify the sealing performance of the extruded rubber 100%. After sufficient verification, the front wall plate is grabbed at the right side of the workstation and transferred to the lower body for assembly and connection through the EMS (conveyor system).
Improvement of welding point hitting indication: Because the rear floor is covered with other small parts during welding, there are a lot of blind spots, so you can only weld blindly according to your feeling and experience, which often leads to half-point welding and welding injuries to the parts, which makes the quality assurance difficult. After the workshop, the team continued to verify the use of laser pointer instructions to hit the point. Determine the laser pointer installation position after the pointing operation, neither affect the welding tongs in and out, also does not affect the welding operation, through the improvement of a substantial reduction in the chance of weld injuries, reduce the repeated aiming action, single operation shortened by 5 seconds, annual savings of 125,857 yuan in rework labor costs.
Automation line robot: equipped with 117 robots produced by KUKA from Germany, 100% automatic welding and gripping of parts, able to quickly implement the full flexibility of switching between the various models of Chang'an Automobile, between the workstations using the most stable and efficient high-speed roller transfer, transfer time ≤ 4S, compared with the traditional transfer efficiency by more than 200%, to achieve precise positioning, smooth operation, efficient transmission, and precise positioning. It realizes accurate positioning, smooth operation and efficient transmission, which is in the leading position in all manufacturing bases of Changan Automobile.
Online Inspection System: This system comes from Cognex of Germany, and is currently at the first-class leading level in the vehicle manufacturing industry. It is an online non-contact measurement system based on visual inspection and laser measurement technology, which breaks through the limitations of traditional coordinate sampling inspection and realizes 100% monitoring of the fluctuation of the whole vehicle's process dimensions to provide effective data support for the improvement of the process. Here, in order to ensure that 100% no defective products flow to the next station, the curing VIN engraving embossing effect has also been improved, thoroughly improved by manual inspection embossing method, in the embossing robot to increase the light source and CCD high-definition camera (later can be connected with the visual inspection system), connected to the manual station monitor, real-time embossing effect transmission in the monitor. And in the bit of work instructions to increase the check embossing effect steps to ensure that the embossing state. Through the improvement of the annual savings of 117,195 yuan in rework and energy costs.
Door line: process layout and Toyota, Shanghai Volkswagen and other international and domestic first-class vehicle enterprises benchmarking, the use of symmetrical layout of the district, effectively avoiding the problem of high inventory of various varieties of doors, site occupancy reduced by more than 30%, shorten the logistics and distribution time by more than 25%. In the process of buckling, we adopt four-mode inverted library system, to realize the extrusion, buckling full-automatic, and realize the shortest time of a single press molds to switch each other, can reach four models of synchronous buckling, the real meaning of the whole process of flexible welding.
Floor Chain Adjustment Line: This is the first floor chain in the same industry in China with a beat of 65JPH. Here, after the upper and lower bodies are put together, carbon dioxide shielding welding, high-position roof, five doors and one cover, and the adjustment of the white body will be completed in turn. The mission of the whole welding process has been successfully accomplished, and this complete and flawless white body is being arranged in an orderly manner to enter the painting process.
Finishing Workshop
Changan Automobile UNI-T Production Base Finishing Workshop, as the largest workshop in Changan Automobile, covers a total area of 91,500 square meters, mainly consists of 9 main lines, 6 sub-assembly lines, 2 auxiliary conveyor lines, 2 inspection lines and 2 rain lines, with a design capacity of 260,000 vehicles/year, and the maximum production capacity of 390,000 vehicles/year. In order to show the leading ability of intelligent and digital assembly, the workshop is equipped with 149 sets of fully intelligent and automated equipments with international first-class quality, accounting for 80% of the total, realizing the intelligent monitoring and management of decision-making among production, equipment, quality and logistics. Production efficiency increased by more than 15%, resource utilization rate increased by more than 10%, product development cycle shortened by more than 25%, operating costs reduced by more than 15%, product defective rate reduced by more than 25%, the operation of key manufacturing equipment monitoring rate reached 100%, assembly workshop manufacturing intelligence out of the industry's leading level.
The production line of final assembly workshop: the production line of final assembly workshop is designed to have a beat of 65JPH. The appearance inspection line, that is, the end of the main line of the final assembly workshop, is where the whole vehicle goes through the five-door debugging, appearance inspection, and gasoline refueling before coming off the line. There are two completion lines, mainly engaged in seat, door, positive pressure inspection and refueling. It is worth mentioning that the four-in-one refueling equipment adopts domestic design and foreign processing form, and the refueling precision can reach 95%, thus guaranteeing the refueling quality of our products.
Door assembly station: when the car body from painting into the assembly to reach the first station of the production line, the door will be removed, the door parts assembly in the door sub-assembly line, and then through the transportation line directly to this place, door assembly, this production line design greatly facilitates the assembly of the car body interior, saving 32 seconds / car assembly time.
Chassis line area:***There are 54 stations in two lines, which are mainly engaged in the assembly of chassis parts such as engine, rear axle, fuel tank, tires, exhaust pipe, etc. In the area of off-weight torque control, the production line is mainly engaged in the assembly of chassis parts such as engine and rear axle. In terms of torque control, there are 75 sets of torque control equipments in ****, adopting French horse head control system to ensure 100% torque qualification rate. On our left is the engine and rear axle assembly station, we are using the Shinsong double lift chassis combined assembly of large AGV, to achieve the engine and rear axle assembly at the same time.
Tire assembly line area: the fastest beat is 12S to complete a tire assembly, which is the highest automation level of tire assembly line in China. Tire assembly line assembly is completed, through the second floor platform conveyor to the tire assembly station, and will be transported to the tire spiral design down to the production line, which not only ensures the inventory and reduces the wear and tear of tires in the manufacturing process.
Assembly workshop logistics area: workshop logistics area of 11,000 square meters, according to the different functions of the logistics area, divided into inventory, packing, centralized sorting of the three functional areas, of which the inventory area of the process route, the site area reserved as the basis for the principle of distribution distance, logistics path for the principle of single-circuit "modular" planning. The planning of pallet storage space 1537, shelves storage space 287; packing area based on MES system, the introduction of Kitting picking system, AGC synchronous distribution system, 270 types of materials (single-vehicle type) packing, AGC single set of materials to achieve intelligent synchronization of the distribution, the rate of intelligent 29%; centralized sorting area of the 196 types of materials, the use of electric trailer distribution, the rate of synchronization up to 65%.This article comes from the author of the automobile home car, does not represent the views of the automobile home position.