Automation – Page 156
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ArticleHarnessed dress-packs for welding robots
igus says it now offers fully assembled dress-packs for rapid replacement of energy chain systems on welding robots. The company explains that these can be custom designed, drop-in replacements, that can be connected quickly and minimise downtime.These packs consist of a multi-axis triflex R energy chain, filled with chainflex cables ...
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ArticleSmall-boring tools
New versions of the 105 Supermini are now available for boring, internal grooving, chamfering, threading, broaching, facing and parting-off exotic alloys and steels, says Horn.The company says these tools feature a new coating, substrate and microgeometry; the carbide inserts are designed to machine bores in highly alloyed materials from 0.2mm ...
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ArticleHuman-robot gap and flush measurement
Nextsense says its Calipri model series for the gap and flush measurement now includes a model variant (C12) suitable for the use in the human-robot collaboration (HRC) area.The company says the C12 variant has been applied to an HRC robot operating with a German premium segment car manufacturer. The HRC ...
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ArticleCompact structured light sensor
LMI Technologies says its Gocator 3210 stereo snapshot sensor is suitable for 3D inspection, quality control applications. Features include two 2-megapixel cameras for high-resolution 3D snapshot scans, a large FOV (120 x 85mm) for picking up multiple features at once, and onboard hardware acceleration to achieve 4Hz for full size ...
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An order for progress
After the dips in demand of recent years, car makers in Brazil and Argentina anticipate an upturn in market fortunes and a boost in vehicle productionEmbattled vehicle makers operating in Brazil are predicting a return to growth in 2017 after the market sunk last year to nearly half its 2012 ...
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ArticleFast curing composite matrix resin
To meet the requirements for automated, short production cycles of composite components, Henkel says it has developed Loctite Max 2 composite matrix resin for RTM processes.The company claims this two-part polyurethane-based product is fast curing, and because of its low viscosity, rapidly fills the mould and quickly, resulting in short ...
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ArticlePortable laser tracker
Faro claims its latest generation of Vantage laser trackers is suitable for large-scale metrology applications, including assembly alignment, part and assembly inspection, machine installation and alignment, and reverse engineering.This product family consists of the VantageE with an operating range of 25 meters and the VantageS with an operating range of ...
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ArticleBMW modernises production areas
Germany – The OEM is cutting “ergonomically unfavourable and strenuous tasks” and enabling personnel to “apply their unique cognitive skills to the best effect”. By the end of 2017, it will use 60 lightweight robots, 230 smart gloves and 64 exoskeletons.“The digitalisation allows the BMW Group to tap a growing ...
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ArticleGestamp acquires plant at Pitești
Romania – The Spanish company has bought a majority stake in the operation through its Turkish subsidiary, Beyçelik Gestamp. It plans to increase turnover by manufacturing more added-value components for vehicle-makers.The plant on the edge of Pitești, an automotive production hub, has a 200-strong workforce and currently makes small and ...
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ArticlePPG sets up new coatings line at Wuhu
China – The $19m installation will make waterborne and high-solids coatings for automotive customers in the country. PPG said demand for coatings with low volatile organic compounds is rising in China due to tighter environmental regulations.“PPG’s high-performance waterborne and high-solids automotive coatings enable our customers in China to meet environmental ...
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WebinarFrom big data to smart data – Siemens MindSphere
Today’s automotive manufacturing plants generate huge amounts of data. While it is important to collect such data, it is essential to handle it intelligently. In this webinar, we’ll explain why cloud solutions are a vital part of the journey toward becoming a productive ...
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ArticleToyota makes American appointments
US – The changes, effective from April 1, are intended to “strengthen regional integration in North America”, according to Jim Lentz, Toyota’s CEO for the area. The company announced in April 2014 that it was establishing new headquarters at Plano, Texas, for its North American manufacturing, sales and marketing and ...
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ArticleSquaring the circular economy
Given the continued increase in global production, vehicle-makers have had to take action on waste managementWaste management in automotive manufacturing has moved beyond the simple recycling of materials toward a concept known as ‘the circular economy’. This is where materials that may previously have either been scrapped or recycled are ...
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ArticleA world of possibilities
Advanced high-strength steel offers advantages for cost and sustainability in automotive manufacturing Looking into the future of automotive manufacturing, some challenges are clear. Vehicle weight, environmental impact and the number of injuries due to accidents must all be reduced, yet costs cannot be allowed to rise. Advanced high-strength steel ...
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ArticleBoytsov to lead Nissan St Petersburg
Russia – From March 1, Igor Boytsov will take over from Dmitry Mikhailov, who is leaving his position as vice-president, Nissan Motor Manufacturing Russia (NMGR) to become vice-president for Quality and Customer Satisfaction at AvtoVAZ. Boytsov joins the company from Alliance partner Renault, where he was plant director.Prior to Renault, ...
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ArticleFinishing on a high note
Grinding, finishing and electrical discharge machining have gone from niche to mainstream manufacturing processes Once upon a time, machining processes such as grinding and electrical discharge machining (EDM) were viewed as ‘black art’ technologies. Today, however, these advanced machine shop methods have entered the mainstream, with the automotive industry among ...
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Article
- 表面处理技术前沿
研磨、表面加工和电火花加工技术已经从利基向汽车制造工艺主流进发很久以前，向研磨、电火花加工等加工技术被视为“魔法”。但今天，这些先进机械车间所使用的方法已经进入主流，而汽车业是最为收益的行业之一。比如Erlson Precision Components公司。公司位于英国Skelmersdale，占地7,000平方米，产品开发与生产厂是加工电子束焊接、平衡涡轮增压轴与转子装配操作的全球中心。研磨误差只有微米已经成为公司业务的特色，尤其公司已经指定生产目标，每周生产33,000辆乘用车，以及2,000辆生用车非公路车辆。Erlson的销量在增长了44%，从2014-2015年的1,600万英镑（约合2,000万美元），增长是2015-2016年的2,300万英镑。为了适应相关生产的增长，Erlson在过去的两年里投资了270万英镑，主要专注研磨能力。这里要求涡轮轴的误差为4微米，工序能力指数（Cpk）保持在1.33以内。总之，21 Toyoda圆柱形弯头和沟道磨床已经由2D CNC机床安装完成，现在预订更多机械。技术服务总监Mark Corns说，“Toyoda使我们的主要磨床制造商，因为对我们而言，高阶机械多功能非常重要。这样我们就能很容易重新配置挤出机械，用于多种应用，并适应工艺变化。”由于机械安装数量，Erlson依赖2D CNC来寻求适当型号的Toyoda磨床，然后进行重组，修理，并加入规格，以满足工艺需求。比如说，公司最近采购了一个弯头圆柱形磨床，目前进行安装前加工能力测试。Erlson生产3中尺寸的乘用车涡轮增压机轴和转子组件，机轴组合有12中形式。对商用车而言，根据使用目标，可以有5种使用普通机轴和1种不同叶轮的形式，最后形成12.7升容量的发动机。与应用和数量要求一致，有些磨床是独立的，其他的要配置成一个单元，特点是拥有一个机轴成型器、沟道磨床和滚丝机。对高生产需求而言，2D CNC规定并供应自动装卸机架，能够完全融入到磨削加工程序当中。高负载组件的高级表面处理除了涡轮轴，汽车业还有一个而重要的研磨抛光应用，那就是曲轴，这是基本的精密磨削操作；这里处处是挑战。比如说，在对车队网络完成评估统计之后，一家知名卡车制造商确定称，由于轴承半径上存在特别高的符合，曲轴受损比率非常高。与德国机械工具制造商Thielenhaus Technologies合作之后，该汽车制造商决定在轴承和转换半径两方面进行修整。为了取得在曲轴周静和半径上相同的表面质量，Thielenhaus开发了一个特别的触靴。FadiusFlex制鞋技术加工处一个重点线，从特殊面两边进入范围，半径可以加工到90°，在60°之前都体现出明显优势。从这个方面看，该卡车制造商的目标大获成功。触靴系统能够融合到Thielenhaus’s CrankStar机械平台，该平台拥有水平和垂直视角，利于加工乘用车或卡车曲轴。钟摆方案在另一家德国机械工具制造商Emag公司里，刚刚取得的突破中包括一个钟摆性研磨工艺，用于转向装置加工。向滚珠丝杆螺母这样的组件需要一种特殊的研磨方法，才能完美地连接到滚珠丝杆主轴上，效率将实现最大化。VLC 250 PDS就是按照客户对研磨滚珠丝杆螺母的需求，特意开发的。虽然一次主轴提取可以将组件从特殊的横向进给系统中移除，并转移到测量探头，但是第二次提取主轴就已经在加工领域当中，将滚珠丝杆螺母转移到两个磨削主轴单重。那么，这种钟摆研磨方案的有点是什么呢？这个答案与机械中正确的工件位置相关：研磨工序开始之前，组件内部轮廓一定要对齐，才能保证主轴置于线的末端 — 这个过程非常耗时。为了成功完成这个工作，就部署了一个特殊的计时系统，用于测量，或在一个工件完成并加工另一个的同时进行摆放，这样就会降低非生产停顿时间。"在汽车部门，有很多零部件需要深度螺纹，通常为75-100mm — 百叶螺纹需要50mm — 这对火化电蚀加工来说，是一个难题" - Brett Mitchell, RP Technologies当然，并不是汽车部门所有的研磨都是生产研磨。这个可以从英国Llantrisant的FSG Tool & Die公司身上可见一斑。FSG公司刚刚安装了一个由RK International Machine公司提供的Perfect PFG80-150AHD 悬臂式平面磨床，用于协助生产工具。随着近几年来，汽车用具变得越来越复杂，成套冲模的尺寸也在增加。因此，FSG Tool &；Die公司日前修订了表面研磨技术，想要将广泛使用的机械换成最新的，能够提高生产力的机械。尽管PFG80-150AHD是Perfect悬臂系列中最小的机械，但是完全可以适应800mm x 1,500mm尺寸的台面，可以用于FSG大部分工作。研磨团队领导Simon Elliott说，“台面尺寸增加，我们可以完成不同的工作；为了提高生产力，并研磨大型零部件（之前是有转包供应商提供）。在定购之前，我们考虑了大量的方法，最后才敲定。与RK谈话之后，我们确信他们不仅仅是在出售机械，而是要确保我们能够得到正确的方案，满足我们的需求。”EDM：最后关头工具制造商还对最新EDM技术进行投资。比如说，英国哈洛的Lynar Manufacturing公司最近换下一个老式电火花加工机械，并换上新款Sodick VL600Q。这样，公司的切削速度加倍，同时又能降低电线消耗。安装这个机械，是为了生产冲压模具，用于挂车轻型装配支架和其他零部件，以及7.5吨以下大型农用卡车上的所有零部件。工具设计部经理Sean Murrells说，“新的机械能运行速度是大型机床的5倍，我们可以生产更大的模具，在同一个工作平台上制造多种小型组件。因此，我们能够处理更多的项目，而制造工序更加高效，成本效益更高。”当用于制造商用车冲床和模具是，机械能够切削10微米的尺寸。但在控制条件下进行切削测试，误差回答道2微米。这在英国Kingswinford注射模塑专家RP Technologies公司的情况也是类似的，公司使用最新安装的Sodick AD55L冲模槽EDM，降低了生产深度螺纹的耗时，从几天降低到几个小时。公司快速周转铝材工具中的60%都是为汽车业而设计，包括从阀盖下面零部件到内饰组件的各种组件。主任Brett Mitchell说，“在汽车部门，有很多零部件需要深度螺纹，通常为75-100mm — 百叶螺纹需要50mm — 这对火化电蚀加工来说，是一个难题。我们的新机械可以在数个小时内就生产这种螺纹，之前我们得需要几天的时间。在所有事情都要压缩时间的汽车制造的舞台上，此次投资绝对是英明的。”切削液开关每年节省24万美元 Quaker’s new heavy-duty neat oil ...
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Honda to establish new R&D centre
Japan – The vehicle-maker announced that it would set up R&D Center X to take a “non-traditional approach” toward “new value” areas including robotics, mobility systems and energy management. The facility will officially be launched in April this year.R&D Center X will initially focus on researching autonomously operated machines and ...
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ArticleHonda celebrates 1m units at Karawang
Indonesia – Production began at the site in February 2003 with the Honda Stream. The original 512,500 sq.m factory had a capacity of 80,000 units; total volume was raised to 200,000 in January 2014 by the launch of a second plant covering 145,760 sq.m. Honda reports that its sales in ...
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ArticleNew press starts at Nissan Sunderland
UK – Installation has been completed slightly over 18 months since groundbreaking and at a cost of £37m ($45.6m). At full capacity, the extra-large press will be able to produce 2.5m panels per year for the vehicles built at the plant: the Qashqai, Juke, Leaf, Q30 and QX30.“The new press ...