Automation – Page 225
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Article道高一尺
AMS探究碾磨工艺在满足产量需求和质量需求上所面临的挑战。为汽车业供应技工部件存在一个特殊的挑战，极大依赖产量提高和精致的质量。这个问题由于机械加工的棱镜性质而使加工操作难上加难。只有认真研究加工、卡具和模具才能找到成功生产汽车零部件的方法。这个问题在英国Welshpool的铝压铸厂CastAlum体现得淋漓尽致。该厂已经开始通过制造铸件来提高产品的价值。在获得了两个汽车公司合约之后，公司发展加速，主要提供加工转向装置和变速箱。这两个合同带动了生产力，今年CastAlum公司将制造700,000个铸件，可以考虑增加一个输送线。但是公司说，如果汽车组件将来发生变化的话，就很难调整。这个输送线的增加也会在产量没有提高之前就增加投资成本。逐步安装HMC之后购买的双棘爪、四轴卧式电机中心（HMC）就是解决问题的方法，因为这个设备可以根据产量的提高逐步安装，而且很容易为任何组件进行重新配置。CastAlum选择Heller H2000模型结合Mapal机床，每个星期检查CastAlum工具箱两次，确保持续可用性。 10 Heller H2000 HMCs populate the production hall at CastAlum今天，共有10个H2000 HMC入驻Welshpool的主楼生产大厅。每个中心都可以加工任何型号的专线装置或变速装置，为制造提供了灵活性。每个机器之间都有起重机，可以迅速改变夹具。铸件从铸造厂出发，装在很长的U型链条式输送机上，途径所有H2000机器，这在一个紧凑的空间里创造了精益的制造环境。每个运输车上都装有芯片，能够识别铸件的型号和目的地，自动将铸件转移到生产线旁边的缓冲区，便于操作员操作。粗铸件经过人工装载到第二个机械托盘上的夹具上，准备进行第一个操作。在完成了前期的加工件卸载工作，以及部分加工组件重新定位到另一个夹具上之后，第二个操作才会进行。两个操作分别对不同的组件进行。因此在完成一个托盘指数之后，加工完成的逐渐就会拉出来，通过输送机送到检测部门，然后再进行发送。CastAlum公司执行董事Keith Brown说，“Heller加工中心的平均运行时间为95%，这对人工装载双侧托盘机械来说已经很高了。这主要依赖于材料到达第二个托盘的效率和到达主轴的速度，这就会减少更换次数。机器工作时间是每周6天，每天24小时，误差为10µm，加工能力为1.67Cpk。”减少产出时间另一个英国转包制造商BCW Engineering也赞成使用卧式电机加工中心。公司日前投资购进Okuma MB5000H HMC，里面有10个托盘共用系统，增加了汽车组件产品的精确度。集团工程总监Tony Kilfoyle解释说，“减少生产次数的一部分原因是托盘从公用系统出来到达主轴的诉苦更快，因此装配无法延误下一个循环的启动。转换因此限制了自动化托盘改变时间，不超过35秒。一旦零部件制造完成，循环也会加速，因为线性轴的速度达到60m/min从而减少了闲置时间。此外，循环中切口内因素也就缩短，而金属切削的速度达到15,000rpm轴。”“这个行业的质量水平和创新程度都非常高，因此我们必须紧跟趋势，保持竞争力” – Thomas Kaiser, Kaiser Werkzeugbau加工时间的大幅降低对很多BCA汽车零部件的生产都非常有意义，比如捷豹路虎，福特，阿斯顿马顿。该转包商是很多公司的以及供应商，开发和供应原型，并在紧急时输送组件。Kefoyle指出，大部分BCW的70个机床都是工作紧张的生产中心，每天24小时工作。结果，公司正在寻求稳健发展，不仅在结构上，而且还在主轴、工具变换器、旋转轴和冷却剂传送系统。这些特别会造成HMC的问题，但是BCW称，MB5000H因其功能可靠性而晋升最高机械行列，而且Okuma标准化有助于将来HMC起重装置。 An Okuma MB5000H HMC with a 10-pallet pool has added capacity at BCW 机械是由英国NCMT供应，10托盘单位拥有很多特点，比如完整数控转台，218位工具库，70bar高压冷却剂。起重装置里还包括2个额外的托盘，能使12个不同的夹具同时启动。用于工件测量的Renishaw OMP60接触式测头，以及用于工具破损检测和自动晋级TS34桌式探头也已经调整。在机械后面安装了木屑管理系统和水雾手机系统。模块方法HMC的替代方法就是更加模块化方法，即同时使用多个曲轴。像Mikron Multistep XT-200这样的模块机械中心，已经开始在单一夹具上利用芯片到芯片短距离循环（不足一秒钟）生产棱镜零部件。除此之外，该系统能在几分钟内就可以更换工具，同时能使用4个加工主轴。这个结果的每个零部件成本都很低。每年使用德国制造商生产的500,000个不同变形的涡轮增压器壳体，成本就能达到35%。涡轮增压器壳体的批量大小区间在500和1000之间。因此，机器操作员不得不经常更换工具。以前的机器要花费80分钟，但是现在使用Multistep XT-200的话，20分钟就足够了。此外，过去由12个员工在300平方米的地方操作4台机器。过去这些机器是多轴加工中心和自动车床，而工件必须要夹紧两次。现在，德国公司生产涡轮增压器铸件，6个员工在只有一半的操作空间利用2台机械工作。所有的这些因素能使每个零部件的成本减少35%。Multistep XT-200机械在一个装置制造的涡轮增压器壳体有5个半面。不同的加工步骤（在30步到40步之间），比如选装、碾磨和钻孔都需要±25µm误差，以及1.67Cpk生产力。据Mikron称，成功应用该技术的有ABS系统、增压器叶轮、共轨喷射系统的喷嘴座、液压泵外壳和散热器。交易工具 Toolmaker RP Technologies now has 12 Hurco machines ...
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ArticleNissan Kyushu to produce Rogue
Japan – Beginning in spring 2016, the crossover SUV (known as X-Trail in its homeland) will be made by the OEM's subsidiary for export to North America. The production of 100,000 units per year will add to that of the current model in Tennessee and Busan, Korea.The company says it ...
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ArticleOlive takes new role at Renault-Nissan
France – The OEM has appointed Jérôme Olive as executive vice-president, Alliance Manufacturing Engineering and Supply Chain Management, effective August 1.Olive, who is currently senior vice-president, Manufacturing and Logistics Europe at Renault, replaces Shohei Kimura, who moves to a new leadership position in manufacturing within the Nissan group. Kimura has ...
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ArticleBMW: Achieving Brilliance in China
Anton Heiss, senior vice-president for Technology and Manufacturing, discusses BMW’s manufacturing success in China, where its Tiexi complex can be considered a production benchmarkAMS: It has been stated that Tiexi is the most sustainable vehicle manufacturing plant in China. Is the plant used as a manufacturing benchmark in the region?Anton ...
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Article- 质量问题
华晨宝马已经在中国东北沈阳建立了强大的制造基地 Nick Nolt会面宝马技术与制造高级副总裁Anton Heiss，一探宝马在中国取得成功的秘诀 AMS：有人说铁西工厂是中国可持续性做得最好的汽车制造厂。这个工厂是不是成为整个地区的制造标尺了呢？ Anton Heiss(AH)：你们可以把宝马铁西放到全球网络中比较，这是最新的工厂，我们把宝马许多发展优势拿过来。这个地区夏天非常炎热，而冬天非常寒冷，因此这里的建筑物设计需要高效的冷热系统，才能节省能源。 而且从生产设备上可能，我们拥有两条高速伺服冲压线，上面还有能源恢复系统，要比液压式高效。使用这种技术之后，我们可以在每压节省大约60%的能源。在汽车车体修理厂里，我们回收冷却焊接机器人散发的热能，为工厂提供热能。我们的喷漆厂使用旋转浸渍工艺，通过预处理浸泡旋转车身，既节省了了能源，又节省了空间。 Dr. Anton Heiss senior vice president Technology and Manufacturing, BMW Brilliance Automotive 在为汽车车体喷漆方面，我们使用IPP系统，可以减少一个喷漆步骤。搞系统综合了第一层和第二层漆，中间不需要加热车身；这样就节约了能源和材料，降低了循环时间，提高了产量。我们还在循环过剩清洁涂层方面使用了最新技术。 在装配区域，我们也能循环来自测试和冷却操作中90%的废水。我们还在主要办公大楼节省了大量的水。我们在宝马工厂里采用一切可以可持续性生产的方法，使铁西成为一个标志性工厂。 AMS：你们目前在沈阳生产3系列、5系列和X1车型。你们不久之后会不会增加新的车型或平台呢？ AH：我们计划在未来两年内引进3种车型。一个是初级汽车，入3系列内，这是特别为中国市场设计的。另一款是高端功能汽车，结合了使用性与宝马典型动力系统，面向家庭用汽车市场。然后我们还要制造X3变体系列。 AMS: 目前在中国生产遇到过什么挑战吗？ AH: 主要挑战来自中国的发展速度。如果你对比一下2009年和去年的数据，生产增长了6倍，在5年的时间里，这算是飞速发展了。仅仅对比2013年和2014年，产量就增长了30%。这种增长即便建立高产量工厂，也是一种挑战，但也是容易解决的问题。除了设备和人员培训之外，这算是最大的挑战了。 BMW works closely with suppliers to ensure sequenced parts delivery 我们的当务之急就是质量，这不仅是机器问题，还是人的问题。因此，我们在员工培训上投入很多；工作之外，我们还安排了6周的培训，然后在继续操作。 ...
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Rolls-Royce and Unipart to form JV
UK – The two companies will work on the development and delivery of manufacturing solutions for advanced fixturing and products applicable across a range of manufacturing industries, including automotive.Based on proven and patented Rolls-Royce technology, the newly formed MetLase will provide engineering solutions to applications where precision and speed of ...
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ArticleMastering the art of machining – with robots and motorcycles
ABB Value Provider, VersaBuilt, based in Boise, Idaho, has developed a universal robotic machine-tending solution that works with any CNC machine. It is affordable for the average machine shop, reduces the total cost of production by up to 50% and has been real-world tested while machining some of the world’s ...
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ArticleTravel blog: Reborn in Dearborn
For some it would be an almost spiritual experience, but for me yesterday’s visit to Ford at the place where it all began (more or less), was about appreciating the enduring human capacity for innovation; from the first moving assembly lines to the robotised manufacturing methods of the 21st century, ...
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ArticlePlastic rear axle component for S-class Mercedes
Germany – ContiTech Vibration Control and BASF say they have developed the world’s first plastic transmission crossbeam for a rear axle subframe. It is being used on the S-class Mercedes-Benz and is made from the engineering plastic Ultramid A3WG10 CR, a special polyamide from BASF which is reinforced and optimised ...
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ArticleGreat Wall Motors invests in press hardening line
China – AP&T has delivered a complete production line for press hardening to the Chinese OEM at its new plant in Xushui Baoding. The line is currently used to produce A-pillars and B-pillars, but it will also produce other components in the future. At present the components are used for ...
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ArticleTravel blog: A tornado in Toledo
What do Toledo and Leipzig have in common? No, it’s not that they both have an ‘e’ (or an 'l') in their name. Nor is it that they’re both European; I’m talking about Toledo in tornado-riven Ohio, not the Spanish city famed for its steel-making since before the birth of ...
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ArticleAdvanced epoxy solutions for automotive markets
Sicomin says it has developed Top Clear a two component, translucent coating system with a very rapid drying time that allows users to speed up the production cycle, helping automotive parts manufacturers adapt to increased production volumes. The company claims the range is suitable for use on interior car components ...
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ArticleSpares and service department
DMG MORI says it is now offering its UK customers a hotline response time of one hour or less and service response times for an engineer on site of 1 day for MORI derived products and 1.4 days for DMG derived products.The company says its service engineers carry test equipment, ...
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ArticleFirst Civic Type R off the line at Honda Swindon
UK – The first production models of the Civic Type R have rolled off the line at the Japanese carmaker’s UK plant. Addressing those gathered for the event, Soichiro Takizawa, managing director at HUM, took the opportunity to thank staff for their continued commitment and hard work.The new Honda Civic ...
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ArticleFCA to build Jeep vehicles in India
US – Investing $280m in the company’s manufacturing facility in Ranjangaon, India, will support the production of a new Jeep vehicle and is expected to begin production in the second quarter of 2017. “Today marks an important step as we continue to expand the availability of Jeep products around the ...
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ArticleMagna to build cars for JLR
UK - Jaguar Land Rover has agreed a manufacturing partnership with Magna Steyr to build some future vehicles in Graz, Austria. JLR says the aim of this collaboration is to create additional volumes needed to support the company's plans for further growth, as its three UK vehicle plants approach operating ...
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Soluções em aço
Os produtores de aço desenvolvem soluções mais leves, mais fortes para enfrentar o desafio de veículo leve.OEMs têm de encontrar um equilíbrio ao selecionar os materiais certos para seus veículos. Esses materiais precisam ser fortes o suficiente para proteger os passageiros em caso de uma colisão, e leve o suficiente ...
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Procurando Capacidade
SGM maximiza a capacidade para atender a demanda no mercado automotivo em expansão na China Nick Holt entrevistou o vice-presidente de Fabricação de Operações GM International (GMIO e GM China) Phil Kienle na empresa China em Xangai para discutir os desafios da produção de encontro à crescente demanda na China.AMS: ...
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ArticleUwe Hück joins VW supervisory board
Germany – The appointment by Braunschweig Local Court is effective July 1, 2015. Hück succeeds Jürgen Dorn, who has resigned his mandate.Hück is chairman of the General and Group Works Council of Porsche; chairman of the Zuffenhausen / Ludwigsburg / Sachsenheim Works Council; deputy chairman of the Works Council of ...
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Soluciones de acero
Los productores de acero desarrollan soluciones más ligeras y resistentes para enfrentarse al reto de los vehículos ligeros de los fabricantesLos fabricantes tienen que alcanzar un equilibrio a la hora de seleccionar los materiales de sus vehículos. Los materiales deben ser resistentes para proteger a los pasajeros en las colisiones, ...