Build the most efficient connecting rod production

2022-08-21
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In recent years, with the rapid development of automotive engine technology, the upgrading and updating of engine products are faster and faster. People put forward new requirements for engine production: the production efficiency of the production line should be high, the investment should be less, and the flexibility of the production line and the product life cycle should be taken into account at the same time

brilliance 1.8T engine connecting rod production line adopts the world's advanced production technology and processing equipment, which minimizes the investment of the production line on the premise of ensuring the high efficiency and high precision of the production line

high efficiency and low cost process scheme

the connecting rod of brilliance 1.8T engine adopts a different production process from the traditional one, and the full body has passed the combustion experiment, showing the concept of "high efficiency and low cost":

1 Adopt advanced breaking process, simplify the process, and reduce the investment in equipment and tools. The connecting rod and SGPPL are a leading enterprise in the production of key components such as sealing, wear and tolerance control functional parts suitable for all kinds of harsh working conditions. The cap separation adopts the rising and breaking process. The split surface after fracture is fully engaged during assembly, and there is no need to process the joint surface. At the same time, it has the function of data recording and simulation reproduction of the experimental process, so the joint surface processing process in the traditional process is cancelled. In actual production, the cancellation of joint surface processing not only reduces the processing labor cost, but also saves the investment of relevant equipment (including tools and inspection tools) required for joint surface processing

the broken separation surface is fully engaged when the connecting rod is assembled with the connecting rod cap, and there is no need to add additional precise positioning, such as bolt hole positioning (or positioning pin), as long as the two bolts are tightened, which can cancel the finishing of bolt holes and the processing of positioning pin holes, and reduce the processing hours and the investment of related tools and inspection tools

2. Adopt the scheme of centralized processing of multiple processes, complete the processing of multiple processes in the same equipment, reduce the number of equipment and compress the equipment investment. Adopt the multi station rotary fixture machining center, cooperate with the composite tool, and concentrate the cutting processing contents other than honing on one machining center, so as to reduce the number of machining centers on the production line to one

advanced equipment ensures that the process plan is feasible

there are only four processing equipment in the connecting rod production line of brilliance 1.8T engine, including one double face grinder, one four spindle machining center, one rotary breaking machine and one honing machine

1. Four spindle machining center

because the three processes of connecting rod bolt hole, large and small head hole and large and small head finishing are carried out in the same equipment, the machining center has many processing contents and long beat, which has become the bottleneck of connecting rod line. In order to expand the production capacity of the machining center, improve the production efficiency of the production line, and ensure that the production line has enough flexibility, the connecting rod line selects the high-efficiency four spindle machining center to process the above three processes

the four spindle machining center adopts a single spindle box, and the four spindles are horizontally arranged in a single row in the same direction, with linkage control. The four spindles move synchronously, and the four connecting rods can be processed with the same content at the same time

according to the needs of the processing content, the four spindle machining center is equipped with four groups of different fixtures, which are overturned and changed by the workbench. In order to facilitate the processing of the 11 ° face of the small head and reduce the complexity of the loading and unloading system, the workbench adopts the vertical turning mode. Four sets of fixtures are installed in the four standard directions of 90 °, 180 °, 270 ° and 360 ° respectively. When machining the 11 ° surface of the small head, the angle compensation is carried out by the rotation of the workbench to ensure that the workpiece maintains the standard angle at the loading and unloading station, which simplifies the structure of the manipulator and the mechanical action of loading and unloading, thus reducing the auxiliary time of loading and unloading and improving the operation efficiency of the equipment

Figure 1 four spindle machining center

Figure 2 vertical turning workbench

the number of spindles of the corresponding machining center, and the number of fixtures in each group is four. The machining center processes four connecting rods at the same time, and the production efficiency is three times higher than that of the ordinary machining center, which effectively improves the production efficiency of the production line

at the same time, the equipment has the function of workpiece loading memory. When the fixture at the loading and unloading station completes the clamping action, the machine tool receives the workpiece loading information provided by the loading and unloading system to confirm whether this group of fixtures are equipped with workpieces. If this group of fixtures are not equipped with workpieces, it will cross the processing of the corresponding station, which improves the operation efficiency of the equipment

2. The automatic feeding system

four spindle machining center completes the processing of three discontinuous processes. The connecting rod that completes the rough processing needs to return to the four spindle machining center for further processing after the rotary breaking machine and double face grinder complete the breaking and pressing procedures. There are three stations in the finishing process, so the workpiece in various states flows between the processes and stations in the processing process, and the flow process is more complex. This requires a loading and unloading system that can respond to the request of the equipment in time and correctly allocate the flow direction of the workpiece, so as to ensure the efficient operation of the four spindle machining center

the automatic feeding system equipped with the connecting rod production line includes manipulator, two op60 WIP temporary storage stations, feeding stations, unloading stations and workpiece upper (lower) row distributor

the automatic feeding system has the function of communicating with the four spindle machining center and the function of detecting the process to be processed. During feeding, the manipulator detects the workpiece state and sends instructions to the machine tool to move the corresponding fixture to the upper and lower feeding stations. During blanking, the machine tool sends the blanking station information, and the manipulator sends the workpiece to the blanking port or the corresponding temporary storage station according to the information

3. Double face grinder

double face grinder is used for the processing of rough and fine grinding of the end face. Since the processing tempo of these two processes is much higher than that of other processes, under normal production conditions, these two processes can prepare sufficient WIP for the next process. Therefore, the switching between the two processes is not automatic, but manual

Figure 3 loading manipulator

during process switching, it is necessary to adjust the position of the grinding wheel, set the grinding thickness, and call the corresponding control program to register the software by classification, time limit, lifetime, etc., and set the position of the workpiece detection and blanking distributor. Because the switching process adopts manual control, the equipment control system is simplified, which greatly reduces the equipment cost and further reduces the production line investment

conclusion

due to the advanced processing technology adopted by brilliance 1.8T engine connecting rod production line, the process route was shortened, the equipment investment was reduced, and the equipment depreciation cost was significantly reduced, so the production cost of products was also significantly reduced. Moreover, due to the short process route, there are only six equipment in the connecting rod production line, which covers a small area, leaving sufficient space for the expansion of the production line. The process design of multiple processes corresponding to one processing equipment not only reduces the investment of the production line, but also improves the use efficiency of the equipment, so that the depreciation period of the equipment is closer to the life cycle of the product, so that when the product is updated, the equipment can be modified or replaced according to the specific situation, creating favorable conditions for the technological upgrading of the production line. (end)

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