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In addition to the ability to produce the same type of products in line, it is also possible to use the self-made combination fixture to process the intake pipe on equipment with sufficient capacity in the individual process of the box. The assembly fixture and programming were carried out at the same time. It took only 2 days to complete the commissioning of the intake pipe equipment. After the production is completed, the combination fixture is removed, the fixture of the cylinder head is reinstalled, and the equipment is immediately restored to normal processing.
Taking advantage of the flexible nature of the machining center, the advantages of multiple varieties in one line are more obvious for products that have already been finalized. Chery's new cylinder head line can be processed in several varieties, including gasoline engines and diesel engines. Since these products are basically shaped, the fixture and loading system can be universally designed, and the design of the tool is also considered to be shared by multiple varieties in order to save costs and reduce tool change time. Due to the type identification on the conveyor roller and the feeding device, the error-proof design is also carried out on the fixture, and the machine tool already has the mixed flow production capacity.
In addition, product switching is also a key part of the multi-variety collinearity. Taking the type switching of the shaft as an example, first, the operator selects the model to be switched in the interface of the product switching, and the system extracts the type of the corresponding type corresponding to the model in the system beforehand, prompting and monitoring the entire changing process; The gripper of the manipulator in the storage system is controlled by the servo motor. The automatic control system issues a command, the jaws are automatically adjusted into position, and the robot returns the completion signal to the control system. The robot also has a diagnostic switch to judge the position. If it is not in place, it will immediately feedback to the control system and issue an alarm. The operator will proceed to the next step according to the alarm prompt information; the fixture part of the machine tool can be automatically adjusted in place within a few seconds by the servo system, and some accessories need manual adjustment or replace. Each manufacturing unit of the production line is equipped with mechanical auxiliary modules and proximity switches for manual replacement to ensure quick and accurate changeover. For example, in the cam grinder on the production line, when the grinder is switched between different types, it is necessary to replace the position of the chuck top and the center frame, and a tool table is arranged on the machine side, and the tooling corresponding to different types of camshafts is placed in the tool table. Each set of different types of tooling is connected to the operating system through a signal switch, and is monitored by the operating system. If the operator forgets to replace the corresponding top, the system will prompt and alarm. Only all the corresponding toolings are taken out and installed inside the machine tool, and the tooling that has been replaced inside the original machine tool is put back into the tool table. After the system judges, it can be determined that the model change is completed, and the instruction that can continue processing is issued.
The production line is switched between the varieties through automatic control and manual adjustment under the control of the automatic control system. The product line switching can be completed within 15 minutes, which ensures the high flexibility and high efficiency of the FMS.
FMS application considerations
The use of FMS places higher demands on product design, process planning and production organization. According to the experience of use, the following points should be noted:
1. Decide whether or not to select and select a flexible manufacturing system based on the characteristics of the product line. When the production program is relatively large (more than 300,000), when the subsequent series of products are few and the products are relatively stable, it is not suitable to choose a flexible system.
2. According to the process characteristics of the product, determine the distribution of the processing unit and select the appropriate logistics and transportation reserve.
3. When there is a big difference between the production line products, in order to reduce the fixture replacement time, the spare tray should be used as much as possible. When the replacement, the fixture and the tray are replaced together to reduce the installation and adjustment time.
4. In the planning stage of the production line, it is necessary to clarify the scope and materials of the post-processed products, and determine the selection of the machining range and power torque of the machine.
5. Due to the large number of production line products, product identification and error prevention are very important. Product design and process planning should be considered adequately, otherwise it will cause a knife or even damage the machine.
6. Flexible production change, mainly the replacement of fixtures and tools and procedures. The fixture mainly considers the contour size of the fixture, the interface and control of the hydraulic oil circuit of the machine tool and the fixture; when the batch size is small and the variety is large, a universal combination fixture can be considered. The tool mainly considers the form of the tool holder interface, the maximum tool diameter and length of the machine tool, and the appropriate tool magazine capacity. Tool life monitoring, automatic tool selection, tool breakage detection and tool torque monitoring should be used on the equipment.
7. For engine manufacturing, in addition to processing, the flexible system should also consider other auxiliary equipment, such as leak detection, cleaning, etc., can use the pallet or multi-station method, through the model identification, automatically select the processing station to achieve flexibility .
8. The production department should organize the production reasonably. After all, there will be a loss of processing efficiency for each type of change, including the first piece of inspection. Especially in the case of replacement or adjustment, the loss of time and the accuracy of machining accuracy are very high.
9. Due to the need for later product expansion, the control system of the flexible manufacturing system should select a common open CNC system, and the control system of the entire line should be as consistent as possible.
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