"Firm " with " soft " choice -- machine of 2V crock lid adds product line to plan

Engine of 6L 2V RSH is limited company of car of masses of one steam · begins to plan from 2003, a of the put into production end 2004 new-style engine. This engine project plans to include a crock to build machine ledger line, camshaft machine ledger line, crock to build cent to install line and motor assembly line to wait. Because investment of crock lid product line is large, detail program workload is heavy, and involve arrive program of product line tooling, support features program, semifinished product is homebred change, quality assures, the product is approbated, the many respects such as manufacturing organization, need departmental door synchronism to start the work, cooperate each other, here, the article emphasizes the craft that adds product line to machine of 2V crock lid to plan to undertake introductory. What craft of product line type selecting plans to be faced above all is problem of product line type selecting, namely: The area that choose rigid product line or selects machining center of in order to to give priority to body workpiece tray (follow a clamping apparatus namely) flexible product line. Current, car market growth of China is immature still, demand of product breed, output is put in variable. Once product line type selecting fails, will cause huge loss. If introduce rigid line, criterion early days is one-time devoted cost is high, the risk is big; And use flexible the risk that the line can reduce product breed and output demand change to bring greatly. Flexible the line realizes much breed very easily in all line production. If need addition new product and original product diversity,not be too big, can wait through transforming tray, cutting tool and numerical control program will satisfy manufacturing requirement. And what need transform expense less, transform cycle shorter also. In addition, to reduce the effect that causes because of output demand change, can will flexible product line is produced can divide carry out for many phase. In production initial stage can realize inferior yield first can, the measure that adds equipment is adopted later raise high yield stage by stage can, because machining center is had very strong can duplicate quality, because this is flexible,line plan facilitates carry out. If market demand is reduced or the product cancels, as a result of flexible investment of line initial stage is less, the loss is opposite also less, dropped rigid line greatly the huge risk of one-time investment. But, flexible line itself also is existing the place of a lot of inadequacy, accordingly, when type selecting even according to product breed, produce what can wait is different, have logical choice. For example: Flexible maintain and uphold a requirement of line tray tall; In all the variety that the line manufactures cannot too much, when more than 2 breed, constituent management difficulty of production can be increased, appear very easily careless mistake; Produce can too tall, usually, when the crock the lid produces per year a quantity to be when 300 thousand less than, relatively appropriate is used flexible line, and should produce per year a quantity to be when 300 thousand above, rigid line more economy; Because tray oneself makes precision (later period wears away) , difference of different tray precision and two clamp (workpiece and tray, tray and equipment) the existence that waits for an element, make the dimension precision of finish machining and stability unwarrantable. Can say, rigid line and flexible the line has advantages and disadvantages each. The characteristic that 2V crock builds is: ● market demand is very big, demand of market of ● of short; of demand production metre also is put in the uncertainty of certain amount, because the program cent of this product line is two phase, the first phase achieves 360 thousand, the 2nd phase makes product line achieves final program yield; ● base material is aluminium alloy, product structure is complex, partial dimension demand is very high; ● is inside the lifecycle of product line, the product changes possibility small. Because the 2nd phase is put in the likelihood of nonperformance, so we undertake the first phase invests only, but do obligate for the 2nd phase, reduced investment risk so. According to the characteristic that afore-mentioned 2V crocks build, line of integrated consideration tigidity and flexible the investment cost of the line, produce can wait for an element, final we chose rigid line plan. After technology program and equipment type selecting are adopting rigid line plan certainly, preliminary make following product line technological process: → of thick, semifinishing machining cleans → to try → of press fitting of leakage → conduit, valve base to cover with tiles the lid assembles → finish machining → to clean the → steel ball, press fitting that block a lid up to reach eventually beforehand try leakage. Craft sort is divided to clean, try leakage, press fitting, assemble and machine add 5 kinds. 1, the type selecting of cleaning machine of rinsing equipment type selecting depends on two element -- metre and cleanness are spent. Accept restriction of these two element, eventually cleaning machine is more expensive. Be being cleaned beforehand is technology of a process, the purpose is to be " try leakage " , " press fitting of tracheal, valve base " , " made of baked clay lid is assembled " these 3 follow-up working procedure are offerred clean, dry workpiece. Right beforehand the cleanness of cleaning machine spends a requirement to be able to relax appropriately, want to be able to make sure follow-up working procedure goes on wheels only can. Our basis carries out experience, make gave an idealer cleanness to spend a worth, namely the clean 25mg spending ≤ that the crock builds, can assure to produce a demand, because this also reduced installation cost. 2, those who try leakage machine type selecting to try leakage machine to carry kind according to workpiece is different, can divide expect for pace type and type of revolving stage coming back. Before one kind of plan has been used extensively, the technology is very mature, but cost is higher; Hind a kind of 5 worker worker that employ drive of turbine, lever (1, 5 same positions) revolving stage (see a picture 1) , undertake fluctuating expecting by manipulator, have a structure the characteristic with simple, low cost, but expect as pace type application is wide. After we chose a kind, rotate namely table tries leakage machine. Up to now, equipment movement is steady. Graph plan of press fitting of type selecting of equipment of Nextpage3 of 1 machine trying leakage, press fitting is chosen contain " method and pressure detect " (see a picture 2) head of dynamoelectric press fitting, can feedback to be versed in each in real time the quality state of a spare parts press fitting. Press fitting establishs the other system of equipment, if workpiece carries system, clamp system, all introduce dynamoelectric drive, its advantage is already managing capital, facilitate again maintenance. And when introducing hydraulic pressure drive before, the system often appears leakage pressing, press fitting does not reach the designated position, pressure useless (work measure out of tolerance, press fitting on pressure head fixed position forbids) wait for an accident, cannot detect however call the police, cause unqualified in shedding next line working procedure, go. Graph curve of 2 pressure method 4, assemble home of plan type selecting to have rich labour force resource, so made of baked clay lid is assembled collect labour of choose and employ persons to screw beforehand the plan of bolt and nut, equipment is simple, low-cost. 4 kinds of afore-mentioned technological equipment are taken no account of flexible, use special device entirely, manufacturing metre achieves the requirement of the 2nd phase directly, and do not increase investment (relative to the first phase) . Relative to at special device character, machine the program that adds program is very complex, product quality and program invest very inaccessible balance. 5, machine the choice that imposes kind of type selecting equipment depends on craft metre. Usually, if machine pitch time to exceed the treatment content of metre of product line craft, choose transfer matic (private plane) more appropriate. Treatment content cent is two kinds, one kind is individual aperture, face, another kind is department of the opening that has composition of the hole with the rule, same size, face by many coordinate, face. Pitch time points to individual aperture, face the time of craft loop process of oneself, aperture, face ties pitch time is the sum of metre of treatment of each aperture, face. For example, advocate oil duct aperture is via, length is 398.

5mm, handling time Yuan Chao gives craft metre, use deep Kong Zuan (private plane) compare machining center economy. To machining the treatment content of pitch time and close of metre of product line craft, equipment type choice is more multiple, ought to integral consideration craft weaves. Current, machine of lid of aluminium alloy crock adds equipment to have two kinds: Transfer matic (private plane) with CNC Machining center. In phase of thick, semifinishing machining, dimension precision requirement is relatively inferior, but man-hour of big, treatment grows mental allowance, transfer matic (private plane) can satisfy all dimension precision requirements with CNC Machining center. According to afore-mentioned principles, in working procedure of thick, semifinishing machining, advocate oil duct aperture, SLS advocate the arrangement such as lid of spirit way aperture, crock and aperture of bolt of cylinder body coupling is in transfer matic, whole process by a transfer matic and 10 double axes machining center is finished. Double axis of the BZ530 that machining center chooses German GROB company and BZ535 machining center, rose to machine efficiency. Transfer matic metre achieves requirement of the 2nd phase directly, need to increase two machining center to be able to achieve goal of the 2nd phase again only. This kind mixes model plan contrasts economy. Spiracle conduit and valve base, camshaft aperture is finished in finish machining working procedure. Spiracle conduit and spiracle valve base are the position with top demand of precision of crock lid treatment, treatment difficulty is great; Camshaft aperture is comprised by aperture of 5 paragraphs of discontinuous bearing, precision demand is high. Transfer matic is very well-rounded technology program, the product pledges the volume assures easily, and stability is good. Finish machining arrangement undertakes in transfer matic, metre can achieve goal of the 2nd phase directly. Manufacture technology optimize 1, in the process of big batch production that the exterior blemish that machines a face covers in aluminous crock, the exterior blemish that machines a face is a widespread presence and the problem that solves thoroughly hard, this basically is decided by the physical character of itself of aluminium alloy material. People group asked to make in the light of the quality of workpiece surface detailed and strict PV standard file. Take no account of semifinished product to cast itself and blame to be machined normally (if cutting tool damages) the exterior defect that the reason causes, be aimed at product line itself only, combine the practice experience of 5V product line and theoretical analysis, we undertook classified to machining the exterior blemish of the face, analysed its to produce an account. Produce an account in the light of these, we made corresponding solution, put forward to must be begged to the supplier (see a table 1) . Afore-mentioned solutions look be like very reasonable, carry out easily also, but, in the process of practical technology distribution of product line, plan 1 not reasonable wasteful also, plan 2 carry out rise more complex also. Working procedure of thick, semifinishing machining, workpiece contains aluminous bits and emulsion, although choose path of makings of stainless steel roller to also cannot avoid the generation of cut, and this kind expects path price is high. Integrated consideration, inside this one technological process, the chain wheel that abandons stainless steel roller expects and using petty gain expects, plan is used 1 times in follow-up process. The Nextpage2, tectonic characteristic that optimizes lid of crock of treatment dimension 2V is can use firebox face and exhaust face to be in only makings carry on the road. These two faces are the fixed position face of crock of lid treatment, it is treatment is finished normally. And we ask to reach actual production experience according to quality, undertook optimizing to dimension, twice part of design of these two faces treatment is completed, withhold after first time treatment is finished 0.

The surplus of 5mm, so that undertake subsequently fabricating (finish machining) . Of firebox face and craft of exhaust face treatment optimize (measure of together with other) , solved the cut problem of these two faces thoroughly. But, finish machining foreword is corresponding (opposite blame optimizes plan) two addition worker worker, also mean the addition of investment. Quality and investment, it is two element of very difficult balance really. 3, crock of purify aluminous bits builds machine addition to taste the aluminous bits inside is from thick add, semifinishing machining working procedure brings. These aluminous bit are thicker, older, card is covered in crock lid water inside or inside treatment aperture, although clean very difficult also purify through cleaning machine. Build the experience of product line according to 5V crock, we enacted following measure: ● optimizes parameter of cutting tool, treatment; ● prevents aluminous bits to enter water to cover inside. Inside machine treatment foreword, in right project use emulsion to rinse water to cover (see a picture 4) , at the same time also can purify part aluminous bits; ● is versed in in what produce older aluminous bit, increase emulsion spray pipe, sweep aluminous bits in time, prevent aluminous bits to enter hole at the same time (antrum) inside (see a picture 5) . Put into production comes nearly one year, in product line expect below check eventually be versed in an aluminous without discovery bits, afore-mentioned measure achieved a goal. Those who sum up new technology, new technology carry out can reduce investment, raise quality to control a standard, if come back,revolving stage type tries what leakage machine and electric dynamic pressure hold a head to apply. But in the program of extensive product line in automobile industry, ought to avoid to be adopted at the same time many, the new technology without extensive test and verify and new technology. Rich experience, mature technology and craft, skilled production maintenance and technical administrator and mature administrative pattern are very important, all these is to reduce investment risk, with period obtain expectant economic benefits as soon as possible. Square hall of author brief introduction is smooth, currently hold the post ofdrive of engine of limited company of car of masses of one steam · implement program branch manager. Transferred into 1992 limited company of car of masses of one steam · , the crock of engine of 4 crocks of 20 valve builds set of the EA113 when be engaged in masses of one steam · building a plant the program of line, camshaft line works; Regarded a project as chief 1997, be engaged in Ao Di early or late 1.

Project of engine of 8L pressure boost, diesel engine project, engine increases produce can the program management of project of project, EA113 RSH engine and MQ250 gear-box project works; Still be participated in and witnessed drive of engine of masses of one steam · implement the whole process that the factory establishs. The program that Mr Fang Dianping builds a line in the crock accumulated rich experience on design and workmanship, plan to having deep knowledge to craft. CNC Milling