In the automobile steering knuckle assembly industry, the assembly of each part of the steering knuckle assembly is completed by manual or semi-automatic assembly line, which has high labor intensity, low assembly accuracy, poor product consistency, high organization and management requirements in production, low production capacity, and can not meet the needs of mass continuous production. With the development of market economy, the manufacturing cost is higher due to the increasing labor cost, and the assembly process cannot be effectively supervised and counted.
Shandong DE sheng, independent research and development of the steering knuckle assembly robot intelligent flexible assembly system, is a collection of industrial robots, the Internet of things technology, cloud computing and big data technology in the integration of intelligent assembly system, and support the seamless connection, such as ERP, MES production management system, intelligent manufacturing, according to customer demand customized hardware and software system.
The intelligent flexible assembly line of steering knuckle assembly mainly includes the following units: steering knuckle conveying unit, one-way sealing ring pressing/bushing grease unit, spacer ring pressing unit, bearing pressing unit, bearing grease unit, nut prescrewing unit, laser coding unit, assembly downline unit.
Electrical control system: It is mainly composed of PLC general control unit, information collection system and electric control cabinet. The PLC general control unit is S7-1500 PLC as the main control equipment, and the information system is realized by the configured industrial computer and Webaccess Internet of Things application platform. The electrical control system realizes the remote communication function and the TCP/IP communication with the machine tool to realize the bidirectional data transmission.
MES system
1) The production line is equipped with MES system, which has the functions of production organization, cleaning machine and production line operation information collection, quality information collection, installation and adjustment process information collection, product code scanning file collection, file tracing, etc., and has the function of uploading product code scanning file to the company's MES system. When the whole line product is switched, it has the line clearing function of the online steering knuckle assembly; When the bearing manufacturer switches, it has the function of line clearing after bearing pressing. Ensure that the steering knuckles in the same station always become the same type, and the bearings used in the steering knuckle assembly are from the same manufacturer.
2) With production line information, quality information and other query and analysis functions, can quickly query each steering knuckle assembly installation and adjustment process parameters and product traceability information; At the same time, it can automatically summarize production information, quality information and fault information and generate corresponding reports and analysis curves.
3) The MES system of the production line has the function of manual production scheduling, and can interact with the cleaning machine to transmit the steering knuckle demand information and display it on the cleaning machine display. After the cleaning machine is scanned online, it automatically collects the product information of the steering knuckle, identifies the type of the steering knuckle, automatically determines whether the steering knuckle meets the requirements, and transmits the release instruction to the cleaning machine according to the judgment result. Record the number of steering knuckle on-line, and pass the information to the cleaning machine.
The assembly line equipment successfully developed by Shandong Desheng Robot is the first of its kind in China, which fills the gap in China and can meet the automation demand of the assembly beat of 30s. The equipment runs stably and efficiently.
After adopting this set of equipment, according to 3 shifts of production, each production line can save 18 labor for the user, can save 1.8 million yuan for the user's salary every year. At present, the equipment has signed a sales contract with Sinotruk, bringing 11.98 million yuan of sales to the company. According to the market research, after mass production, it is expected to undertake about 5 sets of new or intelligent upgrade and transformation orders every year. Based on the sales price of 12 million yuan of equipment, the new sales revenue of 60 million yuan can be realized, which will bring significant economic benefits to the company and society.
Social Benefits:
(1) The successful research and development of project products is the first of our company in the automobile industry, which fills the domestic gap and provides a good solution for industrial enterprises, especially large state-owned enterprises, to turn losses into profits.
(2) Successful R&D of project products is of great significance for reducing product costs, improving labor efficiency, reducing labor intensity, improving production and operation safety of workers, and realizing energy saving and consumption reduction.
(3) the successful development and application of project products meet the national industrial policy, to China's intelligent manufacturing as the main direction, the advance manufacturing digital, networked, intelligent of the first, on the transformation and upgrading, in order to achieve the strategic goal of "made in China 2025" and a step, plays a positive role in promoting economic development, the project has a wide range of social benefits.
