In recent years, flexible manufacturing methods have become more and more popular and have continued to penetrate into many product-intensive manufacturing industries. From a practical point of view, it solves the long-term difficulties of automated multi-variety and small-batch processing, and can also meet the needs of the product constantly updated, so it is widely welcomed by many manufacturers, especially in the automotive parts manufacturing industry.
In general, the flexibility of the automotive industry is mostly reflected in the advanced level of its production lines. The same production platform can produce many different types of components at the same time, which in turn enables flexible supply of customers, shortens product delivery time, and improves customer satisfaction. At the same time, it strengthened product quality management, reduced raw material inventory, and balanced manpower and working hours. In this concept, the author interviewed several car users of the German JUNKER machine tool and learned about the wonderful applications of flexible manufacturing in different manufacturers.
Turnkey Project: Flexible
The crankshaft finishing line of Chery Automobile Co., Ltd.'s second engine plant is a turnkey project for the general contracting of the German JUNKER machine tool. JUNKER has contracted nine machining processes, four of which are mainly for grinding the crankshaft main shaft and the journal. , crankshaft connecting rod journal, thrust journal, flanged flange end, journal end. In the interview with the author, Jiang Renjie, the line leader of the crankshaft finishing line of Chery’s second engine plant, explained that the benefits of the equipment are obvious. It greatly shortens the lead time and results in much faster production. This is mainly due to the maturity of the entire production line. , flexibility is strong.
The production line is equipped with an automatic loading and unloading system, and a random sampling inspection device is integrated between individual processing operations. The total grinding tact time is stable at 59 seconds. The grinding process of each JUNKER machine tool is completed by one clamping. Mr. Jiang introduced that the single class production can reach 260, with a daily production of 800-900 pieces. The degree of flexibility is very strong, can produce 1.3L, 1.6L, 1.9L, 2.0L, 2.3L models of products in the same line, switching between each other is simple and quick, and the replacement cycle is short. For example, he said: "For example, the JUCRANK5000 crankshaft connecting rod grinder uses follow-up technology to adjust the CNC program to flexibly process crankshafts with different number of cylinders and centers. When using a CBN grinding wheel, the line speed reaches 120m/min."
Fully automated manufacturing shortens takt time
Coincidentally, Shanghai Volkswagen also purchased JUFLEX 3000 with two workstations. The machining task is to use a CBN grinding wheel to grind the journals, planes, valve cams, and partial pump cams of the car camshaft as a whole.
JUFLEX3000 machine tool
Ding Wei, the head of the cam axis at Shanghai Volkswagen Powertrain Co., Ltd., explained to the author: “The process is completely automated by a built-in robot and two external loading and unloading conveyors,†he said. Yes, the processing task is reasonable and the beat is split into two modules or two processing stations synchronously. In other words, within the synchronized time period, two machine tool modules can execute 2 completely independently. Processing task. This shortens the takt time and enables simultaneous operation of the twin-headstock. It takes about two minutes to process a workpiece using JUFLEX. According to the progress of the public's three shifts per day, 1,500 camshafts can be machined a day.
As a flexible production line, JUNKER's machine tool sets six types of camshaft production programs. “The program switching between each other is very simple. As long as the processing parameters are input on the machine operation panel, the system will automatically adjust the angle and height of the grinding wheel frame. In this way, all types of camshafts can be ground without changing fixtures, etc. Details of the settings." He said.
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