How is U-NIT made? The Secret of Chang 'an University's Intellectual Creation Experience Day

On April 2 1 day, the first experience officer will lead you into Changan UNI-T manufacturing base. In the form of live broadcast, the whole process will be visualized, leading users to visit the intelligent production process of UNI-T, and interpreting the production stories, technical difficulties and advanced technologies behind UNI-T. Behind the visible intelligent interaction, there are more invisible intelligent processes to protect the high quality of UNI-T.

Changan Automobile UNI-T production base has a total investment of 2.5 billion yuan, covers an area of 475,000 square meters, and has a designed production capacity of 260,000 vehicles per year. After 65,438+04.2 months of construction and development, it was officially put into operation on May 65, 2008.

Changan Automobile UNI-T production base mainly produces SUV, MPV and other models, and the production line adopts advanced technology and equipment. The stamping workshop is a fully-enclosed high-speed dual-arm mechanical production line, with a production beat of 15 times/minute, low noise and environmental protection. At the same time, key technologies such as synchronous control, numerical control hydraulic pad and automatic die changing are adopted. Four types of flexible wires are used for welding for the first time, and the automation rate reaches 50%. The painting workshop adopts water-based 3C 1B+VOC terminal incineration process, and robots are used for bottom pressing, bottom sealing and spraying. The assembly workshop adopts large lifting skateboard, which can intelligently adapt to the working height. Automatic chassis assembly AGV, automatic glass extrusion, torque control system. At the same time, with the logistics concept of "shorter time, lower cost, less inventory and smaller space", we will strive to build a first-class modern factory.

Stamping workshop

The stamping workshop has a total construction area of 25,820 ㎡, and has two 2,400 t double-arm full-automatic high-speed closed stamping production lines, with the highest production beat 15 (stamping times)/minute and the workshop's annual maximum production capacity of 7 million (stamping times), which represents the production level of the most advanced large-scale complete stamping equipment in the world today. According to the lean, agile and flexible production concept, the key technologies such as synchronous control, automatic die changing, energy-saving numerical control stretching pad and full digital monitoring are adopted, which mainly undertake the stamping production task of large-scale outer panels of Changan automobile models.

Stamping production line: it is an advanced intelligent system production line. Adopt fast and efficient automatic die changing system. It only takes 3 minutes to change the mold successfully, which improves the production efficiency and equipment safety of the automation line, meets the flexible production requirements of the automation line and meets the actual production needs of modern automobiles and stamping factories.

Fully enclosed stamping: the stamping workshop adopts advanced hydraulic pad technology, and the parameters can be controlled in the sheet forming process to ensure good formability and rigidity of the parts. The stamping workshop adopts fully enclosed large-scale stamping equipment, which can effectively reduce the noise decibel to the national standard of 85 decibels.

Crane: In terms of improvement, the workshop staff made full use of their wisdom and talents and existing resources to design and manufacture a crane crane, and installed it on the crane of the production line, thus reducing the die changing time of the stamping production line. According to the production of 200 days a year, it can save about 200 hours a year, which greatly improves the efficiency of mold changing and reduces the labor intensity of operators.

Multi-functional warehouse: a multi-functional warehouse for storing end pickup trucks in the stamping workshop, which can realize automatic management of end pickup trucks, data maintenance and query, inventory analysis, report printing and other functions. , and can complete the automatic access of the end pickup truck within 90 seconds, saving the area of 1.800 square meters, which meets the requirements of agile production in modern workshops.

welding shop

The total area of the welding workshop is 42,000m2, which is mainly composed of flexible main line, rigid main line and car body storage and transportation line. The designed production capacity is 260,000 vehicles/year, and the maximum production capacity is 390,000 vehicles/year. In order to highlight the leading ability of intelligent welding quality, the workshop is equipped with 336 fully automatic equipment with world-class quality.

The accuracy rate of body-in-white is 98.9%: since it was put into production, the incidence rate of quality accidents has been "0", and the accuracy rate of body-in-white has climbed to 98.9%, ranking first in Chang 'an automobile manufacturing base.

Finishing center: It's like a super-large X-ray detector. The measurement requirements of large SUVs and MPVs can be met by two cantilever coordinate measuring machines (Swiss imported Heicks Kang coordinate measuring machine, with a maximum load of ≥ 8,000 kg; Single-arm mode space measurement accuracy MPEE≤70um, double-arm mode space measurement accuracy MPEE≤90um), two high-precision laser trackers, 12 auxiliary door cover assembly inspection tools, two sets of PCF comprehensive inspection tools, and 1 set of opening inspection tools, which will carry out/kloc-for parts incoming, fixture testing, mold accuracy and process control in the main welding assembly process of the whole vehicle. The logical correlation analysis and data integration of the anomalies can hide the anomalies generated in the welding process of BIW, 100% can avoid all the problems within the tolerance range of 0.8- 1.2mm, and the precision monitoring of BIW can be improved by 50% compared with the conventional ones. This model is unique in the whole industry and far ahead.

Visual inspection system: the most basic automatic production line for automobile welding. In order to ensure the sealing effect of the chassis, cognex Hawkeye made in Germany was introduced at the beginning of the design. ——? Visual inspection system can 100% verify the sealing performance of extrusion effect. After sufficient verification, enter the right station to grab the front wall plate and transmit it to the lower body for assembly and connection through EMS.

Improvement of spot indication of solder joint: Because the back floor is covered with other small parts during welding, there are a lot of blind spots in the line of sight, so we can only weld blindly by feeling and experience, and sometimes there will be a little welding and welding damage of parts, which makes quality assurance difficult. After continuous verification by workshops and teams, dots are indicated with laser pens. After the installation position of the laser pen is determined, the point operation will not affect the access or welding operation of the electrode holder. Through the improvement, the probability of welding injury will be greatly reduced, the repeated aiming action will be reduced, the single operation will be shortened by 5 seconds, and the repair time will be saved every year 125857 yuan.

Automatic line robot: equipped with 1 17 robot produced by KUKA, Germany, 100% can realize automatic welding and grasping of parts, and can quickly implement fully flexible switching between various models of Changan Automobile. The most stable and efficient high-speed roller transmission is adopted between workstations, and the transmission time is less than 4 s, which is more than 200% higher than the traditional transmission efficiency, realizing accurate positioning and high efficiency.

On-line inspection system: This system comes from cognex, Germany, and is currently at the leading level in the vehicle manufacturing industry. It is an on-line non-contact measurement system based on visual inspection and laser measurement technology, which breaks through the traditional three-coordinate sampling detection limit, and can realize 100% monitoring of the whole vehicle process size fluctuation, providing effective data support for process improvement. ? Here, in order to ensure that 100% of the defective products are transferred to the next station, we have also improved the stamping effect of solidified VIN lettering, completely improved the stamping mode of manual inspection, added a light source and a CCD high-definition camera to the stamping robot (which can be connected to the visual inspection system later), and connected to the manual station display to transmit the real-time stamping effect to the display. In addition, the step of checking the stamping effect is added to the in-place work instruction to ensure the stamping state. Through improvement, the repair cost and energy cost can be saved every year 1 17 195 yuan.

Door line: The process layout is compared with Toyota, Shanghai Volkswagen and other international and domestic first-class automobile enterprises. The layout is symmetrical by region, which effectively avoids the problem of high inventory of various doors, reduces the space occupation by more than 30%, and shortens the logistics delivery time by more than 25%. In the fastening process, we adopt a four-die inversion system to realize automatic glue extrusion fastening, realize the shortest time switching between dies of a single press, realize synchronous fastening of four types of vehicles, and truly realize flexible welding in the whole process.

Floor chain adjustment line: this is the first floor chain with a beat of 65JPH in the same industry in China. Here, after the upper and lower car bodies are assembled, carbon dioxide shielded welding, high top cover, five doors and one cover, and body-in-white adjustment are completed in turn. The mission of the whole welding process has been successfully achieved, and these complete and flawless white bodies are arranged in an orderly way and enter the painting.

assembly shop

As the largest workshop of Changan Automobile, the assembly workshop of UNI-T production base of Changan Automobile covers a total area of 9 1500 m2, which is mainly composed of 9 main lines, 6 sub-packaging lines, 2 auxiliary conveying lines, 2 inspection lines and 2 rain-drenched lines, with a designed production capacity of 260,000 vehicles/year and a maximum production capacity of 390,000 vehicles/year. In order to show the leading ability of intelligent and digital assembly, the workshop is equipped with 149 fully intelligent and fully automatic equipment with world-class quality, accounting for 80%, realizing intelligent monitoring and decision management among production, equipment, quality and logistics. The production efficiency is improved by more than 15%, the resource utilization rate is improved by more than 10%, the product development cycle is shortened by more than 25%, the operating cost is reduced by more than 15%, the defective rate is reduced by more than 25%, and the monitoring rate of key manufacturing equipment reaches 100%. The manufacturing intelligence of assembly workshop is at the leading level in the same industry.

Assembly workshop production line: the design rhythm of assembly workshop production line is 65JPH. The appearance inspection line, that is, the end of the main line of the assembly workshop, is the place where the whole vehicle goes offline after five-door debugging, appearance inspection and gasoline filling. Completed two lines, mainly engaged in seats, doors, positive pressure detection and filling. It is worth mentioning that the four-in-one filling equipment adopts domestic design and foreign processing form, and the filling accuracy can reach 95%, thus ensuring the filling quality of our products.

Car door assembly station: When the car body enters the final assembly from painting and reaches the first station of the production line, the car door will be removed, the car door parts will be assembled on the car door assembly line, and then the car door will be assembled directly here through the conveyor line. This production line design greatly facilitates the assembly of automobile interior parts, saving the assembly time of 32 seconds per vehicle.

Chassis line area: * * There are 54 stations in two lines, mainly engaged in the assembly of chassis parts such as engine, rear axle, fuel tank, tire and exhaust pipe. In terms of off-load torque control, * * * has 75 sets of torque control equipment and adopts French horsehead control system to ensure the torque qualification rate of 100%. On our left is the assembly station of engine and rear axle. At present, we use Song Xin double lifting chassis to assemble large AGV, which realizes the simultaneous assembly of engine and rear axle.

Tire packaging line area: The fastest beat 12S completes a tire packaging, which is the tire packaging line with the highest level of automation in China. After the tire assembly line is completed, it is transported to the tire assembly station through the second-floor platform, and the delivered tires are put down to the production line through spiral design, which not only ensures the inventory, but also reduces the wear and tear on the tires during the manufacturing process.

Logistics area of assembly workshop: The logistics area of the workshop is 1 1000m2, which is divided into three functional areas: inventory, packaging and centralized sorting. Based on the reservation of process route and site area, the inventory area is planned in a "modular" way, with 1537 pallets. Relying on MES system, Kitting picking system and AGC synchronous distribution system are introduced to package 270 kinds of materials (bicycles) in the packaging area, and the intelligent synchronous distribution of AGC single set of materials is realized, with an intelligent rate of 29%. The materials in centralized sorting area 196 are transported by electric trailer, and the synchronization rate reaches 65%.

This article comes from car home, the author of the car manufacturer, and does not represent car home's position.