After some cars are "born", they need months of long-distance raids to recognize their owners. Others can come to us in just a few days.
What I want to talk about today is a brand-new "birthplace", which is very close to us. It was born for the Volkswagen MEB platform model.
How to talk specifically? Only those "numbers" are the most intuitive. Next, let's take a look at the noteworthy "numbers" created by SAIC Volkswagen New Energy Automobile Factory.
SAIC Volkswagen New Energy Automobile Factory is located in Anting, Shanghai. This is the first factory built by Audi to produce MEB platform cars. SAIC Volkswagen New Energy Automobile Factory (hereinafter referred to as SAIC Volkswagen New Energy Factory) started construction in June, 20 18, with a total investment of about1700 million yuan and a planned annual production capacity of 300,000 vehicles. It is planned to be officially put into production in June, 2020.
20 19, 1 1, SAIC Volkswagen new energy factory realized the first full-process prototype off the assembly line. The first product off the assembly line is a MEB platform pure electric medium-sized SUV, which is also the first ID. SAIC Volkswagen's future family model will be officially unveiled in the second half of 2020. In the future, the new factory will also put into production brand-new pure electric vehicles of several brands of Audi.
Keywords: 1400+
SAIC Volkswagen New Energy Factory has adopted many cutting-edge technologies that were first used by Audi or China. It is the most advanced and intelligent benchmark factory of SAIC Volkswagen at present, which further improves the automation rate and production efficiency and ensures the stable production quality. The factory adopts more than 400 industrial robots/KLOC-0, and the car body and battery workshop basically realize unmanned automatic production. The new factory widely adopts highly automated assembly and automatic measurement technology, and puts in many new technologies, such as automatic tightening, automatic wax spraying on door panels, automatic assembly platform, automatic instrument installation, aerial transportation line and AGV trolley, to replace traditional manual transportation and installation, improve production stability and ensure high quality of products.
Keywords: cloud interconnection
SAIC Volkswagen New Energy Factory adopts RFID artificial intelligence identification technology, optical identification technology, AR/VR technology, paperless factory concept, energy management system and other advanced technologies and intelligent equipment to realize the intelligence and digitalization of the whole manufacturing process. In addition, the new factory is the first factory of SAIC Volkswagen to achieve full coverage of industrial wireless networks. A large number of AP production wireless hotspots are arranged in the workshop. Combined with industrial Internet of Things, cloud storage and other interconnection technologies, system integration and data collaboration will be realized, a smart factory management platform will be built, information flow will be opened, and interconnection from design, production to sales will be realized.
Keywords: environmental protection
SAIC Volkswagen New Energy Factory adopts 27 energy-saving and environmental protection measures such as solar photovoltaic power generation, cogeneration, waste heat recovery, rainwater recycling, reclaimed water recycling technology and energy management system to build SAIC Volkswagen environmental protection factory. At the same time, five key environmental indicators of the new factory, such as energy, water, carbon dioxide, volatile organic compounds and waste, decreased by 20%.
With a number of environmental protection and energy-saving technologies, SAIC Volkswagen New Energy Factory passed the green building design evaluation of the Ministry of Housing and Urban-Rural Development, with the evaluation result of 3 stars (the highest level), and obtained the green building design appraisal certificate issued by the Ministry of Housing and Urban-Rural Development. The new factory paid special attention to the intensive use of land at the beginning of design. The area of this factory is one third of that of other newly-built factories of the same size. Each workshop crosses the municipal road through the corridor to realize the complete separation of people and vehicles.
Stamping workshop
SAIC Volkswagen New Energy Factory adopts two Schuler servo high-speed stamping lines with a total tonnage of 6,900 t, and the maximum stamping times of the two stamping lines can reach 18 times per minute. In addition, the stamping workshop is also equipped with the third generation vertical and horizontal manipulator, KUKA robot and high-speed unstacking system. There are 24 KUKA robots, with up to 5 mold processes. Adopting the most advanced automatic die changing and tool changing system, the whole line of die changing can be completed within 5 minutes, which improves the production efficiency and accuracy.
In the aspect of environmental protection and noise reduction, the stamping line covers the second generation of Schuler's integral sound insulation cover, which can reduce the noise up to 16dB(A). The waste recycling room in the workshop adopts internal screen sound insulation technology, which reduces the noise in the waste recycling room and effectively improves the working environment of employees. For the first time, the heavy-duty omni-directional AGV is applied to the off-line transportation of parts in the stamping workshop. The maximum load 1.5T adopts magnetic stripe navigation to support the right-angle turning of the omni-directional car body, and no forklift is needed for the whole process from the off-line stamping to the parts storage area.
The workshop uses a three-layer mold crane, and the three-layer molds are stacked by hand grips, which not only increases the mold storage by 50%, but also improves the running speed and mold preparation efficiency. At the same time, the running position of the mold accurately plans the path through automatic positioning, which effectively improves the safety in the process of mold lifting. Using automatic flat car, the automatic operation of cross-line transportation between mold, material sheet and loading position can be realized; Can reduce the labor intensity of employees; According to the fixed route, it can automatically run, improve the working efficiency and realize the intelligent operation of flat car. At the same time, the workshop adopts TPMS system to realize the integrated and systematic maintenance of molds.
Body repair shop
Body shop is divided into two layers, the first layer is mainly composed of door cover, bottom plate 1 and assembly line. The second floor is mainly composed of side walls, bottom plate 2, assembly and intersection. The design and production capacity of the body workshop is 60JPH, that is, 60 white bodies can be completed every hour, with an annual output of 300,000.
A large number of advanced intelligent manufacturing technologies have been adopted in the workshop, among which At-line online measurement, EMS air transportation, robot automatic tightening process and CMT+ cold metal transition welding process are all used by SAIC Volkswagen for the first time. In addition, the workshop also has the fastest laser welding in Audi ag factory and the longest workshop assembly line in SAIC Volkswagen to ensure the consistency of parts during transportation.
There are 946 robots in the workshop and the automation rate is as high as 84%. It is the body workshop with the highest automation rate of SAIC Volkswagen. In addition, the body shop has? Two online measuring stations and eight measuring robots carry out 100% visual online inspection on the parts and key parts of the body-in-white. Through laser measuring sensor, image processing, temperature compensation and computer control, the accurate measurement of the spatial size of the object is realized, and the repeatability is as high as 0.2mm, which ensures the stability of the quality of the body-in-white production process to the greatest extent.
Compared with the traditional metering station which needs to transport the vehicle to be inspected from the production line to the metering area, online metering connects the metering station in series to the production line, which can directly take the vehicle out of the production line for inspection, effectively saving the transportation time, improving the inspection efficiency and increasing the inspection quantity. At the same time, combined with the factory intelligent manufacturing system, cloud data verification is realized. The online test results are transmitted to the quality control room and released to the system. Technicians can directly see the quality status online and track and optimize it in time, which ensures the stability of the BIW manufacturing process, realizes the cloud storage analysis and automatic networking of the quality status, and greatly improves the quality and stability of the final product.
The workshop assembly line is 150m long, and the traveling belt reduces the walking distance of workers by half. It is used together with air EMS*** to realize the automatic handling of parts, reduce the intensity of manual handling and ensure the consistency of parts during transportation. High-speed laser welding has the advantages of high power density, good directivity and high welding speed. Laser welding can replace spot welding of the roof and side walls, and it is not necessary to install sealant tape on the roof. At the same time, the heat input can be accurately adjusted and controlled, the burning loss of galvanized layer is less, and the deformation of weldments is reduced. At present, the high-speed laser welding speed used in the car body workshop can reach 1 10mm/s, which is the highest speed in Audi ag factory. High-density repair welding can be applied to different vehicles, and the welding ability is improved by 3 times. There are 14 welding robots in the workshop, which can be expanded to 16 in the future.
120JPH paint workshop
120JPH paint workshop is the first high-capacity paint workshop of Audi ag. Adopting a number of new technologies, adopting brand-new environmental protection technology and intelligent technology, and supplying MEB factory and Anting Automobile No.3 factory at the same time. Compared with the traditional two 60JPH standardized paint workshops, it saves the building area 12%. The paint workshop has seven processes: pretreatment, electrophoresis, PVC, polishing, finishing, submission and wax injection.
The production capacity of the workshop is 120 vehicles/hour, which is twice that of the standardized workshop, and the annual production capacity after production is 600,000 vehicles. The total amount of equipment is 2.5 times that of the standardized painting workshop, the number of robots is ***3 18, and the automation rate reaches 73%, which is the workshop with the highest automation rate in SAIC Volkswagen. In the future, it can produce three models, MQB\MLB\MEB * * 12, and it is the paint workshop with the largest number of models and colors in the world.
In terms of environmental protection, silane membrane technology is used to replace the traditional zinc phosphating technology in the pretreatment process. The silane film does not contain nickel, which meets the latest requirements of Shanghai local environmental protection regulations for heavy metal nickel, and the nickel emission index is reduced by ten times. Secondly, the process is simple, the process is shortened, and there is basically no slag, low water consumption and low energy consumption, so as to achieve high efficiency and environmental protection. At the same time, Venturi dry paint mist absorption system is adopted, which cancels the circulating water system and avoids the loss of tap water and the generation of wastewater. No more chemicals are used, and no harmful waste will be produced. The air recovery ratio can be as high as 95%. Compared with the traditional wet paint mist treatment, it saves about 60% energy.
assembly shop
The design and production capacity of the assembly workshop is 60JPH, and the annual production capacity is 300,000 vehicles after commissioning. At present, it is the production car assembly workshop with the highest automation rate in Audi AG, with an automation rate of 26.2% and higher modularity and flexibility. The platform on the second floor of the workshop has a complete transportation line, and the car body is transported from the painting workshop to the assembly workshop through the corridor; The battery pack reaches the second floor platform of the assembly workshop through the conveyor chain and goes down to the chassis pre-assembly line through the elevator.
The assembly workshop is characterized by intensive land use and high automation rate, occupying only 2/3 of the standardized assembly workshop. The automation rate reaches 26.2%, which is the assembly workshop with the highest automation rate at present. The workshop adopts SAIC Volkswagen's first fully automatic assembly platform. Through automatic tightening and automatic nail feeding technology, as long as the bolt is poured into the equipment, the bolt will be automatically sent to the tightening shaft, and the whole process will be unmanned, improving production efficiency and installation accuracy.
In addition, compared with the traditional instrument panel installation, which requires manual handling and installation by operators, the automatic instrument installation manipulator adopts visual recognition system, which is the first technology applied by Audi and is suitable for many types of vehicles. Compared with the traditional manual installation, it is more accurate and efficient. PGD all-glass roof installation process, the ID car that will be put into production soon is the first all-glass roof product designed by SAIC Volkswagen. All-glass roof gluing installation equipment, 6 visual cameras, automatic gluing installation through a central positioning device with positioning and glass roof identification functions.
After completing the electrical inspection, the vehicle leaves the assembly line and enters the toe drum area for inspection. The light detection and non-contact laser measurement in the form of double light boxes are adopted for the first time here, and the steering wheel leveler is used to ensure the accurate positioning of the wheels. It is also the first time to adopt an open/transparent drum room, which can be used for ABS, ESP, braking force and other tests.
Battery workshop
The battery workshop is the first all-aluminum battery shell self-made and battery packaging workshop of SAIC Volkswagen, with a planned annual production capacity of 300,000 units. The workshop has two floors. The second layer is the battery shell wire. The finished shell is automatically transported by elevator to the battery assembly line on the first floor. After the battery pack is assembled, it is automatically transported to the battery pack sorting center on the second floor by the elevator. After each battery pack is matched with the car shell, it is automatically transported to the assembly workshop through the corridor.
For the first time in the history of SAIC Volkswagen, the aluminum battery case was made by itself, and it was also the only one that adopted JIS(Just? Are you online? Sequence) sequencing, Audi ag's first instant production pull-type battery workshop, the battery assembly was directly coupled with the assembly workshop for the first time, and the battery pack was delivered to the assembly workshop at the production speed of 60JPH. Workshop * * * has two production lines for housing and assembly, producing two kinds of aluminum battery housings and three kinds of battery packs for MEB platform, with more than 138 robots, and the automation rates of production lines and assembly lines reach 88% and 78% respectively.
When the battery module is put into the box, the support design of the bottom water cooling plate is a case of MEB project "Shanghai factory solution". The workshop adopts the design scheme of "movable support plate" to more effectively adapt to the product characteristics of "large-size deformable parts" of battery case. This design can support the bottom water cooling plate better than the German scheme (integral supporting plate). The separation design of battery pack and AGV car in manual assembly station is another "Shanghai factory solution" of MEB battery project. In order to meet the ergonomic problems of manual assembly of low-voltage wire harness, a 66 inclined roller assembly line is adopted, which is more in line with ergonomics and ensures stable assembly quality.
In the three core processes of welding, gluing and testing, automatic inspection robots are used to monitor and measure the weld seam, size, gluing and air tightness in real time to ensure the stability and quality safety of battery products. The battery pack produced in the workshop has passed 203 rigorous tests, which are far higher than the test requirements of national standards. At the same time, in order to meet the more stringent battery standards in China, SAIC Volkswagen independently designed a complete thermal control system, which can control the open flame from the battery case for 5 minutes in extreme cases to protect the safety of drivers and passengers.
MEB platform battery adopts a new thermal grease process. Compared with the traditional MQB platform battery hot pad technology, MEB platform battery has better interface filling ability, fewer interface bubbles and better gap applicability, which makes MEB battery pack have better thermal management ability. The long-life performance design of the battery pack is much longer than the service life of 8 years (1.2000 km) (the battery charge-discharge cycle test reaches1.6000 times, and each cycle is equivalent to 350-550 km for the whole vehicle).
Summary: advanced modern factory? Is the foundation of everything? This is also a good start.
When a tall building rises from the ground, the first thing you need is a rock-solid foundation, which is the foundation of everything. For cars, an advanced modern factory, like that foundation, is the foundation of everything and a good start.
As a new automobile market, new energy is not perfect and mature enough, but there are many uncertainties. However, the general trend of new energy has begun to take shape. Volkswagen Group and SAIC Volkswagen have effectively taken the lead by virtue of their keen insight and mature analysis of the market. The domestic new energy market has gradually become one of the largest new energy markets in the world. The completion of SAIC Volkswagen's new energy automobile factory also means that Volkswagen Group and SAIC Volkswagen attach importance to the domestic new energy market.
From the start of the catch Volkswagen new energy automobile factory to the official production, in just two years, we can clearly feel that the layout of Volkswagen Group and catch Volkswagen in the new energy field is accelerating, and only in this way can we really catch up with the tide of new energy vehicles.
This article comes from car home, the author of the car manufacturer, and does not represent car home's position.