SAIC Volkswagen is one of the oldest automobile joint ventures in China. The company signed the contract and laid the foundation stone on June 1984. Headquartered in the famous Anting, Shanghai, we have established production bases in Nanjing, Yizheng, Urumqi, Ningbo and Changsha. The number of factories is the largest among domestic manufacturers. At present, it produces products of Volkswagen and Skoda brands. So before introducing Ningbo factory, we might as well briefly review the general situation of other factories.
Compared with the above-mentioned factories, Ningbo factory is relatively new, with 202 1 and 10 completed and put into operation, second only to Changsha factory. The factory is located in Hangzhou Bay New District, Ningbo, with a construction land of 6.5438+0.87 million square meters and a planned annual production capacity of 300,000 vehicles. It took only 22 months from the establishment of the factory to the official production, setting a new record for the global construction speed of Volkswagen Group.
The supporting facilities around Ningbo factory are also very mature. The supplier park is nearby, covering an area of 3,000 mu, and more than 75% of the materials and parts of the factory come from here. In addition to higher efficiency, it also greatly saves transportation costs. About the general situation of the factory, here is an introduction. Next, we walked into the workshop. It should be noted that this visit is not allowed to take photos, and there are only a few official maps, and more can only be shared in words.
Efficient stamping workshop/welding workshop
According to the production process, let's start with the stamping workshop, which is responsible for stamping body parts. The stamping workshop covers an area of about 30,000 square meters and has two stamping lines. Including a 9100t high-speed servo stamping line, the machine tool comes from Shule, Germany. The whole production line consists of six presses, which can complete the stamping production of stretching, stamping, trimming and forming.
According to the characteristics of Octavia station wagon and Touran large-size body, Ningbo Factory adopts the most advanced and automated mechanical stamping production line of Volkswagen Group, and the blanking table with a width of 4.6m*2.5m can meet the production of full-size parts. At the same time, the stroke curve of servo press can be adjusted at will, which can effectively improve the surface quality and shape freezing of parts. However, using six-sequence stamping, more complex parts can be produced.
In order to improve the matching accuracy between parts, the factory adopts high-precision molds to control the dimensional fluctuation of molded parts within 0.2 mm, thus ensuring the accurate matching of the whole vehicle. Used for car body side wall, door inner panel and bottom plate, etc. Adopting integral stamping technology can avoid secondary welding, effectively strengthen the strength of the car body and greatly improve the consistency and aesthetics of the appearance.
All qualified stamping parts will be transferred to the parts warehouse. Because the warehouse has strict requirements on temperature and humidity, it is equipped with dehumidification equipment to prevent stamping parts from getting wet. According to reports, the spare parts reserve of the warehouse is 3 days output plus 1.5 days reserve, following the principle of "first in, first out", ensuring that the parts that rush out of the warehouse first are used for the production of the next car.
After visiting the stamping workshop, we came to the welding workshop, where all parts of BIW will be welded together by welding. The welding workshop of Ningbo factory, like Changsha factory, covers an area of 6,543,800 square meters. There are 536 robots in the workshop, with an automation rate of 86%, which is one of the most automated factories in SAIC.
Even compared with other joint venture factories, the automation degree of Ningbo factory is above the mainstream. It should be noted that the above data are for reference only. With the adjustment and progress of major manufacturers, I believe that the degree of automation will continue to improve. At present, Ningbo factory can produce up to four in-line models, with an average of one body off the assembly line every 5 1 second, so it is also called "Minute Factory".
At the same time, laser welding also greatly improves the assembly accuracy of the whole vehicle, effectively improves the vibration and noise, and ensures the beauty and smoothness of the weld in the connection process. Generally speaking, laser welding and the extensive use of high-strength steel have significantly improved the bonding accuracy and rigidity of Ming Rui family car body, making it difficult for the car to deform when it is driving violently or without pavement.
Its manipulator is equipped with ISRA visual positioning system, which can perform real-time visual positioning on the blanking station of the inner and outer plates on the side wall of the vehicle: the camera shoots the positioning holes, calculates the actual position of the empty parts, and instructs the robot to take materials according to the actual position of the parts, thus controlling the assembly accuracy of the parts within 0.05mm and effectively ensuring the welding accuracy of the car body. The positioning system also has perfect functions of alarm, diagnosis, monitoring, data acquisition and user report, which is convenient for real-time monitoring and maintenance of assembly data.
The A-pillar, B-pillar, front foot empty cross beam, central passage, rear longitudinal beam and cross beam of Mingrui station wagon are all made of hot-formed steel. Hot forming technology is mainly used to process ultra-high strength materials that are not easy to form at room temperature. It heats the steel plate to 950℃, then forms it once, and then cools it quickly, thus improving the strength of the steel plate in an all-round way. The tensile strength of hot-formed steel plate is nearly 3-5 times higher than that of ordinary steel plate, the yield strength exceeds 1200 MPa, and it can bear the pressure above10t per square centimeter. What is this concept? This is equivalent to a coin can bear the weight of two adult elephants.
On-line laser measurement passes the 17 measuring robot to monitor 802 points of the car body in real time. This technology can realize 100% monitoring of the important dimensions of the body-in-white, find the defects of each dimension in time, make quick diagnosis by using the relevant tools provided by the system, and give an alarm to the monitoring personnel to eliminate the quality hidden danger in time.
The painting/assembly workshop strives for perfection.
After coming out of the welding workshop, the white body enters the painting workshop. Ming Rui family car models provide six body colors, and the welded body-in-white can only show different colors after pretreatment electrophoresis, PVC sealing, topcoat and wax injection in the cavity.
As for the technical highlights, firstly, in pretreatment electrophoresis, RODIP technology was adopted in the workshop. Car body turnover technology can effectively improve the quality of electrophoretic coating, ensure that the thickness of electrophoretic film on the outer surface and inner cavity meets the standard, and ensure the anti-corrosion performance of car body. After electrophoresis, the bottom and inner cavity of the car body are sealed with PVC by automatic robots, which can fully protect the bottom of the car during road driving and wading. In addition, for the body cavity, SAIC Volkswagen adopted wax injection technology to form a uniform protective film on the surface of the body cavity, which ensured the anti-corrosion of the 12 model.
The workshop is equipped with 7-axis automatic spraying robot, which greatly improves the paint utilization rate while ensuring the product quality. At the same time, in order to ensure the quality of the whole spraying process, during the spraying process, the film thickness is detected online by the film thickness robot, and the thickness and uniformity of the paint film are ensured by detecting 50 points of each car body within 90 seconds, and the thickness of the paint film is in the range of 90- 1 10 micron. It is worth mentioning that the back floor, the bottom of spare tire groove, the doorsill, the inner side of wheel cover and other areas of Ming Rui family cars are sprayed with PVC stone protective film to protect the bottom from the impact of gravel and the damage of car paint.
The assembly workshop is the last workshop of automobile production, where all parts are assembled. The assembly workshop of Ningbo factory reached 6,543,800 square meters, equivalent to 654.38+ 05 standard football fields. What impressed me deeply was its order and efficiency.
The workshop is equipped with chassis and body assembly system. Chassis assembly work is divided into 10 assembly stations, and the tightening torque is strictly controlled with high-precision guns to ensure product quality. Two automatic tightening stations automatically position and tighten the chassis through 14 automatic positioning high-precision tightening shaft, so that more than 40 connection points of the vehicle chassis can be closed in place at one time, which improves the stability and consistency of chassis installation and better transmits vehicle power.
All models of Ming Rui family have panoramic skylights, among which the new Ming Rui adopts large-area skylights with bright black design, and the maximum opening range can reach the B-pillar position. For the installation of large-size sunroof, SAIC Volkswagen is equipped with PSD sunroof installation equipment, which can quickly and flexibly grab the parts by picking up the manipulator and automatically assemble the sunroof and the car body by installing the manipulator, effectively ensuring the positioning accuracy during installation and meeting the requirements for the sealing height of sunroof installation.
19 intelligent automatic traction trolley lines were introduced into the assembly workshop, with a total of 103 AGV trolleys. Through the ground magnetic track and low-power automatic charging technology, these cars can realize full-automatic circulation from the unloading crossing to the assembly line station, which reduces the physical consumption of assembly workers and has higher efficiency.
After the assembly line is completed, each vehicle must pass the 100% off-line inspection. The final report can only be delivered and removed from the production line after the vehicle has successfully completed all inspections. Off-line inspection includes toe/drum function inspection, abnormal noise inspection in road test, rain-proof sealing inspection, etc.
Random vehicles will be tested in all directions, including comfort test, vibration test, electrical test, vehicle noise test and vehicle odor test. Among them, for the smell inside the car, in addition to the low-odor, low-emission raw materials and water-based adhesives for the interior decoration, there is also a professional "Golden Nose" team to evaluate the smell inside the car.
Full text summary:
Walking into SAIC Volkswagen's factory again, I feel that everything is so familiar, not to mention the layout of the factory, even the canteen is almost the same, except the food. It's actually quite normal. After all, the same brand, the same production standard, the same technology and the same equipment are standardized and modular, but the models produced are different. The Ningbo factory we visited this time is at a relatively high level among the same level manufacturers in automation, efficiency and quality control. Specific to the vehicle type, Ming Rui family car may have more detailed requirements in details and technology, but it is still relatively standardized on the whole. I hope this article can give you a deeper understanding of family cars in Ming Rui. @20 19