Our company has a key enterprise research and development platform in Zhejiang Province, and it has a complete set of high-end equipment processing production base including sheet metal, machining, and CNC processing centers. We have also invested 200 million yuan in upgrading the automated and intelligent factory, featuring Mazak FMS automated flexible production line, Haitian FMS small lathe production line, lathe mechanical automation cells, welding robots, etc. We have established the first batch of intelligent factories in Xiaoshan District and digital workshops in Hangzhou.
Scene 1: The core production line of the machining center - HCN6800L-FMS This is the first set of flexible high-performance production and manufacturing units we purchased, and it is the main equipment for the third phase of our machining center. It has already performed exceptionally well among all the equipment in the machining center. Not only is the equipment flexible, but also the management and software have comprehensive flexibility. Working principle: It consists of five Mazak 6800L horizontal lathes, two loading/unloading stations, one automatic loading cart, 32 workstations, and a flexible manufacturing unit. Workers are mainly responsible for programming on the computer, assigning production tasks to the machines, and assembling and disassembling parts at the loading/unloading stations. The entire production process is completed through the transportation of the carts between the machines, stack stations, loading and unloading ramps, and loading/unloading stations. The five machines are responsible for shape processing, the flexible manufacturing unit is responsible for the automatic transportation of parts, solving the problem of multiple transfers and multiple clamping of box-type and frame-type parts for our shuttle loom.
Automation features: Compared with ordinary equipment, it requires fewer personnel, is more stable, has a higher output, and better quality. It integrates high technology, high precision, and high intelligence, and can meet the characteristics of a booming market.
Scene 2: Heidman CNC Lathe Automation Processing Unit
It consists of 4 T55 turning centers and 2 six-axis articulated arm robots. It can meet the production requirements for various types of core parts such as shafts, bearing housings, and coupling shafts. For example, (for a transmission shaft, originally it took 3 hours to process one piece using an old machine, but now through the automated production line, the processing time only takes 20 minutes. One mechanical hand can operate two machines simultaneously, meaning that 20 minutes can produce 2 fine parts. One person can produce only 1 rough part in 3 hours. If planned for 8 hours, the machine can produce 48 pieces. While with manual lathe operation, it is only 2.6 pieces. For 24 hours, the machine can produce 144 pieces, and the manual lathe can produce 8 pieces. Through the adjustment of the automatic production line, it has been upgraded from a single person and single machine to a single person and a group production line, enabling 24-hour production, thereby reducing labor costs and improving production efficiency and product quality. (Equipped with material handlers and operators).
Scene 3: Digital Screen
Through the construction of the "Digital Workshop" project, intelligent equipment such as "Haitian", "Mazak", and "Heidemann" were introduced, enabling the networking of 60 machine tools. Using the board to display various data, summarizing and analyzing statistics, the equipment operation rate was increased and production efficiency was improved. Through data acquisition, business insights were gained, and all levels of business personnel could analyze data independently. Through the application and improvement of technologies such as equipment replacement, process optimization, and automatic piece counting. It became an intelligent, information-based, digital, automated, and unmanned workshop. First, the machining center was transformed into a digital workshop, and then it was promoted and applied to other workshops, completing the final data integration platform of the warehouse system and creating a future factory.
Scene 4: One-to-six Stand Integrated Flexible Manufacturing Unit: 72 workstation material storage at the line edge, manual clamping, automatic transfer of workpieces within the production line, through the exchange zero-point module (sub-plate), to achieve CNC automatic processing of workpieces. The line body uses German KUKA heavy-duty robots, Siemens PLC, Taiwan Shuangyin guide rails, German LEAN helical gears, and American Jergens zero-point module. It provides efficient work with a maximum speed of 1m/s and a repetitive positioning accuracy of the exchange sub-board of 0.05mm. Compared with traditional single-machine equipment, it does not require repeated debugging of parts, does not require workers to be in position to clamp parts, and reduces the number of workers on duty, effectively improving the production utilization rate of machine tools, while increasing production output and reducing production costs.
Scene 5: The AGV vehicles transport the materials produced in the workshop to the storage area, including 3 production workshops and X warehouses. One set of the intelligent material automation control and scheduling system [WCS system] is provided. Through the workshop RCS robot scheduling system, remote control can be achieved to enable the AGV transport vehicles to automatically move materials and semi-finished products between various machine stations. This reduces the risks brought by manual operations and heavy lifting. Through the integration of RCS, MES, and WCS, it realizes the internal logistics linkage based on the production business flow, improving the production turnover efficiency and reducing the accumulation of semi-finished materials and line-side materials. Heavy-duty AGV (suitable for heavy-load transportation, supporting cross-transfers in the workshop, with high lifting accuracy) trolley AGV (high stability, adaptive, flexible configuration, flexible and efficient, safety guaranteed) concealed AGV (high flexibility, efficient transportation, intelligent navigation and positioning, automatic charging). The vehicle body is low, flat, and can enter the goods on the shelves, pallets, etc. Tasks include receiving, path planning, driving and obstacle avoidance, unloading and returning.