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APPENDIX
Car assembly technique situation and the development trend of the market forecast
[abstract] the article expounds auto, engine, transmission, and other key parts assembly process equipment manufacture level of general situation and the present situation, and for the next five years of automotive assembly process equipment demand forecasting is analyzed. (priceless cows back I don't need to hesitate)
1. The engine, transmission, rear axle of key parts and whole vehicle assembly process equipment
1.1 engine assembly process equipment
With the rapid development of China's automotive industry, especially in the technology and the introduction of foreign second-hand equipment to make the engine of recycle, assembly equipment level increased significantly. Engine assembly technology and equipment are divided into five types: assembly and points assembly assembly line; Move over load equipment; Automatic tight equipment; Special assembly equipment and testing equipment.
1.1.1 engine assembly line type and development (mainstream capital real purpose, analysis found that the best profit opportunities!) Every domestic engine manufacturing enterprise the engine assembly line type more, can be reduced to roughly; Free groove + double chain bridge car type; Free groove + anti-shear traction ground track car type; Free groove + take with the ground plate stent; Free groove + anti-shear traction ground track car type + take with the stent board type; Hanging chain, etc. All of these are the main assembly line for compulsory water (continuous or batch), and the operation of the main assembly object is consistent with the synchronization), is called (synchronous assembly line or rigid assembly line. Along with the development of the car industry, engine assembly line is from rigid to the flexible assembly line assembly line direction development, flexible assembly line is characteristic of the assembly can beat within a certain range of free adjustment, can achieve more varieties mixed flow production and adapt to the change of production program. And because in the assembly operations assembly object and the assembly workers remained relatively static state, to ensure the high quality of the assembly and using special assembly equipment provides convenient conditions, is easy to realize the automation of the assembly. So of the introduction of domestic car motor assembly line adopted the flexible assembly line (i.e. asynchronous assembly line).
At present domestic used for engine assembly asynchronous assembly line, the main types have single GunGang type, friction for flexible roller type, double roller chain plate and scales, etc. Of General from the United States and Japan imported engine asynchronous assembly line for friction flexible roller type, such as faw two hair and days; Imported from German engine asynchronous assembly line for the single GunGang type, such as for Shanghai Volkswagen and faw Volkswagen. The big assembly (medium) asynchronous assembly line in China's development, along with introducing car technology and foreign second-hand equipment reuse and developed. Beijing internal combustion engine plant and faw engine plant in the 80 s were introduced American general motors 2.0 L engine production line and the Chrysler 488 engine production line, this two production lines in assembly and points of the assembly line is the assembly synchronous assembly line. This time can say flexible assembly line is China's small and medium-sized machinery in the assembly production to application after the new China, several large motor plant, such as Shanghai Volkswagen, faw Volkswagen, tianjin internal combustion engine factory assembly lines are used to introduce the engine of asynchronous assembly line. A few equipment manufacturer in China through the imported technology digestion absorption, already can be designed and made for the small and medium-sized machinery asynchronous assembly line, and used in the production. But with the introduction of equipment, there is still a gap compared, the main problems and technical difficulties is poor reliability, the roll and GunGang wear-resisting of low intensity, and affect the service life of equipment. At present the device is still to introduce primarily, therefore in this respect has yet to be developed further, the domestic equipment will make the cost of production line is greatly reduced and so in our country are wide development prospects.
1.1.2 engine assembly line of the special assembly equipment and testing equipment
The application of the flexible assembly line to ensure that products of high quality and high productivity special assembly machine created the conditions. In the car engine assembly used widely in the DuoTou set torque bolt (mother) tightening machine (also called assembly machine). Tight method using the control torque-corner method, this method is currently the world's most advanced threaded connection method. In addition to the valve to be automatic assembly machine, assembly manipulator, automatic glue machine, the equipment that the domestic engine assembly technology level close to the international advanced level. In the car engine assembly, some important joint surface (such as oil pan, water pump shell, etc and cylinder surface), the combined with rubber seal new craft, replace with the shim between surface, which simplifies the production process and also to improve the seal quality. In the key assembly procedure with special inspection after using automated detection equipment, location of assembly quality control, such as the crankshaft rotating torque and axial clearance check assembly sealing check etc.,
Main engine assembly equipment and the current domestic production level see table 1.
Table 1 engine assembly main equipment and the current domestic production level
Serial number device name domestic manufacturing level
1 engine assembly asynchronous assembly line can design and manufacture, but low quality, the service life is short,
2 the synchronization of cylinder assembly line current use of the equipment and the introduction of mainly.
3 the piston connecting rod asynchronous assembly line
4 gas door lock installed clamp pressure
5 the spark plug catheter pressure installed
6 piston assembly machine design and manufacturing, and domestic to reliable quality, but not now
7 the piston pin pressure have professional production factory, installed production to disperse, influence the overall level equipment
8 block turn connecting improve, current use of the equipment to domestic manufacturing primarily.
9 the piston insert the turntable
10 turn transfer carrier aircraft
11 engine Numbers printer
12 the Lord bearing cover bolts tight machine can design and manufacture, but low quality, high failure rate.
13 the connecting rod bolt tightened at home for some factory machine to save the investment of the key to tighten head
14 the oil pan is tighten bolts introduction, body part machine manufacture its own, basic can meet to use
15 to tighten bolts for cylinder head machine. Current use of the equipment for the introduction of more than 95%.
16 the flywheel bolt tight machine
17 after oil pan and oil seal glue machine can design and manufacture, but low quality, high failure rate.
At present domestic some factory as the key to save the investment of the measured seal
18 the crankshaft rotary torque testing machine without a try introduction, body parts manufacture its own, basic can meet
19 valve and catheter sealing testing machines use requirement. Current use of the equipment more than 95%
20 engine assembly and testing machine sealing introduction.
21 valve clearance adjustment machine
1.1.3 engine test equipment factory
The engine test engine products of the factory is final inspection, in large production, in order to increase the production efficiency and accuracy of the test data, the engine test-bed system to the factory automation system, automatic test bench development factory test-bed system mainly includes three aspects of content.
(1) test standard procedure control and various data automatic test. Through the program control, the engine can be set according to the program automatically according to the requirement of the specifications complete test and automatic measurement and data analysis, and all kinds of judgment measurement data stored in a computer inside.
(2) the test-bed automatic rapid convergence. Quick connection test in a very short time to finish the various pipe automatic quick connection; The engine test bench in the automatic positioning and clamping; The drive shaft automatic docking and a series of actions, and realize the test bench test installation of automation, reducing the connection in the test of auxiliary time.
(3) the engine automatic conveyer. The factory test automation is the third part of the content and automation test-bed for supporting the automatic conveyer line, line type generally USES the product put type friction roller conveyor line. It is equipped with transportation, storage and the function of automatic identification, the control system based on the bed put forward feeding sequence of test bench and the material on the slippery reservoir inventories, the judge recognition engine conveying the signs on the tray, automatic pilot test will be the engine to needed test bench or store material on the slippery, will test the qualified engine to referral point, test unqualified engine to repair station will be empty tray, automatic back to online points.
Automatic factory test-bed system in China, began in the 80 s, when some domestic large at the end of the car factory has introduced a small engine test-bed factory automation, such as Beijing jeep car limited company to introduce the Ingersoll rand automation test-bed. Some equipment manufacturer in digest imported technology basis, combining with the actual situation of China imported equipment, the generic now stand, test specification of procedure control, the test data of automatic testing technology and automatic transmission technology in our country is mature, and have a few manufacturer to design, manufacture and application in production. Technical difficulties is rapid convergence technology, especially the drive shaft rapid convergence of torsional vibration resistance and resistance to the excitedself vibration technology, this technology is to be further perfected. If the equipment can localization will make their cost greatly reduce prices for imported equipment, only one over ten, so in China will have broad development prospects.
附 錄
汽車裝配工藝現(xiàn)狀 發(fā)展趨勢和市場預測
[摘要]全面闡述了汽車整車、發(fā)動機、變速器等關(guān)鍵零部件裝配工藝裝備概況及制造水平現(xiàn)狀，并對未來五年汽車裝配工藝裝備需求情況進行了分析預測。(千金難買?；仡^ 我不需再猶豫)
1. 發(fā)動機、變速器、后橋等關(guān)鍵零部件及整車裝配工藝裝備
1.1發(fā)動機裝配工藝裝備
隨著中國汽車工業(yè)的快速發(fā)展，特別是引進技術(shù)和國外二手設(shè)備的再利用，使發(fā)動機裝配的設(shè)備水平大幅度提高。發(fā)動機裝配工藝裝備主要分為五個類型：總成和分總成裝配線；移載翻轉(zhuǎn)設(shè)備；自動擰緊設(shè)備；專用裝配設(shè)備和檢測設(shè)備。
1.1.1發(fā)動機裝配線的型式及發(fā)展(剖析主流資金真實目的，發(fā)現(xiàn)最佳獲利機會！)國內(nèi)各發(fā)動機制造企業(yè)所采用的發(fā)動機裝配線型式較多，大致可歸納為；自由滾道＋雙鏈橋架小車式；自由滾道＋單鏈牽引地面軌道小車式；自由滾道＋帶隨行支架地面板式；自由滾道＋單鏈牽引地面軌道小車式＋帶隨行支架地面板式；懸掛鏈式等。以上各裝配線的主線皆為強制流水(連續(xù)或間歇)，裝配對象與主線的運行是一致的(同步)，故稱為同步裝配線或剛性裝配線。隨著汽車工業(yè)的發(fā)展，發(fā)動機裝配線正由剛性裝配線向柔性裝配線方向發(fā)展，柔性裝配線的特點是裝配節(jié)拍可以在一定的范圍內(nèi)自由調(diào)整，可以實現(xiàn)多品種混流生產(chǎn)并適應(yīng)生產(chǎn)綱領(lǐng)的變化。又由于在裝配作業(yè)時裝配對象和裝配工人保持相對靜止狀態(tài)，對保證裝配的高質(zhì)量及采用專門的裝配設(shè)備提供了方便的條件，便于實現(xiàn)裝配的自動化。因此國內(nèi)引進的轎車發(fā)動機裝配線均采用了柔性裝配線( 即非同步裝配線)。
目前國內(nèi)用于發(fā)動機裝配非同步裝配線主要型式有，縱置單滾杠式、摩擦式機動輥道式、雙鏈滾輪式和鱗板式等。一般從美國和日本引進的發(fā)動機非同步裝配線為摩擦式機動輥道式，如一汽二發(fā)和天內(nèi)；從德國引進的發(fā)動機非同步裝配線為縱置單滾杠式，如上海大眾和一汽大眾。大總成(中型)非同步裝配線在中國的發(fā)展，是隨著引進轎車技術(shù)和國外二手設(shè)備再利用而發(fā)展起來的。北京內(nèi)燃機廠和一汽第二發(fā)動機廠在80年代末分別引進的美國通用汽車公司2.0L發(fā)動機生產(chǎn)線及美國克萊斯勒公司的488發(fā)動機生產(chǎn)線， 該兩條生產(chǎn)線上總成和分總成裝配線采用的就是非同步裝配線。這一時間可以說柔性裝配線已經(jīng)在中國中小型機械的裝配生產(chǎn)中得以應(yīng)用，以后國內(nèi)新建的幾個大型發(fā)動機廠，如上海大眾、一汽大眾、天津內(nèi)燃機廠等發(fā)動機裝配生產(chǎn)線均采用引進的非同步裝配線。我國少數(shù)設(shè)備生產(chǎn)廠通過對引進技術(shù)的消化吸收，已能自行設(shè)計和制造這種用于中小機械的非同步裝配線，并用于生產(chǎn)中。但與引進的設(shè)備相比還有一定的差距，主要問題和技術(shù)難點是可靠性差，輥子和滾杠耐磨強度低，影響設(shè)備的使用壽命。目前這種設(shè)備仍以引進為主，因此在這方面還有待于進一步研制，采用國產(chǎn)設(shè)備將使生產(chǎn)線的成本大大降低，因此在我國有廣泛的發(fā)展前景。
1.1.2發(fā)動機裝配線上的專用裝配設(shè)備和檢測設(shè)備
柔性裝配線的應(yīng)用為確保產(chǎn)品高質(zhì)量、高生產(chǎn)率的專用裝配機創(chuàng)造了條件。在轎車發(fā)動機裝配中普遍地采用了定扭矩的多頭螺栓(母)扭緊機(也稱裝配機)。擰緊方法采用控制扭矩—轉(zhuǎn)角法，這種方法是目前世界上最先進的螺紋連接方法。此外還采用氣門自動裝配機、裝配機械手、自動涂膠機等設(shè)備，這些設(shè)備的采用使國內(nèi)發(fā)動機裝配技術(shù)水平接近了國外先進水平。在轎車發(fā)動機裝配中，一些重要的結(jié)合面(如油底殼、水泵殼等與缸體結(jié)合面)，采用了涂密封膠新工藝，取代結(jié)合面間的墊片，既簡化了生產(chǎn)工藝又提高了密封質(zhì)量。在關(guān)鍵的裝配工序后都設(shè)有專門的檢查工位，采用自動化檢測設(shè)備控制裝配質(zhì)量，例如曲軸旋轉(zhuǎn)力矩及軸向間隙的檢查、總成密封性檢查等。發(fā)動機裝配主要設(shè)備和目前國內(nèi)制造水平見表1。
表1 發(fā)動機裝配主要設(shè)備和目前國內(nèi)制造水平
序號 設(shè)備名稱 國內(nèi)制造水平
1 發(fā)動機總成非同步裝配線 能夠設(shè)計制造，但質(zhì)量不過關(guān)，使用壽命短，
2 缸蓋非同步裝配線 目前使用的該類設(shè)備以引進為主。
3 活塞連桿非同步裝配線
4 氣門鎖夾壓裝機
5 火花塞導管壓裝機
6 活塞環(huán)裝配機 國內(nèi)能夠設(shè)計制造，并且質(zhì)量可靠，但目前沒
7 活塞銷壓裝機 有專業(yè)生產(chǎn)廠，生產(chǎn)分散，影響設(shè)備整體水平
8 缸體翻轉(zhuǎn)機 提高，目前使用的該類設(shè)備以國內(nèi)制造為主。
9 活塞插入橫轉(zhuǎn)臺
10 翻轉(zhuǎn)移載機
11 發(fā)動機編號打印機
12 主軸承蓋螺栓擰緊機 能夠設(shè)計制造，但質(zhì)量不過關(guān)，故障率高。
13 連桿螺栓擰緊機 目前國內(nèi)一些廠為節(jié)約投資采用關(guān)鍵的擰緊頭
14 油底殼螺栓擰緊機 引進，機身部分自行制造，基本能滿足使用要
15 缸蓋螺栓擰緊機 求。目前使用的該類設(shè)備95％以上為引進。
16 飛輪螺栓擰緊機
17 油底殼和后油封涂膠機 能夠設(shè)計制造，但質(zhì)量不過關(guān)、 故障率高。
目前國內(nèi)一些廠為節(jié)約投資采用關(guān)鍵的密封測
18 曲軸回轉(zhuǎn)力矩檢測機 試無件引進，機身部分自行制造，基本能滿足
19 氣門及導管密封性檢測機 使用要求。目前使用的該類設(shè)備95％以上為
20 發(fā)動機總成密封性檢測機 引進。
21 氣門間隙調(diào)整機
1.1.3發(fā)動機出廠試驗設(shè)備
發(fā)動機出廠試驗是發(fā)動機產(chǎn)品的最后檢驗，在大量生產(chǎn)中，為了提高生產(chǎn)效率及試驗數(shù)據(jù)的準確性，發(fā)動機出廠試驗臺架系統(tǒng)向全自動化臺架系統(tǒng)發(fā)展，全自動出廠試驗臺架系統(tǒng)主要包括三方面的內(nèi)容。
①試驗規(guī)范的程序控制及各種數(shù)據(jù)的自動測試。通過程序控制，發(fā)動機可以按照設(shè)定的程序自動按規(guī)范的要求完成試驗并自動進行數(shù)據(jù)測量和判斷分析，并把各種測量數(shù)據(jù)儲存在計算機內(nèi)。
②試驗臺架的自動快速對接?？焖龠B接試驗臺能夠在極短時間內(nèi)完成各種管路的自動快速連接；發(fā)動機在臺架上的自動定位和夾緊；驅(qū)動軸的自動對接等一系列動作，實現(xiàn)測試臺架裝拆連接的自動化，從而減少在試驗臺上所占輔助時間。
③發(fā)動機的自動輸送。出廠試驗自動化的第三部分內(nèi)容就是與自動化試驗臺架配套的專用自動輸送線，該線的型式一般采用積放式摩擦輥道輸送線。該線具有輸送、儲存以及自動識別的功能，控制系統(tǒng)根據(jù)各臺架提出的上料先后順序和臺架外儲料滑臺上的備料情況，通過判斷識別發(fā)動機輸送托盤上的標志，自動將預試的發(fā)動機送到需要的臺架上或儲料滑臺上，將測試合格的發(fā)動機送到下線點，測試不合格的發(fā)動機送到檢修工位，將空托盤自動送回上線點。 全自動出廠試驗臺架系統(tǒng)在中國的發(fā)展，始于80年代末，當時國內(nèi)一些大型汽車廠先后引進了少量發(fā)動機自動化出廠試驗臺架，如北京吉普汽車有限公司引進美國英格索蘭自動化試驗臺架。一些設(shè)備生產(chǎn)廠在消化吸收引進技術(shù)基礎(chǔ)上，結(jié)合中國的實際情況對引進設(shè)備進行仿制，就目前的情況看，試驗規(guī)范的程序控制、試驗數(shù)據(jù)的自動測試技術(shù)及自動輸送技術(shù)在我國已經(jīng)成熟，已有少數(shù)生產(chǎn)廠能夠設(shè)計、制造并應(yīng)用于生產(chǎn)中。技術(shù)難點是快速對接技術(shù)，尤其是驅(qū)動軸快速對接抗扭振和抗自激振動等技術(shù)，這項技術(shù)還有待進一步完善。這套設(shè)備若能國產(chǎn)化將使其成本大大降低，價格僅為進口設(shè)備的十分之一，因此在中國將有廣闊的發(fā)展前景。
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