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FAW Jiefang Engine Division advances into Industry 4.0

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In the cradle of China's national industry and township industry, Wuxi, the birthplace of the Sunan model, FAW Jiefang Engine Division (formerly Xichai) took four years of entrepreneurship through the 40 years of reform and opening up, from "catch up to the times" to "lead the times" Great leap. It not only provides a high-end power for the rise of China's automobile industry, but also continuously upgrades into industrial 4.0 with industrial upgrading, and continues to write a new chapter in the history of "China's wisdom".

Looking back at history: four times of entrepreneurship laid the status of "national brand" industry

The first steam ejected from the Watt steam engine has brought mankind into the era of industrialization. Every country that tries to engrave its own chapters on the human history scroll has a common feature, that is, it has built a strong and complete Manufacturing system. Regrettably, until the founding of the People's Republic of China, in the process of world industrialization in the past two hundred years, the Chinese nation, which once created a splendid civilization, was far behind because of its own steadfastness.

On September 26, 1943, the predecessor of Xichai, the central agricultural implement experimental factory opened by Wang Puppet Government, officially started production. From the earliest production of threshing machine, keel waterwheel, gas engine, to the National Government Ministry of Agriculture and Forestry after the victory of the Anti-Japanese War. To manufacture large-scale diesel engines to cope with large-scale pumps and large-scale agricultural machinery. After the establishment of New China, trial-produced disc-type diesel engines, unattended diesel generator sets, and “straight-six” aircraft engines, Xichai has never had a long-term development strategy. It was not until the reform and opening up that the historic transition from the agricultural machinery industry to the automobile industry and the production of diesel engines for vehicles was officially unveiled.

Over the past 40 years, Xichai has always insisted on hard work and independent innovation as the "core" era of FAW. It has developed the CA6DL diesel engine and formed seven series of products. It has slammed the "Aowei" brand and has surpassed the sales revenue of over 10 billion. Steps; owns 4 platform products of Aowei, Hengwei, Conway and Jinwei. The displacement covers 2 to 13 liters and the power covers 40 to 550 hp. With low fuel consumption, low emission, low noise, high torque and strong power, The quality of the product features are well received by users; the one-million-kilometre-free Aowei engine won the first national scientific and technological progress award in the engine industry; in August 2017, it was uniformly deployed in accordance with China FAW and the Liberation Business Division. Integrate Deutz FAW (Dalian) Diesel Engine Co., Ltd., FAW Wuxi Oil Pump Nozzle Research Institute, FAW Technology Center Engine Development Center, and establish FAW Jiefang Engine Division to continuously improve manufacturing force from technology to production, marketing and service. The “soft” and “hard” strengths have enhanced the brand value of the engine division and pushed the company to move toward high-end manufacturing.

This is not the past: smart production ensures that "high-end power" is absolutely leading

The previous engine manufacturing process used a manual registration method, which was simple and time-consuming. Now, a digital nut can record 2 kilobytes of information, not only the data is more accurate, but also can continuously record the entire production process, greatly improving the manufacturing efficiency; enterprise managers can control the large-screen production scheduling through the production line to control at a glance.

Nowadays, in the production area of ??heavy-duty vehicle engines of the FAW Jiefang Engine Division, the Aowei 6DM machining production line uses a large number of intelligent control equipment. The proportion of flexible equipment has accounted for 67%, and the numerical control rate has reached more than 90%. The assembly line adopts KUKA, ABB robots, high-computation test bench and other automation equipment to achieve automatic operation, automation equipment accounts for 65%; machining production line has 60 processes, the automation rate reaches 78%; total assembly line has 138 The station has a 28% automation rate. At the same time, the machining production line is equipped with equipment for full collection analysis and real-time control of machining accuracy. The assembly line is equipped with automatic tightening, gluing, conveying, assembly and other equipment, and is equipped with key dimensions, torque, appearance and seepage. Leak and other re-inspection equipment. These equipments are sufficient to ensure that the accuracy, reliability and production consistency of the products can reach the international advanced level.

At the same time as the construction of “smart factory”, the engine business unit continuously developed the application of production logistics management, human-machine interaction and other technologies in the industrial production process: the Planning and Development Department cooperated with the heavy machinery department and other departments to invent the “implementation of cylinder block multiplex The development of the assembly robot system, can use a robot to achieve the three assembly process content, improve the efficiency of the robot's equipment use, reduce costs; the development of the Ministry of Planning and Development of the "heavy diesel engine oil cooler part of the process", overcoming the original There are shortcomings such as low efficiency of workbench, large workload, and inconvenient operation of oil cooler leak detection, so that only 4 people can complete the assembly of 250 sets of oil coolers in a single line of the process; The "detection process of the piston cooling nozzle installation state", after the engine is in position, the camera is driven by the robot to the set position, and then the piston cooling nozzle installed in the engine cylinder body is photographed, and the visual software recognizes the photo and The preset data is compared to check whether the installation state of the piston cooling nozzle is qualified. ..... Through various advanced equipment and production methods, Xichai can off-line a heavy-duty diesel engine every 120 seconds, leading the country in production efficiency.

It is understood that since 2016, FAW Jiefang Xichai's “Dangerous Vehicle Engine Intelligent Manufacturing Pilot Demonstration Project” has been reviewed by the Ministry of Industry and Information Technology and has become one of the first 64 pilot demonstration projects in China. The current FAW Jiefang Engine Division automation assembly line is more traditional. The engine production line has increased labor productivity by 50%, energy efficiency by 30%, operating costs by 20%, and machine rework by 15%. Created the first “first” in China: the first creative “X” type production line; the first use of three-axis robot to realize automatic lubrication and automatic installation of cylinder liner; the first use of fiber-optic sensing non-contact detection technology; the first use of visual error-proof technology; The intelligent AGV automatic distribution concept is implemented in the entire assembly line component. These advanced intelligent production modes ensure that the FAW Jiefang Engine Division is the absolute leader in the domestic industry.

Aiming at the future: to build smart logistics for industrial 4.0

At the moment when the tide of Industry 4.0 has swept the world, the FAW Jiefang Engine Division, which has taken the development of the complete ball industry giant for only a few decades, is taking the whole machine as the leader, the power as the core, and the intelligent logistics. A diversified ecological structure for the new format. The intelligent logistics system of FAW Jiefang Engine Division, which has just been put into test, will become another milestone in the modernization of China's automobile industry.

Minister Li Hongjian of the Heavy Machinery Department of the FAW Jiefang Engine Division introduced that the FAW Jiefang Engine Division is integrating resources through the Internet, the Internet of Things and the logistics network to fully utilize the efficiency of the existing logistics resource suppliers: various barcodes, radio frequency identification technologies, and sensors. Advanced technologies such as UWB are widely applied to the logistics, logistics, warehousing, distribution and other production links of the engine division to achieve automated operation and efficient management of cargo transportation processes, improve service levels in the logistics industry, reduce costs, and reduce natural and social resources. Consumption. It truly emphasizes the concept of “customer-centered”, promotes the development of the regional economy and optimizes the allocation of resources in the world to achieve socialization.

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It is understood that the intelligent logistics project of FAW Jiefang Engine Division realizes real-time pulling of material information production line, material cleaning and transportation and automatic smoothing by building logistics information management system, building air corridor, three-dimensional library, error-proofing device and automatic AGV distribution. delivery. After the system is completed, the assembly line logistics will be automated, punctualized and intelligent, and the first assembly line in the industry will be fully automated. Intelligent logistics can not only achieve less people's work, but also integrate with intelligent production management system, respond quickly to production anomalies, make accurate decisions through intelligent algorithms, and intelligently dispatch people, machines and objects in the first time, thus greatly reducing The production line was shut down, breaking the bottleneck of production efficiency. The implementation and landing of the intelligent logistics system of the engine business unit will have exploration and reference value for the informationization and intelligent development of China's automobile industry in the future.

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Qian Hengrong, secretary of the party committee and general manager of the FAW Jiefang Engine Division, said that under the current situation, the engine division is aiming at the international first-class overall positioning, focusing on the goal of “enhanced level of intelligent manufacturing maturity level 3.5 and challenge level 4”. The construction of intelligent logistics system, intelligent production dispatching system and intelligent production guarantee system will continue to lead in the heavy machinery market by implementing the “Four Big Changes”, “Four Enhancements” and “Four Strategies”, and achieve leading in the light and light market. The overseas market has expanded its influence and is constantly moving towards the goal of “domestic leading and international first-class”.