一汽轿车学习总结.pptx

目目 录录 Content一、一汽轿车冲压车间概况 General situation of fawcar stamping shop 1.车间整体规划及平面布置图 The overall planning and workshop layout 2.一轿各车型核心自制件 The core parts of home made list 3.冲压相关配套厂家 Stamping related manufacturers二、一轿冲压设备简介 Stamping equipment introduction 1.冲压生产线简介 Press line introduction 2.模修设备及维修管理 Die repair equipment and maintenance management三、一轿冲压新工艺应用 New stamping technology application 1.激光拼焊板的应用 The application of laser tailor-welded board 2.内高压成型的应用 The application of Internal high pressure molding四、新产品冲压工艺开发流程简介 The new product stamping process development introduction 1.新产品冲压工艺开发流程 The new product stamping process development flow 2.冲压生产准备重点阶段 Stamping product preparation key stage一汽轿车冲压车间概况：一汽轿车冲压车间概况：General situation of faw car stamping shop建筑面积：建筑面积：31229.3 Construction area 投资投资：现有厂房及工艺设备投资7亿 investment:total 700 million产能产能/年：年：27万辆（两条线、三班、300天、22.5小时/天），2012年将投产一条3500T伺服多工位冲压线、2013年投产一条5500T伺服自动冲压生产线，产能将达到56万辆/年。Capacity/year:270 thousand vehicles per year,3500T several location servo press will go into operation in 2012,5500T servo automatic press line will go into operation in 2013,then capacity will be 560 thousand vehicles per year冲压设备：冲压设备：stamping equipment设备：冲压A线、冲压B线、2000T研配压机1台、1000T研配压机1台、50/16T天车6台、有轨转运车1台；equipment:A press lineB press line 2000T die repair press1000T die repair press6 sets 50/16T crane RGV设备特点：冲压A线由5台压机组成，冲压B线由4台压机组成；均由德国米勒万家顿（舒勒）制造，采用自动化设备（SPEEDBAR）传输；压机为多连杆传动，头台为2000T压机，带液压拉伸垫；后续为1000T压机，带上打料装置；配备有拆垛机、清洗机、涂油机、对中台、上下料机械手、线尾皮带输送机等先进的自动化上下料系统，从毛坯的上料到冲压件的下线可自动完成。Equipment feature:Press line made by Muller Weingarten,automatic transmission type is speedbar.Full automatic press line is efficient,its highest SPM is 13 strokes per minute.工艺特点：自动生产线分别可以采用一模一件、一模双件、一模三件、一模四件，全封闭、人机分离的生产方式；生产最高连续节拍13次/分钟，模具转换时间为7分钟。Process feature:stamping process type include 3 parts in a die and 4 parts in a die.Die convert time is short,just need 7 minutes.Stamping shop layout 一汽轿车各车型核心自制件清单一汽轿车各车型核心自制件清单 The core parts of home made list一汽轿车冲压配套厂家一汽轿车冲压配套厂家 Stamping related manufacturers剪切配送厂家：宝友，蒂森，云顶，天利 Shear and delivery steel plate supplier:baoyouThyssen Kruppyundingtianli 冲压件厂家：四环变速箱，云顶，长拖，长消，天利 Stamping parts supplier:sihuan speed changing box yunding changtuo changxiao tianli 工位器具厂家：长春三鑫，鑫达，瑞鑫 Station equipment supplier:sanxinxindaruixin 模具制造厂家：大型覆盖件选择日本、德国供应商，大型结构件选择一汽模具 等国内大型供应商，中小结构件选择长春周边、华北、华东地区的供应商。Die supplier:big covering panel should choose japanese supplier and germany supplier,big structure panel choose large civil supplier,small and medium-sized structure panel choose changchun surroundingnorth chinaeast china supplier冲压冲压AB线简介线简介整条冲压生产线由德国米勒万家顿制造，其中包括线头拆垛机、清洗机、涂油机、对中台、中部的机械压力机、speedbar传送机械手及线尾的皮带输送机。Press line is made up of unstackerclean machinestrip oilercenter calibration machinepressspeed barbelt conveyor.A线压机组成：1台2000T+4台1000TB线压机组成：1台2000T+3台1000T冲压线特点：每台压机的上下台面分别布置四个传感器，模具安装在下模台面上开入压机后，滑块下行与模具上平面接触后，传感器对自走式夹紧器发出指令，夹紧器自动完成对上模本体的装夹操作，从而缩短模具安装时间，该生产线的换模时间为7分钟。There are four sensors on upper working stable and lower working stable,when die load on lower working stable and slide block contact with top of die,then sensor give orders to clamp machine,clamp machine will autocomplete clamping die,so convert die time is short,just need 7 minutes.各压机之间工件传输采用speedbar机械手，该方式具有速度快，稳定性高的特点，适用于高速生产线，不过投资较大。speed bar s feature is high speedhigh stability applying to high speed press line,but need greater investment.AB两线为高速冲压线，A线最大SPM为12次/分，B线最大SPM为13次/分，单机最大SPM为18次/分。A/B两线均为全封闭自动化生产线，生产过程及制件传输都是自动控制，无需操作人员，仅线尾需要人员对冲压件进行检测和装箱。冲压线整体图片如下：冲压线整体冲压线线头模具及speedbar冲压线线尾模修设备及维修模修设备及维修管理管理 Die repair equipment and maintenance management冲压车间有1000T验配压机、2000T研配压机、剪板机、车床、铣床、摇臂钻各一台，可以进行小型机加维修。Die repair equipment:1000T tryout press2000T tryout pressplate shear machinelathemillerdrill.模具保养维修分为两种：预知维修和计划维修模具保养维修分为两种：预知维修和计划维修Die repair method:Precognition repair and planning repair1.预知维修：针对生产中发现的模具问题和冲压件问题进行模具维修Precognitiong repair:If die or stamping part has issue,notice repair staff.2.计划维修：根据模具类型进行定期定量保养，拉延模具每10000冲次进行一次保养，拉延后续模具每15000 冲次进行一次保养Planning repair:According to the stroke of die,there is a maintence for draw die per 10000 strokes,draw follow-up die per 15000 strokes.激光拼焊板的应用激光拼焊板的应用 The application of laser tailor-welded board 在欧美发达国家激光拼焊板已广泛应用于汽车制造业，而我国的激光拼焊工艺才刚刚起步。The laser tailor-welded plate has been widely used in automobile manufacturing in developed western countries,but the laser tailor-welded process has just started in china.激光拼焊板的定义：采用激光能源将不同材质、不同厚度的多块钢板拼焊成一体的组合钢板。Definition:several different material,different thicknenss of the steel plates weld into a whole by using laser energy.激光拼焊板的优点：采用激光拼焊板工艺不仅能够降低整车的制造成本、物流成本、整车重量、装配公差、油耗和废品率，而且可以减少外围加强件数量，简化装配步骤，同时使车辆的碰撞能力、冲压成型率和抗腐能力提高。此外，由于避免使用密封胶，也使其更具有环保性。Feature:the laser tailor-welded process can reduce manufacturing cost,logistics cost,vehicle weight,assembly tolerance,oil consumption,scrap rate,parts,assembly steps,can improve the vehicle collision ability,stamping form rate,corrosion resistance ability.内高压成型的应用内高压成型的应用 The application of Internal high pressure molding内高压成型的定义：也叫液压成形或液力成形，是一种利用液体作为成形介质，通过控制内压力和材料流动来达到成形中空零件目的的材料成形工艺。Definition:Also called hydraulic forming,its a hollow parts forming process that using liquid as forming media,throuth controlling the pressure and material flowing to achieve the purpose of material forming.内高压成型的优点：内高压成形的构件质量轻，产品质量好，并且产品设计灵活，工艺过程简捷，同时又具有近净成形与绿色制造等特点，因此在汽车轻量化领域获得了广泛的应用；与冲压焊接件相比，管材液压成形的优点是:节约材料,减轻重量,一般结构件可减重20%30%,轴类零件可减重30%50%，可减少后续的机加工量和组焊工作量；提高构件的强度与刚度,材料利用率为95%98%；降低生产成本和模具费用30%。Feature:Parts made by internal high pressure forming have some advantages:lighter weightbetter qualityflexible design simpler processgreen manufacturing.This process can reduce the cost of materail and die.副车架内高压成型工艺流程：副车架内高压成型工艺流程：The subframe of Internal high pressure molding弯弯 管管 bending预成型预成型 preforming 内高压成型内高压成型 Internal high pressure molding新产品冲压工艺开发流程新产品冲压工艺开发流程 The new product stamping process development flow生产制造监制Manufacture producer产品评审Product reviews冲压件数据锁定Stamping math date locked投资预算Investment budget初版工艺Primary process招 标Tendering procedure设 计Design会 签 Drawings sign金属材料消耗定额制定Formulating Metal material consumption quota模具制造调试Die manufacturing debugging预验收Prepare buy off冲压模具回厂调试Die try out in plant终验收Final buy off冲压生产准备重点阶段冲压生产准备重点阶段 Stamping product preparation key stage 根据冲压工装开发进度、冲压件质量提升、工装调试及生产能力提升、整车质量提升等几方面因素相结合制定了一下几个关键节点及其重点控制项目.According to Stamping tooling development progressimproving stamping qualityimproving manufacture abilityimproving vehicle quality,etc.making this key stage.PCF：制件在检具上开始匹配的开始时间点。一般在此阶段，由匹配技术人员发出修正指示，这部分修正指示在模具厂家修改完成。PCF可以分成不同阶段，如：PCF0、PCF1、PCF2等等 PCF stage :When tools is in suppliers,panel matching on the check fixture is start time,matching engineer will Issue revised instructions.TTO：利用量产设备，采用量产材料，由量产之后的工作人员进行操作冲压设备，调试出的冲压件的过程，这段时间称为TTO。TTO一 般为焊装开始时间，冲压的开始时间一般需要提前三周。冲压在此阶段发现模具的安装问题、废料的排出问题，模具适应设备问题（模具的闭合高度、气垫压力等）。TTO stage:staff operates production equipment and material to try out the qualified stanmping in plant.TTO is the start time of welding,so start time of stamping need advance three weeks.If stamping manufacturing has some problems,stamping engineer need solve these problems.在此阶段，匹配会根据装车的情况发出修正指示，冲压工艺员考虑制件修理的难易程度，对修正指示进行会签并负责落实In this stage,according to the situation of the match will Issue revised instructions,stamping engineer should consider the difficulty of the repair,sign and implement the revised instructionsPP：此阶段重点为培育设备、工装的批量生产能力阶段，同时完成TTO阶段的修正指示。批量生产能力：制件工序间搬运、废料的排出、工位器具、物流、工艺卡文件、批量生产材料到货等。在此阶段将逐步与冲压件生产车间交接，进行生产性调试.PP stage:this stage will improve the ability of batch production.MP：初步具备生产能力，但对质量要进行重点管理，形成稳定的生产能力。MP stage:having primary product ability,but quality management is key,forming stable product ability.