Transmission assembly line introduction
Assembly is the final manufacturing process for transmission manufacturing, including assembly, adjustment, inspection and downline testing, and bench testing. Assembly work has a direct impact on the quality of the transmission and the completion of the production plan. Assembly process procedures are technical documents that guide assembly work. To meet the requirements of quality, productivity and cost when formulating assembly process rules, according to the structural characteristics and production type of the transmission product, comprehensively consider the process method of ensuring assembly accuracy and quality, determine reasonable operation specifications, and try to use mechanical automation assembly. The method is to correctly arrange the assembly process and operation plan to ensure the technical requirements of the transmission assembly, strive for the maximum quality reserve, reduce the labor intensity, shorten the assembly cycle, improve the efficiency, optimize the layout design, and reduce the floor space of each process and the entire production line. Strive for maximum productivity per unit area.
Assembly line process and layout
The assembly line is a complex engineering system involving processes, technology, equipment, tooling, fixtures, gauges, gauges, staffing, machine operations, logistics trends, and production tempos. The entire assembly line can be seen as a main line and several auxiliary lines, dividing each assembly process. Considering production balance and logistics optimization, the production arrangement is linear, square, elliptical and circular. The use of industrial PCs enables the production process parameters and production process information of each assembly process to be tracked and recorded throughout the process, facilitating analysis and product traceability.
As shown in Figure 1, the assembly process flow visually represents the various assembly unit division and assembly processes. The layout of the assembly line layout is based on this design basis.
Figure 1 Schematic diagram of the transmission assembly process
Formulation of assembly process procedures
To formulate the transmission assembly process specification, first analyze the product, study the assembly drawing and assembly technical requirements of the transmission product, and then perform dimensional analysis on the product structure, and then perform assembly process analysis on the product structure.
1) Decompose the product into assembly units that can be assembled independently to organize parallel flow operations for assembly work. Figure 2 is a five-stage assembly unit system in which the assembly is a fixed connection of a few parts combined, the assembly is a combination of several components and parts, and the components are often assemblies with independent functions on the transmission. As can be seen from Figure 2, each individual assembly unit can perform assembly operations simultaneously. In the case of partial or final assembly, it is based on a certain part or component, and the remaining parts are successively entered into the assembly position to realize the flow operation.
Figure 2 Five-level assembly unit
In the entire vehicle assembly line, the transmission is only one of the components. The above components, components and components are relative to the transmission. Some parts, components or components are purchased as a whole purchased part, which parts need to be made and which parts need to be purchased, which is determined by the company's manufacturing strategy. The hierarchical relationship of each component belonging to the first level and the first order can also be reflected by querying the transmission product BOM.
2) Formulating the assembly process specification of the transmission also requires determining the assembly organization form and determining the assembly process. The assembly process includes the assembly work items, the process specifications, the corresponding equipment and tooling, fixtures, measuring tools, assembly methods and assembly process parameters according to the mechanical structure and its assembly technical requirements, and determine the assembly work sequence. Regardless of which level of assembly unit, select a part or the next assembly unit as the reference part, first enter the assembly work, and then specify the order of other parts and assembly units according to the specific structural requirements and considerations for easy calibration and connection. .
3) Formulating the transmission assembly process specification also requires calculating the working hour quota for the assembly work of each process. Working time quota is the basis for arranging production plans, calculating product costs and economic accounting, and economic remuneration. It is also important information for determining equipment and personnel quotas when new or expanding factories are established.
Complete the above steps, document the above identified contents, compile, and fill in the assembly process specification documents to guide production.
Transmission assembly line process
Taking the DCT transmission assembly as an example, the specific process of the transmission assembly process is:
Input shaft assembly → Output shaft 1 assembly → Output shaft 2 assembly → Gear shaft engagement → Shift assembly assembly → Transformer assembly → Transformer assembly assembly → Connection plate bolt tightening → Shaft and variable shell assembly On-line → differential part installation → differential main reduction assembly → main reduction bolt tightening → differential cone bearing and chip gear assembly → double gear and differential assembly, etc. → part detection → differential pad selection measurement → Bonding surface coating → Photographic inspection → Standby station (manual glue) → Clutch housing upper line → Off-shell assembly (pressure bushing, etc.) → Clutch housing part 2 → Off-shell selection pad measurement → Input shaft Front bearing plate assembly→cone bearing outer ring and oil seal press→transmission box→rocker arm assembly and box bolt pre-tightening assembly→input shaft oil package→transmission reverse and pre-assembled box bolt→tight bolt tightening→reserve Position (unqualified bolt tightening)→Shell bolt assembly→Assembly MAM→Speed sensor and TRS assembly→Locking steel ball assembly assembly→General assembly plus oil drain screw plug and lock steel ball screw plug assembly→Online flip→Airtight Sex detection→Transmission assembly leak detection and repair → Perform rod assembly to the tube and clutch → assemble the meshing assembly and excitation device → motor assembly → input shaft grease and double clutch hoisting → install double clutch and small snap ring → pinion and snap ring assembly → pass the transmission assembly → no Qualified assembly off-line → final assembly harness and replacement and oil-discharge connector → transmission assembly weighing → refueling, running-in, pumping → gantry detection → transmission assembly pumping, weighing → qualified transmission assembly off line → unqualified The transmission assembly is screened out.
Transmission assembly line features and technical requirements
The characteristics and technical requirements of the transmission assembly line can be reflected by the technical requirements of the station and process equipment. According to the characteristics of the transmission assembly, the work station can be divided into gear shaft assembly area, gear meshing area, clutch part loading area, assembly line and test line. Among them, the gear shaft part loading area adopts the external pressure machine to work off the island, and the parts to be press-fitted are transported here by the logistics trolley, and the pressed parts are transported to the gear meshing area by the logistics trolley, and other areas are respectively Independently adopting a circular arrangement, the meshing, clutching, busning and testing are completed in the corresponding areas, and the automatic conveying logistics conveying system is formed between the zones, and the overall arrangement adopts a ring, a square or an ellipse according to the factory-set area. Even in the form of a straight line, it is also necessary to consider the logistics of the entire plant, that is, to reduce the handling, and to reduce the valueless or low-value labor of the operator taking the material action.
The equipment requirements and operating procedures of each station, the completed process content, job description, work posture, equipment related description and main components of the equipment are described according to the work content of each station. If necessary, design tasks should be submitted for special tools and equipment, and the design tasks should be clearly defined by technical agreement. The work objectives and technical conditions and requirements to be achieved by special tools and equipment should be clarified as an important basis for the acceptance of tools and equipment.
At present, the equipment industry of domestic transmission assembly is generally good. Beijing Machinery Industry Automation Research Institute, Dalian Haosen Reid Equipment Co., Ltd. and Shenyang Xinsong are all representatives with considerable technical strength. Its station equipment interface is shown in Figure 3 and Figure 4.
Figure 3 Example of station equipment interface of Beijing Machinery Industry Automation Institute
Figure 4 Example of the station equipment interface of Dalian Haosen Reid Equipment Co., Ltd.
The widespread use of industrial PCs, using Siemens control system, can visually display the content and results of the operation instructions of each station's operation content in front of each operator. The station HMI can manually enter information such as operator account, password, part name, part drawing number, product quantity, and lot number. Fully automated information recording throughout the manufacturing process facilitates product analysis and tracking.
