RFID technology helps domestic heavy-duty engine factories to liberate power and build smart manufacturing factories
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On September 26, 2019, the country’s first intelligent manufacturing plant for heavy-duty vehicle engines was put into use. The plant will elevate my country’s intelligent manufacturing of heavy-duty truck engines to a new level. Through the application of RFID, DNC and other Internet of Things technologies, the factory has created three intelligent manufacturing systems integrating intelligent production scheduling, intelligent production guarantee and intelligent logistics systems, realizing real-time collection of production information, algorithmic decision-making and automatic feedback. At the same time, it successfully developed a dual command platform, integrated various subsystems of intelligent manufacturing, and formed a solid, comprehensive, and feasible intelligent factory management system.
Walking into the assembly workshop of the intelligent manufacturing factory, from the perspective of the layout of the workshop, the software and hardware environment, and the advanced automation equipment, in terms of the level of intelligent manufacturing, the power of China’s independent brands has achieved the level of power in Europe and the United States. In the factory’s 50,000 square meter production area of heavy-duty diesel engines, one engine is successfully rolled off the assembly line every 110 seconds, and 130 engines are produced per capita each year. Compared with the beginning of production in 2012, the per capita annual output has increased by 117%. Here, the proportion of flexible equipment has accounted for 67%, the numerical control rate has reached more than 90%, and the automation rate has reached 78%.
The most intuitive feeling in the workshop is that there are not many workers at the workstations in the workshop. Many processes are completed by robots and robotic hands. Various intelligent unmanned AGV vehicles are shuttled back and forth with crankshafts and other parts. In addition to the use of multiple intelligent unmanned AGV vehicles, an intelligent logistics system with aerial corridors, self-made three-dimensional warehouses, and cold test SPS as subsystems, has realized the automatic logistics distribution of the assembly line.
Over the past three years, the domestic heavy-duty engine intelligent manufacturing plant has built three major systems integrating intelligent logistics, intelligent production scheduling, and intelligent production guarantee. The improvement of intelligent manufacturing level has expanded production capacity, optimized product structure, and improved efficiency. The factory’s achievements in smart manufacturing: production capacity increased by 52%, manufacturing cost decreased by 20.5%, logistics accuracy rate increased by 50%, product defect rate decreased by 39.3%, energy consumption per unit output value decreased by 8%, and annual cost reduction of 21 million Yuan. These data not only effectively enhance the market competitiveness of Jiefang vehicles, but also allow more Jiefang truck users to spend less money and use better quality and performance engines.
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