Every day, cars of different sizes and shapes are moving around, carrying the hard work of countless people. China has been ranked first in the global auto market for 9 consecutive years. Manual, automatic, unmanned... People drive The pursuit of experience has spawned the iteration and renewal of manufacturing technology.
The success of any new product is not the result of a single breakthrough. It is necessary to rely on the overall strength of the entire industry chain. In Shanghai – China's automobile 'leading boss' SAIC Group, a well-performing best-selling car continues underground Line; in the Liuhe High-tech Development Zone of Taicang City not far from it, China's well-known auto parts enterprise, Chongqing Nanyan Group's new energy transmission component manufacturing plant is also full-scale production of EDU at full speed. EV, DCT and other transmission pinion products. These high-quality components are urgently needed by SAIC. They are transported to SAIC's manufacturing base, assembled with other components, and finally sailed to thousands of households.
The close cooperation between SAIC and Nanyan is certainly an example of a car company and parts suppliers going hand in hand; but if you delve into it, you will find that there is another key figure in this 'full industry chain breakthrough'. The world's machine tool giant - EMAG.
Top equipment overcomes many difficulties
As early as 2005, Nanyan became a supplier to SAIC, supplying products with manual transmission (MT) pinion; with the advent of the new energy era, technology track conversion, automatic transmission (AT), dual clutch transmission (DCT) ), continuously variable transmission (CVT) and other increasingly become the mainstream of the market, but the breakthrough of these new products is not easy. 'Automatic transmission has not been made in China before, MT technology can not be applied to DCT. To break through, need to improve design and manufacturing capabilities The design aspect is more mature, so the key lies in manufacturing. This depends on the improvement of the overall technical level of our component companies, and we need excellent processing equipment. 'He Jian, president of Taicang Nanyan New Energy Transmission Co., Ltd., said, ' Furthermore, electric vehicle transmission gears and gear shafts are different from traditional ones. The speed of conventional vehicles is 6000-8000 rpm, and the speed of electric vehicles is generally over 20,000 rpm. This requires very high precision for the product. Process capability is our improvement. The top priority of competitiveness. '
Figure 1: He Jian, president of Taicang Nanyan New Energy Transmission Co., Ltd. said that process capability is the top priority for its competitiveness.
Without the transformation to automation, it will not continue to grow and develop. However, the strict precision requirements have become the first difficulty in front of Nanyan. Wan Yanqun, Minister of Technology Department of Taicang Nanyan, tells us that the key process of the manufacturing process is gear teeth. The precision of the finishing, the accuracy error should be less than 0.01, the roughness should be RA0.2-0.3, and the structure of the workpiece is special, the thickness is relatively thin, the taper and cylindricity of the inner hole are very difficult to control, so the equipment is very tested. Performance and process level. If the performance of the equipment is not up to standard, a slight difference in the pool will result in processing scrapping and loss.
What to do? The only way is to carefully select the top processing equipment. To this end, Nanyan has turned its eyes to the world. After heavy screening, EMAG and several other machine tool manufacturers have entered the vision of Nanyan. In the end, through the actual processing competition, EMAG defeated a number of powerful opponents and successfully won. This is the official combination of the old partners who have already known each other.
Figure 2: Strict accuracy requirements are the first difficulty for both sides to overcome. At the same time, the on-site operators reduced the 50%, and the production efficiency increased by 30%. The stage goal was achieved, and the competitiveness of Nanyan was increased in a short time.
After the 9th grinding center of EMAG entered the Nanyan, the situation changed immediately. Its exceptionally strong performance fully met the stringent precision requirements. For the specific situation of the production site of Nanyan, the EMAG technical team tailored it. The process plan has been customized. As a result, the excellent equipment and excellent process plan have formed a strong manufacturing capability: The compact structure and stable performance of the equipment ensure the high precision and high quality of the product, which has won the high recognition of SAIC. Automatic feeding ensures consistent workpiece clamping, thus ensuring the best results; matching tools, grinding wheel solutions, reducing wear and tear, reducing costs... Processing problems are solved, manufacturing strength is greatly enhanced, all this makes Nanyan He always praises: 'The processing strength, technical grade and precision grade of EMAG grinding center are the top level in the world. Looking at the world, there may be few equipment manufacturers that can reach this level.'
After the accuracy is difficult to overcome, another problem comes along, which is to improve production efficiency. The South Yan Production Minister said that SAIC does not even have a holiday during the Spring Festival. In order to guarantee the supply of its products, Nanyan needs to adopt 'three shifts two Down, 24 hours without stopping the production rhythm, and, production efficiency directly determines the efficiency of the enterprise. In the face of fierce market competition, continuous improvement of production efficiency is inevitable pursuit. In order to solve the efficiency problem, EMAG has set up a double for the wild geese Spindle machine tools, its powerful strength makes the efficiency increase quite remarkable.
The EMAG twin-spindle machine includes the loading and unloading workpiece transport system, the TrackMotion automation system and the modular basic structure of the machine tool, and combines them into an efficient production system to achieve maximum productivity in the smallest space; the machine's powerful torque and Abundant power ensures fast and precise cutting; 12 tools are placed on the cutter head, covering all machining processes such as outer circle, end face and lead angle; the twin-spindle machine is seamlessly connected with the grinding center to form a highly automated Smooth production line, reduced manual operation... The excellent combination of strong performance has greatly improved the production efficiency of Nanyan, and the production cost has been rapidly reduced. It fully meets the demand of 'no stop work, improve efficiency' - production cycle of Nanyan It has reached more than 50 seconds and has become the industry's top level. The amount of work that can be completed by the original three equipments in the car grinding process can now be completed with only one EMAG machine; the entire site operator is reduced by 50%, and the production efficiency is Compared with the original, it has increased by 30%! The efficiency problem is perfect, which will undoubtedly make Nanyan in the booming and high-speed automobile manufacturing industry. Have a stronger competitive edge.
'Day and night companion' to help grow
In fact, in the cooperation with Nanyan, EMAG is not only simple to provide top-level equipment, but also provides a well-rounded 'turnkey' solution, as well as wholehearted efforts, grow together with customers, and create value together. In-depth service.
Minister Wan said that to win the trust and order of customers, process design capability is the key. Therefore, when SAIC started designing a new product project, Nanyan participated in the technical exchange with SAIC to ensure that the designed products were available. Manufacture. In this process, EMAG has contributed a great deal of wisdom – to coordinate with Nanyan to make a process plan, adjust the process layout, and enhance the technical strength to win orders.
In actual production, EMAG provides a turnkey solution for Nanyan by improving efficiency and enterprise energy level – including processing equipment, process plan, tool plan, process parameters, production cycle, etc. : 'We have a hole in the product that is long, and it is a difficult problem to process. The tool, the grinding wheel, can not be too short or too long, and we must ensure the roundness is up to standard. EMAG has developed a tool and grinding wheel solution for us. Processing needs. They helped us overcome the problem and quickly solidified the process. We just need to follow this process plan.
EMAG's technical team is a long-term 'staying' at the production site of Nanyan, providing process and equipment training for Nanyan, on-site tracking service, and working closely with Nanyan's technical team to continuously optimize production line capacity and enhance production. Efficiency, lower production costs. Sun Jiaxi, the head of the EMAG Nanyan project, which is busy at the production site, said: 'In addition to a large number of standardized trainings, we also specifically train the needs of Nanyan, and, regardless of the night shift, we They are all on the scene. Everyone is fighting hard, that is, to serve Nanyan. In the cooperation with Nanyan, we can use our solution ability to promote the rapid growth of Nanyan, and ultimately serve the customers of Nanyan and help them. Upgrade. '
Figure 3: Mr. Sun Jiaxi (right), Chief Owner of EMAG Project, Wan Yanqun, Technical Director of Taicang Nanyan (left)
It is said that EMAG and Nanyan are a pair of 'old companions' who have already known each other. They are worthy of the facts. He always said that they have been in contact with EMAG for nearly 10 years. In the past 7~8 years, There is no real business cooperation between the two parties. However, EMAG still provides technical and technical support for many projects in Nanyan, accompanied by the growth of Nanyan. 'For a long time, we did not purchase equipment from EMAG, but They spent a lot of thoughts on docking our projects. Sincerely, in all equipment suppliers, I think EMAG is doing very well, otherwise we will not be equipped with 19 devices at a time. We buy equipment, actually more What is important is the value generated by the equipment. EMAG has done it!
Just a few months ago, the Nanyan Taicang factory was just a newly completed factory building, which was slightly quiet; now, just like the increasingly hot weather, the production here is already in full swing. EMAG uses its deep technology to accumulate, flourishing Innovative strength and comprehensive in-depth services help Nanyan to quickly overcome problems and build strong technical strength and manufacturing capabilities. The high-quality components that are off the assembly line of Nanyan Factory are quickly and quickly supplied to customers such as SAIC. Help them compete for the industry wave. It is in this 'interlocking, relying on each other', the overall breakthrough of the industrial chain, the rise of new things, and the transformation and catch-up of a country's industry, can be quickly played.
Nowadays, in the endless stream of engine roaming, more and more 'new figure' is pouring into - low noise, low energy consumption, smart and light new energy vehicles. After hundreds of years of development, the global automotive industry is ushering in a huge The change, the replacement of fuel vehicles by new energy vehicles is considered to be the trend of the times. Without the shackles of traditional fuel technology, China is making new energy technologies to achieve the 'big to strong' and 'curve overtaking' of the automotive industry. Those who are good at The 'voyagers' who choose, cooperate and work side by side are ready to go. He always points to nearly one-third of the factory: 'We plan to be in place within 3 years, with an annual output of 1 billion, new energy components The product will be our next commanding height. '
Figure 4: There are currently 19 EMAG machine tools in the factory that has been put into use in Taicang Nanyan, creating value for each day of production delivery. There are still one third of the plants in the planning, where EMAG and Taicang Nanyan will work together to explore the huge space of the new energy vehicle market
About Taicang Nanyan New Energy Transmission Co., Ltd.
Founded in October 2016, the company is one of the three wholly-owned subsidiaries of Chongqing Nanyan Industrial Group. It has a registered capital of 300 million yuan, a total investment of 850 million yuan, covers an area of 77.63 acres, and a total construction area of 38,000 square meters. The company's main business is to equip Shanghai Automotive Transmission Company with new energy transmission gear shafts such as EDU/EV/DCT, keeping up with SAIC's R&D pace, achieving simultaneous planning and simultaneous development. It is an important strategic cooperation supplier of SAIC. Other high-end new energy vehicle market.