The Great Wall Motor Power Division was established on October 26, 2007. Its predecessor was the Engine Research Group of the Technical Research Institute. At present, the five gasoline engines that have been planned from G01 to G05 have a displacement of 1.5L to 0.8L, taking into account the four-cylinder and three-cylinder two series. The first-stage production line that is now in use has the capacity to produce 100,000 units per year for the G01-G03 engine.
Although the Great Wall Motor Power Division was established for a short period of time, through rapid development and solid management, it has fully possessed the ability of product planning, design, CAE analysis, matching, trial production and testing, as well as in process planning and manufacturing. Showing strong strength, especially in equipment management, production processing and tool management, it has its own unique side.
Strong production and processing capacity The first phase of the construction of Great Wall Motor Power Division has been basically completed, and it has already had mass production capacity. Into the Great Wall Motor Power Division 30,000m2 plant, giving people the first feeling is clean and orderly. The five production lines of engine block, cylinder head, crankshaft, assembly and thermal test are neatly arranged. Complete equipment installation, commissioning and mass production capacity in just half a year, which is inseparable from the selection, management and maintenance of equipment.
Ding Chunsheng, head of Planning Department of Great Wall Motors Division, said: "All the processing equipment of Great Wall Power Division is CNC machine tools, 90% of which are imported equipment, only some domestic brands used in CNC grinding machines. Among them, cylinders and cylinders The cover production line is mainly composed of 17 German HELLER high-speed machining centers, NAGEL honing automatic lines, Italian MARPOSS measuring machines and auxiliary machines. It can complete tasks such as machining, cleaning, air tightness test and offline inspection. It can realize various models. Co-line production. The crankshaft line is a fully automatic production line. The loading and unloading of the process is realized by the truss manipulator. The whole line is made up of German BOEHRINGER CNC lathe, follow-up high-speed milling machine, JUNKER CNC grinding machine, HEGENSCHEIDT fillet rolling machine, Italy MARPOSS. The advanced equipment such as measuring machine not only ensures the production precision of the crankshaft, but also improves the production efficiency."
The selection of these devices is not blind, but the Ministry of Power has determined through detailed investigation and multi-party argumentation. Mr. Ding said that when purchasing production equipment, many Japanese, Korean and domestic machine tool manufacturers have had plans. Compared with the equipment provided by German manufacturers, although they have advantages in single price, they produce the same products. The number of machine tools required is large, so that the cost of spare parts, power consumption, tool configuration, and staffing will increase in the later period. Therefore, the overall cost is not reduced, but it is increased. The number of machine tools is relatively small, the efficiency of single machine is high, and the solution with short production line reflects the lean idea and the cost performance. The initial investment in this form may be higher, but the maintenance is less in the later stage and the number of personnel is small. Less power consumption and savings in the long run.
“Taking crankshaft processing as an example,†said Ding Kechang: “The material is ductile iron. We use high-speed external milling of BOEHRINGER in Germany for roughing. With double-cutter processing, it can realize three shifts of 100,000 with one machine. The output of Taiwan. There are two machines in China that can do such a machine, but the efficiency is much lower, it can be 1~2 times worse, and the precision will be lower. We also want to buy domestic brand machine tools, but due to the low general processing efficiency. The auxiliary time is longer and it is not suitable for mass production. For example, the machine tool change table in Germany needs 9s, while the domestic machine tool needs 15s, so the accumulated auxiliary time will be a lot."
Appropriate tool selection The design and manufacturing capabilities of tools and machine tools are two major aspects of measuring the advancement of manufacturing. These two aspects are not strong enough to become a manufacturing power. In the processing and production of engines, in addition to advanced CNC machine tools, the ability to use tools also occupies a very important position.
Mr. Ding said that most of the current processing machines use the US Kenner tools, only a small number of special tools used MAPAL and OSG. The reason why not all brands are selected is that there are certain differences in the characteristics of the tools of each manufacturer. For example, the problem of short tool life during machining, such as fine cylinder bores. At the beginning, Kenner tools were used in the machining process, but many problems were found in the actual machining process. Later, the MAPAL tool was used. By optimizing the parameters, the machining effect is better, the life is much longer, and the noise vibration during the machining process is Be small. In this way, the combination of the two superior tools achieves the best conditions for production and processing.
The tool materials used in the cylinder head and cylinder processing cover high speed steel, carbide coating, CBN and diamond. The drilling tools are mainly made of cemented carbide coated tools; the face milling cutters are made of diamond. The material tool is mainly used; the crank hole processing mainly uses CBN material cutter. In the clamping method of the tool, the three sets of the heat sleeve, the hydraulic pressure and the clip are selectively used according to different processing procedures and precision requirements, mainly because different clamping methods are used in each processing process. Each has its own strengths. For example, the drill tap is mainly composed of a clip and a hot set clamp, and the reamer uses a hydraulic handle. The machining accuracy of the tool compared with the hydraulic tool holder is relatively high.
Non-standard tools are also used in the machining of engine parts. When determining the tool plan, because the parameters of each tool are different, the machining accuracy and durability are different, and the manufacturer with the overall solution capability is required to assist. Mr. Ding said that “there will be factors to reduce costs in the future, and it may be possible to select domestically produced tools in terms of the use of some tools. This is beneficial to the enterprise, and it must be clear that this will be a more complicated process. In terms of the requirements of the use of tools, many domestic manufacturers now have a large gap between the materials, coating quality and tool accuracy, and the large international companies. In the above, the requirements cannot be met. For example, when a tool fails to be processed and a new design and solution is required, the domestic tool manufacturer will not be able to meet the requirements in terms of technology and delivery time, which will cause the production line to be discontinued."
Tool management for the factory "Now we want to manage the tool in a simple way." Ding said. “In terms of tool management, we initially considered adopting the US Kenner tool management system, but considering the current production status, the entire supporting system has not yet reached a certain scale, so this management system is not suitable for the factory at present. Of course, with the construction of the second phase of the Power Division and the start of mass production, the adoption of a suitable tool management system is already under consideration."
At present, the tool management of the Great Wall Power Division is mainly handled by the equipment division tool group. Tool combination, adjustment, storage, and tool change during production are all done by a dedicated person. In order to avoid the occurrence of a knife in the production process, in addition to the tool change by the special tool group, the NC program is also maintained and modified by the programming team to ensure the safety of the tool and the machine. In order to ensure the quality of the processing, a forced tool change method is adopted. Under normal production conditions, the number of workpieces is taken as the standard, and a certain amount of machining is required to perform a forced tool change to avoid excessive tool wear. In general, the machine is equipped with an alarm program that automatically alarms when a certain number of workpieces are machined. When the production line is in normal operation, a spare tool is placed under the line to prevent the tool from being untimely and affecting the operation of the production line.
Emphasis on scientific research and innovation and talent cultivation Scientific research and innovation capability is the source of sustainable development of a company. Talent cultivation and reserve are the driving force for a company to maintain a strong development momentum.
In order to meet the needs of the expansion of new models in the future, the Power Division has made a big fuss in the serial production of engine products. In the design of each product, try to balance the positioning reference and the clamping position, such as 1.5L and 1.3L displacement engines, except for the cylinder head is completely universal, most of the other parts are also universal; The height of the body and the diameter of the cylinder bore are slightly different, but the overall positioning and clamping are unchanged, so that the series of engine platforms built can quickly complete the new model design and reduce the production cost.
Since the beginning of 2008, PTC's PDS (Product Data System) has been used for design management. This system has improved the overall development capability and achieved top-down design. The networked collaborative design model enhances the designer's overall concept. To reduce unnecessary mistakes and effectively shorten the development cycle.
In terms of talent development, the Power Division has done a lot of work. Cultivating people, retaining people, and using good people are an important task of the human resources department. Through the planned training for employees, each employee's work ability can be improved and meet the job requirements. When the reporter visited the workshop, he saw at least three training courses in progress. Mr. Ding said: "The conditions and environment faced by young people today are relatively good. The machine tools that are in contact are very advanced, the starting point is very high, and the resources available are relatively high. As long as the time is fully utilized, it can be improved in a short period of time. Self-level. In addition, the company provides a fair competition platform that gives each employee a space to showcase themselves."
Mr. Ding said: "Cultivating young people's rapid growth is a difficult task that requires us to constantly explore. At the same time, we hope that each young employee can fully demonstrate his or her strengths and abilities in his own job. Fan career."
Although the Great Wall Motor Power Division was established for a short period of time, through rapid development and solid management, it has fully possessed the ability of product planning, design, CAE analysis, matching, trial production and testing, as well as in process planning and manufacturing. Showing strong strength, especially in equipment management, production processing and tool management, it has its own unique side.
Strong production and processing capacity The first phase of the construction of Great Wall Motor Power Division has been basically completed, and it has already had mass production capacity. Into the Great Wall Motor Power Division 30,000m2 plant, giving people the first feeling is clean and orderly. The five production lines of engine block, cylinder head, crankshaft, assembly and thermal test are neatly arranged. Complete equipment installation, commissioning and mass production capacity in just half a year, which is inseparable from the selection, management and maintenance of equipment.
Ding Chunsheng, head of Planning Department of Great Wall Motors Division, said: "All the processing equipment of Great Wall Power Division is CNC machine tools, 90% of which are imported equipment, only some domestic brands used in CNC grinding machines. Among them, cylinders and cylinders The cover production line is mainly composed of 17 German HELLER high-speed machining centers, NAGEL honing automatic lines, Italian MARPOSS measuring machines and auxiliary machines. It can complete tasks such as machining, cleaning, air tightness test and offline inspection. It can realize various models. Co-line production. The crankshaft line is a fully automatic production line. The loading and unloading of the process is realized by the truss manipulator. The whole line is made up of German BOEHRINGER CNC lathe, follow-up high-speed milling machine, JUNKER CNC grinding machine, HEGENSCHEIDT fillet rolling machine, Italy MARPOSS. The advanced equipment such as measuring machine not only ensures the production precision of the crankshaft, but also improves the production efficiency."
The selection of these devices is not blind, but the Ministry of Power has determined through detailed investigation and multi-party argumentation. Mr. Ding said that when purchasing production equipment, many Japanese, Korean and domestic machine tool manufacturers have had plans. Compared with the equipment provided by German manufacturers, although they have advantages in single price, they produce the same products. The number of machine tools required is large, so that the cost of spare parts, power consumption, tool configuration, and staffing will increase in the later period. Therefore, the overall cost is not reduced, but it is increased. The number of machine tools is relatively small, the efficiency of single machine is high, and the solution with short production line reflects the lean idea and the cost performance. The initial investment in this form may be higher, but the maintenance is less in the later stage and the number of personnel is small. Less power consumption and savings in the long run.
“Taking crankshaft processing as an example,†said Ding Kechang: “The material is ductile iron. We use high-speed external milling of BOEHRINGER in Germany for roughing. With double-cutter processing, it can realize three shifts of 100,000 with one machine. The output of Taiwan. There are two machines in China that can do such a machine, but the efficiency is much lower, it can be 1~2 times worse, and the precision will be lower. We also want to buy domestic brand machine tools, but due to the low general processing efficiency. The auxiliary time is longer and it is not suitable for mass production. For example, the machine tool change table in Germany needs 9s, while the domestic machine tool needs 15s, so the accumulated auxiliary time will be a lot."
Appropriate tool selection The design and manufacturing capabilities of tools and machine tools are two major aspects of measuring the advancement of manufacturing. These two aspects are not strong enough to become a manufacturing power. In the processing and production of engines, in addition to advanced CNC machine tools, the ability to use tools also occupies a very important position.
Mr. Ding said that most of the current processing machines use the US Kenner tools, only a small number of special tools used MAPAL and OSG. The reason why not all brands are selected is that there are certain differences in the characteristics of the tools of each manufacturer. For example, the problem of short tool life during machining, such as fine cylinder bores. At the beginning, Kenner tools were used in the machining process, but many problems were found in the actual machining process. Later, the MAPAL tool was used. By optimizing the parameters, the machining effect is better, the life is much longer, and the noise vibration during the machining process is Be small. In this way, the combination of the two superior tools achieves the best conditions for production and processing.
The tool materials used in the cylinder head and cylinder processing cover high speed steel, carbide coating, CBN and diamond. The drilling tools are mainly made of cemented carbide coated tools; the face milling cutters are made of diamond. The material tool is mainly used; the crank hole processing mainly uses CBN material cutter. In the clamping method of the tool, the three sets of the heat sleeve, the hydraulic pressure and the clip are selectively used according to different processing procedures and precision requirements, mainly because different clamping methods are used in each processing process. Each has its own strengths. For example, the drill tap is mainly composed of a clip and a hot set clamp, and the reamer uses a hydraulic handle. The machining accuracy of the tool compared with the hydraulic tool holder is relatively high.
Non-standard tools are also used in the machining of engine parts. When determining the tool plan, because the parameters of each tool are different, the machining accuracy and durability are different, and the manufacturer with the overall solution capability is required to assist. Mr. Ding said that “there will be factors to reduce costs in the future, and it may be possible to select domestically produced tools in terms of the use of some tools. This is beneficial to the enterprise, and it must be clear that this will be a more complicated process. In terms of the requirements of the use of tools, many domestic manufacturers now have a large gap between the materials, coating quality and tool accuracy, and the large international companies. In the above, the requirements cannot be met. For example, when a tool fails to be processed and a new design and solution is required, the domestic tool manufacturer will not be able to meet the requirements in terms of technology and delivery time, which will cause the production line to be discontinued."
Tool management for the factory "Now we want to manage the tool in a simple way." Ding said. “In terms of tool management, we initially considered adopting the US Kenner tool management system, but considering the current production status, the entire supporting system has not yet reached a certain scale, so this management system is not suitable for the factory at present. Of course, with the construction of the second phase of the Power Division and the start of mass production, the adoption of a suitable tool management system is already under consideration."
At present, the tool management of the Great Wall Power Division is mainly handled by the equipment division tool group. Tool combination, adjustment, storage, and tool change during production are all done by a dedicated person. In order to avoid the occurrence of a knife in the production process, in addition to the tool change by the special tool group, the NC program is also maintained and modified by the programming team to ensure the safety of the tool and the machine. In order to ensure the quality of the processing, a forced tool change method is adopted. Under normal production conditions, the number of workpieces is taken as the standard, and a certain amount of machining is required to perform a forced tool change to avoid excessive tool wear. In general, the machine is equipped with an alarm program that automatically alarms when a certain number of workpieces are machined. When the production line is in normal operation, a spare tool is placed under the line to prevent the tool from being untimely and affecting the operation of the production line.
Emphasis on scientific research and innovation and talent cultivation Scientific research and innovation capability is the source of sustainable development of a company. Talent cultivation and reserve are the driving force for a company to maintain a strong development momentum.
In order to meet the needs of the expansion of new models in the future, the Power Division has made a big fuss in the serial production of engine products. In the design of each product, try to balance the positioning reference and the clamping position, such as 1.5L and 1.3L displacement engines, except for the cylinder head is completely universal, most of the other parts are also universal; The height of the body and the diameter of the cylinder bore are slightly different, but the overall positioning and clamping are unchanged, so that the series of engine platforms built can quickly complete the new model design and reduce the production cost.
Since the beginning of 2008, PTC's PDS (Product Data System) has been used for design management. This system has improved the overall development capability and achieved top-down design. The networked collaborative design model enhances the designer's overall concept. To reduce unnecessary mistakes and effectively shorten the development cycle.
In terms of talent development, the Power Division has done a lot of work. Cultivating people, retaining people, and using good people are an important task of the human resources department. Through the planned training for employees, each employee's work ability can be improved and meet the job requirements. When the reporter visited the workshop, he saw at least three training courses in progress. Mr. Ding said: "The conditions and environment faced by young people today are relatively good. The machine tools that are in contact are very advanced, the starting point is very high, and the resources available are relatively high. As long as the time is fully utilized, it can be improved in a short period of time. Self-level. In addition, the company provides a fair competition platform that gives each employee a space to showcase themselves."
Mr. Ding said: "Cultivating young people's rapid growth is a difficult task that requires us to constantly explore. At the same time, we hope that each young employee can fully demonstrate his or her strengths and abilities in his own job. Fan career."
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