In the rumbling workshop, it was another scene. Several six-story heavy-duty machines are undergoing final inspection. They are about to go to the car factory to perform their mission.
These behemoths that make people look up are a major product of Jinan No. 2 Machine Tool: CNC stamping equipment. Don't underestimate them, the big guys equipped with high-precision technology also have great wisdom.
Among the four major processes of stamping, welding, painting and final assembly in automobile manufacturing, stamping is the key first step. According to the shape of the mold, the flat steel plate is hard pressed, cut or perforated under the action of 3 to 5 punching machines to form body parts. In the body of a car, more than 70% of the parts are stamped.
In 2013, the documentary "Heavy Power of a Great Power" took the screen by storm. When talking about the Jinan Second Machine Tool, the film said, "In 2009, China became the world's largest automobile producer. More than 80% of the outer cover parts are produced by stamping equipment made in China. This makes the cost of automobile manufacturing very large. Reduced, allowing cars to enter the families of ordinary people on a large scale at least 3 years in advance."
In this regard, Xu Hongping, deputy director of the Mechanical Optimization Office of Jinan No. 2 Machine Tool, was quite touched. "More than 20 years ago, a Santana sedan sold for about 200,000 yuan. At that time, the per capita monthly income in Jinan was only about 100 yuan. Now, the car dream is no longer as far away as it was in the past." He said.
"At present, among the four major processes of automobile manufacturing in China, only stamping equipment has achieved localization. This is largely due to the Jinan Second Machine Tool." He said proudly.
The stamping line produced by Jinan No. 2 Machine Tool is operating normally in the automobile factory
20 years togetherFrom the initial small arsenal to the top three automotive stamping equipment manufacturers in the world, the success of Jinan No. 2 Machine Tool did not happen overnight. After 2003, the domestic automobile market began to advance by leaps and bounds, and Jinan No. 2 Machine Tool ushered in an opportunity to take off. But being able to seize this opportunity depends on the profound "internal strength" laid down through integrated innovation and independent innovation over the years. Among them, Siemens also played an indispensable role.
Siemens and Jinan No. 2 Machine Tool became attached since 1996. At that time, Siemens' 840D CNC system began to be installed on the machine tool produced by Jinan No. 2 Machine Tool. With the deepening of cooperation, Siemens' Totally Integrated Automation (TIA) systems are increasingly integrated into the automotive stamping equipment produced by Jinan No. 2 Machine Tool. From PLC (Programmable Logic Controller), motion control system to drive system, Siemens products and solutions help improve the efficiency and reliability of the press line.
With the accelerated upgrading of the automotive industry and increasingly fierce market competition, the requirements of automotive factories for the accuracy, efficiency and flexibility of the stamping line are also increasing. To meet these challenges, digital technology is particularly critical.
Since 2010, Jinan No. 2 Machine Tool has started to use Siemens PLM (Product Life Cycle Management) software, which has taken a solid step in digital manufacturing.
The structure of the press line is becoming more and more complex, the design difficulty is increasing, and the number of parts involved in a single press is as high as more than 10,000. Compared with the original two-dimensional design software of Jinan No. 2 Machine Tool, the three-dimensional design software Solid Edge developed by Siemens specifically for the machinery industry is more intuitive and practical, and the design efficiency is higher. The Teamcenter software is used for data flow management of the product life cycle.
"We have been using 2D design software for 30 years, and many ready-made design modules accumulated in the past can be used. However, turning to 3D design requires starting from scratch and accumulating. Nevertheless, we are still vigorously promoting Solid Edge because It represents the development trend of virtual design." said Li Zhengshuang, mechanical designer of Jinan No. 2 Machine Tool.
Car shell parts stamped by the stamping equipment of Jinan No. 2 Machine Tool
According to Xu Hongping, deputy director of the Mechanical Optimization Office, Jinan No. 2 Machine Tool has spent two years on extensive investigations before finally selecting Siemens' PLM software. "In addition to the product itself, we are fond of Siemens' comprehensive solutions covering product design, production planning, production engineering, production implementation and services. This will be of great help to our deployment of a digital manufacturing industry chain that covers the entire product life cycle." He says.
This year is the 30th year that Xu Hongping has worked at Jinan No. 2 Machine Tool. When he first joined the work, he just caught up with the 2D design software to replace the drawing board, set square and pencil, and brought the first qualitative leap in mechanical design.
"Designing on the computer was a very fashionable thing at the time. I have been doing it for most of my life now, and I have to follow the general trend and move towards a more cutting-edge three-dimensional development." He said.
"Virtual Lab"In order to ensure the high efficiency and safety of the press line, the testing process is indispensable. In the past, the debugging of the press line was a real practice of "real guns and live ammunition". A small error can cause equipment damage. Now, Siemens Press Line Simulation Software (PLS) has built a "virtual laboratory" that can help optimize the rhythm of stamping and the movement trajectory of the feeding equipment, and improve the efficiency of the entire line.
In 2013, after the introduction of the Siemens PLS software framework, Jinan No. 2 Machine Tool cooperated with Siemens and Shanghai General Motors to start the secondary development of the software to better meet actual needs.
Siemens technical engineer Xu Lihua is a member of this three-party development team. In 2014, she traveled to Jinan and Shanghai several times to provide technical support to partners. When encountering difficult technical problems, it is common to discuss late at night.
After the PLS is put into use, Jinan No. 2 machine tool can greatly reduce the debugging time and design flaws. Simulation data can also be imported into the production system to correct production parameters.
"PLS can help Jinan No. 2 Machine Tool and Shanghai General Motors to carry out the whole line simulation of the stamping line, this is the first time in China." She said.
"More importantly, with PLS, equipment manufacturers and end users can perform simulations in the design stage. It is easier for some special processes to find out the rules and modify the design through simulation, which greatly shortens the time to market for new products and truly reflects the digital The core advantage of manufacturing." Said Zhou Xiaodong, Metal Forming Industry Development Manager, Factory Automation Department, Siemens Digital Factory Group.
Simulation of Siemens Press Line Simulation Software (PLS)
ShipbuildingThe ambitions of Jinan No. 2 Machine Tool are not limited to China. In 2011, the "marriage" with the Ford Motor Company of the United States marked that it has truly set foot on the international stage. This year, Ford placed an order for 5 stamping lines.
After the manufacturing is completed, these devices are split into nearly 2,000 large packaging boxes, and after more than 60 days of long-distance travel by sea and land, they arrive at Ford's two factories in Kansas and Detroit.
From China to the United States, the 20,000-kilometer transoceanic road is not easy. Ford, with a century-old history, has always been harsh in choosing a "marriage partner" and must be "named." This is the first time that Ford has thrown hydrangea to a stamping equipment manufacturer outside of Germany in the past 20 years.
From the moment the order was received, the Jinan No. 2 machine tool went up and down into the first-level preparation state. And Ford's stamping equipment planning supervisor said in an email to Jinan No. 2 Machine Tool that if there is a problem with this project, his career "will end here."
Facts have proved that the rise of Jinan's second machine tool overseas is not a flash in the pan. Since 2011, Jinan No. 2 Machine Tool has successively received orders for 7 press lines from Ford. In the design process, they all use Siemens Solid Edge software and integrate Siemens electrical equipment to ensure stable and efficient operation.
According to Zhang Shishun, deputy general manager of Jinan No. 2 Machine Tool, these lines represent the world's highest level, capable of stamping 15 large-scale automobile panels per minute. The improvement of the efficiency of the stamping line is like a 100-meter race, every half-second increase is extremely difficult.
"The technical leap from the previous 12th line to the 15th line is like a leap from'EMU' to'high-speed rail'." Zhang Shishun said.
"The development of the automobile industry is changing rapidly. The Jinan No. 2 machine tool can meet the ever-changing market demand, a very important reason is the implementation of the concept of digital manufacturing. And the cooperation with Siemens is making our digital road wider and wider." He added. Tao.
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