The hottest car engine assembly line

2022-07-30
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Car engine assembly line

Dalian Modular Machine Tool Research Institute, taking advantage of comprehensive automation development, recently designed and cooperated with Shenyang Zoje friendship factory to successfully develop China's first complete car engine assembly line (see the cover), which has been commissioned on site and put into production

1 general arrangement

the car engine assembly line is used for the automatic transmission of six different types of engine assembly and the completion of relevant process contents of engine assembly. The beat time of single station in the assembly process is 1.5min/piece. The whole line consists of 2 main transmission lines (divided into four sections a, B, C and D), 4 branch transmission lines and related equipment (see Figure 1). The main transmission line is used to transport the engine cylinder block, and the branch transmission line is used to transport the cylinder head, transmission, piston connecting rod and crankshaft respectively. Each transmission line is equipped with assembly, transposition, test and other equipment. The assembly of relevant engine components and assemblies is completed manually along the transmission line

Figure 1 general layout of engine assembly transmission line

equipment composition:

zhs-q089 engine assembly friction roller transmission line (main line)

zhs-q090 engine assembly rotating bar transmission line (main line)

zhs-q091 cylinder head assembly transmission line (branch line)

zhs-q092 transmission assembly transmission line (branch line)

zhs-q093 piston connecting rod assembly transmission line (branch line)

zhs-q096 crankshaft assembly transmission line line (Branch)

zhs-q094 cylinder block parallel transfer machine

zhs-q095 cylinder block turnover transfer machine

zhs-z058 rear extension housing oil seal press machine

zhs-z059 main drive gear bearing press machine

zhs-z060 front bearing retainer oil seal press machine

z1.71 ~ 2.00hs-z061 spark plug conduit press machine

zhs-z062 piston ring assembly machine

zhs-z063 piston pin assembling machine

zhs-z064 connecting rod nut loosening machine

zhs-z065 main bearing cap bolt loosening Machine

zhs-z066 transmission lock nut tightening machine

zhs-z067 transmission main shaft pressure bearing machine

zhs-z0684g64 piston ring assembling machine

zhs-z069 front cover crankshaft rear oil seal pressing machine

s1 marking machine

s2 cleaning machine

s3 torque detector

s4 gluing machine

s5 testing machine

s6 leakage tester

s7 running in tester

s8 valve lock clamping and pressing machine

2 technical introduction

2.1zhs-q089 engine assembly friction Roller transmission line (section a)

2.1.1 layout form

the line is arranged in a straight line, and the engine cylinder block is directly transported by the friction roller of the motorized raceway. After finishing the assembly, enter the main line of zhs-q090 to assemble the engine assembly

2.1.2 composition equipment

the line is composed of 5 motorized raceways and indexing devices. The line is equipped with marking machine, cleaning machine, main bearing cap loosening device and torque detector

2.1.3 structural features

● each motorized raceway is driven by the reducer to drive the chain sprocket and straight tooth bevel gear to drive the friction roller to rotate, so as to realize the linear transmission to the engine cylinder block. The transmission speed is v = 2 ~ 6m/min. the frequency of the reducer motor is adjusted by the frequency converter to realize stepless and adjustable transmission speed. The material blocking and separating mechanism on the motorized raceway is equipped with a buffer device driven by the air cylinder. The material separating action is automatically completed by the electrical control, which can prevent the workpiece from colliding with each other

● there are three positions of the cylinder block on the transmission line: a) the cylinder block enters the first motorized raceway, with the top facing upward and the front facing backward. After passing through the marking machine and cleaning machine, enter the second motorized raceway for assembly. b) The cylinder block is turned 180 ° by the turnover device, so that its top face is downward, and the front is behind. After the main bearing cap is removed by the main bearing cap loosening device, it enters the third motorized raceway for assembly. The cylinder block is turned over 90 ° on the piston inserted into the rotary device. After the piston connecting rod assembly is installed, it is turned over 90 ° in reverse to the original position and enters the fourth motorized raceway for assembly. c) The cylinder block enters the fifth motorized raceway and is horizontally rotated 90 ° clockwise by the rotary table to make its top face downward and the front face to the left. After assembly, it passes through the torque detector and finally goes offline

● button stations are set at each assembly station to manually control the blocking and separation of workpieces on the transmission line. Both the turnover device and the rotary device can realize automatic circulation, and an adjustment button table is set

● the piston size transmission system and the whole process monitoring and management system are composed of a sever host, four work station computers, printers and bar code printers. It can realize automatic transmission of cylinder hole, crankshaft and piston size; Automatic selection of connecting rod bush, crankshaft bush, piston and other assembly parts; As well as the tracking display and monitoring of the whole process of workpiece assembly, and can regularly count, manage and print reports, etc

2.1.4 main specifications

● total power 2kw

● conveying base height 1000mm

● long outline dimension × wide × Height = 28 × one × 1.6 (m)

2.2zhs-q090 engine assembly rotating bar transmission line (sections B, C and D)

2.2.1 layout form

the transmission line is divided into three sections B, C and D, two sections B and C are assembly transmission sections, arranged in a straight line, and Section D is repair transmission section, arranged in a rectangular closed manner. Two pins on one side of the engine cylinder block are positioned on the conveying tray. The conveying line is a double-layer structure. The upper layer drives the tray conveying cylinder block, and the lower layer drives the empty tray to return quickly

2.2.2 composition equipment

the line is composed of 6 double-layer transmission lines, 3 single-layer transmission lines, 2 elevators and 4 rotary tables. Parallel transfer machines and turnover transfer machines are arranged on the line. Press fitting machine, glue applicator and leak testing machine are arranged along the line

2.2.3 structural features

● each transmission line is driven by the reducer to drive the chain sprocket to drive the driving roller to rotate, so as to drive the tray to transport in a straight line. The conveying speed of the upper pallet is v = 2 ~ 6m/min, and the return speed of the lower pallet is v = 6 ~ 12m/min. the frequency converter adjusts the motor frequency of the reducer to realize stepless and adjustable conveying speed. The material retaining and separating mechanisms on the transmission line are driven by air cylinders

● the tray is equipped with a special drive mechanism to drive the tray to move in a straight line. The tray can rotate horizontally and be positioned automatically, and is equipped with a buffer device

● the head lifting device lifts the empty tray returned from the lower layer of the transmission line to the loading station; The tail lifting device lowers the empty pallet after unloading the workpiece from the upper layer of the conveying line to the return position of the lower layer

● there are two positions of the cylinder block on the transmission line: a) the manipulator of the line head parallel transfer machine grasps the engine cylinder block from the end of the zhs-q089 transmission line, moves up and down, and places it on the pallet at the first loading position. The cylinder block is positioned on the tray with the top facing down and two pins on one side. The rotating bar drive tray carries the cylinder block to the B section transmission line for assembly. b) After the cylinder block enters the turnover transfer machine, it is turned 180 °. Make its bottom face downward, one side and two pins are positioned on the tray, and the rotating bar drives the tray to take the cylinder block to the C-section transmission line for assembly

● Section D is a repair transmission line, which is composed of 4 rotary tables, 2 double-layer transmission lines and 3 single-layer transmission lines, and is rectangular closed. Automatic dispatching through the monitoring system. The qualified products reach the tail cylinder feeding station of the line through two double-layer transmission lines; The unqualified parts turn back to the repair bypass (3 single-layer transmission lines) and then turn back to the front end of section d after manual repair, and then go directly to the end of the line

● button stations are set at each assembly station to manually control the blocking and separation of workpieces on the transmission line. The lifting device, turnover device and rotary table can realize automatic circulation, and are equipped with an adjustment button table

2.2.4 main specifications

● total power 10KW

● long tray size × wide ×= six hundred and thirty × 510 (mm)

● the height of conveying base is 1000mm for Section B and C and 650mm for Section D

return section 200mm

● long outline dimension × wide × Height = 46 × eight point three × 1.0 (m)

2.3zhs-q091 cylinder head assembly transmission line

2.3.1 layout form

the transmission line is arranged in a straight line. The engine cylinder head is transported manually on the unpowered roller conveyor track. The assembled cylinder head assembly enters the zhs-q090 main line for engine assembly

2.3.2 composition equipment

the line is composed of four conveying raceways. The line is equipped with a leak tester, a spark plug guide tube press fitting machine, a valve lock clamp press fitting machine and a cleaning machine

2.3.3 structural features

fewer assembly processes, manual conveying and simple structure

2.3.4 main specifications

● conveying base height 1000mm

● long outline dimension × wide × Height = 28 × zero point seven × 1.0 (m)

2.4zhs-q092 transmission assembly transmission line

2.4.1 layout form

the transmission line is arranged in a straight line, the transmission is positioned on the transmission tray, the transmission line is a double-layer raceway, and the upper layer drives the tray transmission; The lower layer drives the empty tray to return quickly. The assembled transmission enters the zhs-q090 main line for engine assembly

2.4.2 composition equipment

the line is composed of 5 motorized raceways and 3 lifting devices. Sound insulation room, running in testing machine and oil pouring platform are arranged on the line. Four press mounting machines and one tightening machine are arranged along the line

2.4.3 structural features

● each motorized raceway is driven by the reducer to drive the chain sprocket and the straight bevel gear to drive the roller to rotate, so as to drive the tray to transport in a straight line. The conveying speed of the upper pallet is v = 2 ~ 6m/min, and the return speed of the lower pallet is v = 8 ~ 12m/min. The frequency of the reducer motor is adjusted by the frequency converter to realize stepless and adjustable conveying speed. The material retaining and separating mechanism on the conveying line is driven by the air cylinder

● the conveyor line is divided into two sections by the head, tail and middle elevators:

the first section: the transmission assembly and external accessories are assembled from the head lifting device to the middle lifting device. The pallet is loaded at station 1, assembled at stations 2 to 10, and unloaded at station 11. The empty tray enters the middle lifting device and descends. After returning to the conveying raceway and quickly returning to the head lifting device, it is lifted to its original position

the second section: from the rear end of the middle lifting device to the tail lifting device is the transmission commissioning, repair and shipping section. The tray carrying the transmission reaches the end of the line after passing through the running in test machine and oil pouring platform in the sound insulation room. The unloaded empty tray is lowered by the end of the line lifting device, and then returns quickly after returning to the conveying raceway. If the test material should be flattened or straightened back to the middle lifting device, it will reach the head of the second section of the line after being lifted. The two conveyor lines operate independently

● the forms of pallets used in the two sections are different. The pallets used in the first section line are double-layer and can be rotated in a plane. They also can be rotated in space by small-scale rapid trial production and value-added service. They are positioned by the joint surface of the transmission, locked at four points, and equipped with a buffer device. The tray used in the second section is the special tray for transmission running in test

● button stations are set at each assembly station to manually control the blocking and separating actions of workpieces on the conveying line. The lifting device can realize automatic circulation and is equipped with adjustment button stations

2.4.4 main specifications

● gradually show everyone the total power 5kw

● long tray size × Width = 520 × 420 (mm)

● upper conveying raceway conveying base height 800mm

● long outline dimension × wide × Height = 26 × 1.2 × 0.8 (m)

2.5zhs-q093 piston connecting rod assembly transmission line

2.5.1 layout form

the transmission line is a straight-line rectangular layout, the piston connecting rod is positioned on the pallet, and the pallet is transported in a straight line, moved horizontally, and returned in a plane. Manual loading and unloading, and the assembled piston connecting rod enters the zhs-q089 main line for engine assembly assembly

2.5.2 composition equipment

the line is composed of two longitudinal conveying lines and two transverse conveying lines. One piston pin assembly machine, two piston ring assembly machines and one connecting rod nut loosening machine are arranged along the line

2.5.3 structural features

● all conveying lines adopt electric rollers

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