How does the distribution technology of cylinder block and cylinder head processing automatic line overcome the difficulties of precision and efficiency?
Publish Time: 2025-04-24
In the cylinder block and cylinder head processing automatic line, intelligent distribution technology is breaking through the dual shackles of precision and efficiency with innovative means. Under the traditional production mode, material distribution relies on manual experience and fixed route planning, which is prone to production stagnation or inventory backlog due to information lag. Intelligent distribution technology achieves a paradigm shift from extensive management to precision control by building a closed-loop system of "perception-decision-execution".
The solution to the problem of precision begins with the fusion of all-factor information. By deploying RFID reading and writing devices and QR code readers in the blank warehouse, buffer area and processing station, the system can collect 12 types of core data such as material part number, batch number, processing progress, etc. in real time, and compare them with the process route and BOM list in the MES system at the millisecond level. For example, when the AGV car arrives at the buffer warehouse, the RFID antenna automatically scans the pallet label. If the material part number does not match the MES plan, the system immediately triggers an audible and visual alarm and locks the pallet to ensure that the wrong material cannot enter the production line. For multi-variety mixed-line production scenarios, dual-frequency RFID tag technology can simultaneously store workpiece part numbers and processing status information, so that the robot arm can achieve ±0.02mm precise positioning based on the double verification results of the surface QR code and the pallet label when grabbing the cylinder head.
Breaking through the efficiency bottleneck depends on dynamic decision-making and flexible execution capabilities. The intelligent scheduling system built on the digital twin platform can collect the status of more than 200 devices, work-in-process inventory and AGV location data in real time, and optimize the distribution path every 15 seconds through an improved genetic algorithm. When the assembly workshop suddenly changes orders, the system automatically calls historical order data and equipment OEE analysis models, completes the production plan rescheduling within 3 minutes, and generates a new distribution task list. In the practice of an engine manufacturing company, by introducing a seven-axis collaborative robot with autonomous obstacle avoidance and a composite AGV, the material handling efficiency was increased by 40%, and the empty driving rate was reduced from 28% to 7%. More importantly, the intelligent distribution system and processing equipment are deeply coordinated: when the CNC machining center completes the fine milling of the cylinder top surface, the PLC signal immediately triggers the AGV scheduling command, so that the arrival time of the new material is completely synchronized with the tool change time of the machine tool, and the single-station changeover time is compressed to less than 90 seconds.
The improvement of quality traceability and flexible adaptation capabilities further enhances the system performance. By establishing a digital archive containing more than 200 quality data for each cylinder head, the system can reversely trace environmental parameters such as temperature and humidity in the material distribution path, as well as vibration spectrum data during AGV handling. When a batch of cylinder heads has a cylinder bore diameter that exceeds the tolerance, the quality engineer can quickly locate the specific distribution batch and AGV number through the system, and retrieve the operation log of the equipment during that period. In the face of the processing needs of complex structure cylinders such as V-type 16 cylinders, the modularly designed distribution unit can be quickly reorganized into a double-layer stereoscopic warehouse and a circular track system. By replacing the end effector, flexible grasping of cylinder heads of different sizes can be achieved, and the equipment changeover preparation time is shortened from 8 hours in the traditional mode to 1.5 hours.
This intelligent distribution system has gone beyond simple technology integration and evolved into a core engine driving the transformation and upgrading of the manufacturing industry. It not only makes the overall equipment efficiency of the cylinder block and cylinder head processing automatic line exceed 85%, but also opens up a new dimension of process optimization and supply chain collaboration for enterprises through the accumulation and mining of data assets.
