The pandemic that began in early 2020 pressed the fast-forward button for digital reinvention. For many businesses, digital reinvention is no longer an option, but an inevitability. How to correlate data at the production, IT and even management levels is a basic prerequisite for optimizing the value creation process in the automotive production industry. Balluff develops and manufactures innovative sensor, identification and network solutions in all areas of the automotive industry and works with partners to conceptualize specific solutions that increase productivity, profitability and competitiveness.
The pandemic that began in early 2020 pressed the fast-forward button for digital reinvention. For many businesses, digital reinvention is no longer an option, but an inevitability. How to correlate data at the production, IT and even management levels is a basic prerequisite for optimizing the value creation process in the automotive production industry. Balluff develops and manufactures innovative sensor, identification and network solutions in all areas of the automotive industry and works with partners to conceptualize specific solutions that increase productivity, profitability and competitiveness.
As one of the four major processes in the automotive industry, the importance of welding process is self-evident, shouldering the important mission of body forming and providing a support framework for the whole vehicle. In order to improve the precision, quality and efficiency of body welding, the welding production line often adopts flexible design, and when planning the flexible production line, Balluff RFID can be used to identify vehicle models and component categories, and is suitable for many types of vehicles, so it has become the best choice for many automotive equipment manufacturers.
Recently, Balluff provided a comprehensive welding line application solution for an automobile manufacturing base, helping it to build an automated, digital and intelligent resource-saving and environment-friendly factory, and to build a full-process production base for frames, stamping, welding, painting, final assembly and vehicle delivery centers.
The project is expected to have a total investment of 14.6 billion yuan, 1,200 acres of land, can meet the collinear production of 3 platform models at the same time, has 277 robots, 117 AGV trolleys, can realize multi-process production automation and material distribution, fully automated body frame stamping, welding main line, painting and other processes, the annual output is expected to reach 200,000 new energy intelligent urban commercial vehicles.
Predictive Maintenance - Wisdom Eye
The production mode is changing rapidly, and more and more manufacturers are beginning to pursue small batches, diversification, short cycles, and replacement of operators without downtime. In order to meet these demands, especially the consequent safety requirements, the human-robot collaborative production model is being made safer through new standards and new technologies for secure communication.
IO-Link is a powerful standard (IEC 61131-9), a digital interface that is fieldbus-independent and a master that supports a wide range of major bus protocols and can communicate at distances of up to 20 m. The IO-Link master module with a wide range of diagnostic functions such as short circuits and overloads helps automotive equipment manufacturers to plan inspections and reduce scrap and thus ensure optimal tool utilization while saving money.
High-speed and transparent - traceable
The high-speed RFID system from Balluff ensures that the circular inventory of the automated assembly system is tracked. The flexible BIS V processing unit utilizes high-speed read/write heads to process large amounts of data in the shortest possible time. They are processed up to 8 times faster than the ISO 15693 global standard, which helps to reduce cycle times and increase yields.
RFID systems collect all data in real-time across most areas, knowing where, when, and how vehicles are assembled, as well as the materials used in the vehicles, to help make corrections in the process, streamline just-in-time deliveries, create lean manufacturing processes, improve productivity, and achieve process transparency.
Welding manufacturing process – flexible and changeable
The distinctive characteristics of modern automobile production are large quantities, many varieties, the reduction of individual varieties in batches, and the continuous acceleration of model upgrading. In order to meet the new requirements of users for safety, comfort, energy saving, environmental protection and cost reduction, modern body welding needs to keep pace with the times and innovate, and the welding workshop of the automobile factory has become the workshop with the highest degree of flexibility.
RFID technology from Balluff can be used to identify vehicle models and component categories, and RFID technology can be used in all welding processes to achieve flexible switching between multiple vehicle types, increasing cycle time and automation rates. As a key parameter in the flexible manufacturing process, specifications describe all the variables that arise during the production of a particular part. Specifications can be stored either in the RFID tag itself or in a central database where the identification tag can be recognized.
Nowadays, the global digital wave is reshaping the way of life of society and promoting the transformation of business models, among which, it is imperative for the high-end manufacturing industry represented by automobiles to apply digital technology to improve production efficiency and stimulate the driving force by optimizing processes and improving working methods in the process of fully embracing digitalization. Balluff will continue to adhere to the corporate motto of "innovation and automation", promote the development of the entire value chain and the new energy vehicle industry with digital innovation, empower a low-carbon society and achieve sustainable development.
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