Since its inception, diesel engines have been favored by many heavy-duty vehicles for their high torque, low speed, and higher thermal efficiency and economy than gasoline engines.
Like the gasoline engine, as the most technology-intensive key component in the automotive field, the rolling flat assembly line of the diesel engine is particularly important in the assembly process due to the diversity of assembled parts and the cumbersome process. Today, with the full automation and digitalization of this critical assembly line, the world's leading providers of industrial RFID technology such as Balluff are providing a powerful "power" for innovation for some diesel engine manufacturers.
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In the production of diesel engines, the assembly line usually takes the cylinder block as the basis of assembly, from the inside to the outside, and assembles parts section by section, including the installation of cylinder liners, piston rings, piston connecting rod groups, piston connecting rod groups, oil pump installation and dozens of other links.
The assembly line is the display of the final state, final structure and final accuracy of the engine, which is very important to ensure the accuracy and quality of the engine, and will directly affect the economy, reliability and service life of the diesel engine. As an assembly line process for sequential assembly of engines, it is necessary not only to ensure the assembly technical conditions of the engine and achieve high precision, but also to ensure the assembly beat and achieve high efficiency; It is necessary not only to assemble multiple models at the same time to achieve high flexibility, but also to effectively control the assembly accuracy and achieve high quality. Since each station is an assembly line production, the control and cooperation of each station link must meet this series of requirements.
In a domestic veteran diesel engine manufacturer factory, the rolling flat line is an important production line in the production and assembly of diesel engines, a total of 15 stations are installed sequentially, in addition to the starting hoisting station and the final packaging off the assembly line, of which 13 stations need to assemble different parts on the engine according to different models, due to multi-station, multi-model, mobile assembly, so there are often missing and wrong installation problems, which has a great impact on the quality of diesel engines, and the after-sales pressure is also huge.
In order to ensure the quality, flexibility and efficiency of the assembly line, the plant met the above assembly challenges by using Balluff's UHF series RFID products and PLC control system to achieve production traceability of engine assembly information.
Ensure assembly quality
Balluff's experience in the field of industrial identification dates back to the 80s of the 20th century, when it was already a pioneer in the field of industrial identification of low-frequency systems for the manufacturing industry. Today, Balluff has complete solutions and industrial implementation capabilities for a full range of RFID technologies from low to high and ultra-high frequencies and ensures high reliability and quality, strong resistance to shock/vibration, electrical interference/inductive interference/electromagnetic interference, etc.
The UHF RFID series supplied by Balluff to the plant includes RFID read-write processors, antennas, and tags to meet the requirements for large read distances in the field
When the engine to be assembled is conveyed to the vicinity of the assembly station, the limit switch automatically jams the tray, and the RFID read-write processor reads the Tag information installed on the engine, according to the order of reading the tag in the PLC, based on the content of each electronic tag, the station PC displays the name and model of the parts that should be installed at the station, and guides the manipulator or worker to carry out the correct operation by comparing the work order, that is, the sequential assembly is realized, and the PLC also records the assembly information simultaneously.
If it is found that the engine is unqualified, it will automatically enter the repair area, and the reader will extract the written information, compare it with the relevant information stored in the database, and display the cause of the failure and the relevant station solution on the PC of the repair station, and then enter the repair program, and the repair will be completed.
The UHF series RFID provided by Balluff not only has an adjustable reading and writing distance to meet the flexibility of on-site assembly, but also realizes a one-in-four product structure of one processor corresponding to four antennas, simplifying the installation of the processor and saving the customer's costs. In the end, it helped the customer's diesel engine assembly line to realize electronic work order operations, guide the assembly to avoid manual negligence, greatly improve the assembly quality, reduce after-sales service work, and create a powerful engine product with a meticulous spirit of innovation.
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