"Shisheshesheshesheshesheshesheshesheshes..." On the left of the corridor are soldering flowers, and on the right are AGV cars connected in real time, shuttled through the production line in an orderly manner. After "one-click start", they can automatically avoid obstacles in complex production environments and actively track to the designated location on the production line according to preset instructions and path planning.
At this time, the robot at the assembly station picks up the parts on the AGV cart and completes the assembly, and the cart will follow the rhythm of the production line and automatically sends the parts to the next station.
This is the production scene seen by a reporter from Workers' Daily on January 13 at the body workshop of the BAIC Group's New Energy Xiangjie Super Factory (hereinafter referred to as Xiangjie Factory). Relying on the strength of intelligent manufacturing, Xiangjie Factory responds to production needs in real time through intelligent scheduling, optimizes logistics paths, and maximizes the efficiency of the production process.
Xingjie Factory is located in Miyun, Beijing. On June 30, 2024, the first product produced by the factory, Xiangjie S9, entered the mass production stage.
Transformation
The intelligent production scenarios of the body workshop of the Xiangjie Factory occur every day.
The body workshop covers an area of 100,000 square meters and consists of 25 production lines. The entire workshop has 527 robots, including welding, riveting and other processes.
"We Xiangjie S9 is a smart car model that is mixed with steel and aluminum and equipped with Huawei's high-end technology. There are very few workshop workers now. It is completely intelligent production, and robots can achieve production and ensure quality." Wang Xingang, director of the body workshop of Xiangjie Factory, stood in front of a display operating table of about 1 square meter and introduced to reporters.
According to Wang Xingang, the body workshop was originally handheld welding, which has been transformed into the current robot's automatic welding and riveting, and the technical quality guarantee has changed from the original master to the current visual guidance, blue light calculation and big data background comparison.
"Workers have changed from labor and technical talents to current 'intelligent' talents for robot operation and maintenance." Wang Xingang sighed.
Yu Dehai from the body workshop of Xiangjie Factory has been working in welding and sheet metal repair work for more than 20 years and is a great craftsman in the company.
Yu Dehai is very good at hand. He needs to file a few millimeters of sheet metal repair. Without measuring, he can do it by just looking at the hand file. But now the robot accuracy is guaranteed to reach 0.06 mm. Yu Dehai has been transformed into technical management and robot maintenance work, and has grown into workshop scheduling, production and technical management are all in charge, becoming an "intelligent" talent.
Replace
"Our stamping workshop has transformed from the original labor-intensive to the technology-intensive. A workshop with an annual output of 200,000 vehicles can be operated with only more than 30 people." Liu Shening, director of the stamping workshop of Xiangjie Factory, was also deeply touched. Against the background of intelligent manufacturing, the stamping workshop has undergone earth-shaking changes in press and automation technology, mold technology, production and quality inspection technology, etc.
"Previously, the manual stamping line was manually used as a robot to transmit parts, completing 200 punches per hour; now, the application of advanced automation and servo technology can complete more than 800 punches per hour." Liu Shening pointed to the running production line and told reporters, "With the support of lean management and advanced mold technology, the part size can be controlled within ±0.3 mm, achieving millimeter-level steel rate engraving, and the average pass rate of appearance parts products can reach more than 97% at one time."
"We currently have 57 robots in the painting workshop, and the core main line (glue coating, LASD, spray painting) has achieved 100% automation, completely unmanned." Tu Yulin, director of the painting workshop of Xiangjie Factory, took over the conversation and invited the reporter to the workshop to experience it.
"The painting workshop mainly provides 'beautification' for steel and aluminum body, bringing customers colorful painted body. It is designed according to the production capacity of 30 units/hour and can meet the spraying of 12 colors at the same time. The first Xiangjie S9 model has 5 colors." Tu Yulin introduced.
The reporter saw that the shells of cars were slowly moving on the production line, with robots spraying in front, back, left and right.
"The undercoat glue operation is positioned by intelligent visual AI + 12 robots, completely replacing the traditional human work. It turns out that skilled painter becomes a paint robot operator, and a physical operator becomes a brain operator." Tu Yulin pointed to a black car shell that had just been sent to introduce to the reporter.
Confidence
Ma Yunpeng, senior manager of vehicle inspection at Xiangjie Factory, has a deeper feeling about the leap in driving experience brought by intelligent manufacturing in cars.
At the end of the inspection line of the final assembly factory, the reporter saw a special inspection room, which is a fully automatic intelligent driving calibration room used in the Xiangjie model. The inspection was completely automated, and there was no one on the scene.
"The entire room is covered with wave absorbing materials, and there are as many as 13 targets that can be automatically opened around and on the ground. These targets are used to calibrate up to 27 vehicle lidars, millimeter-wave radars and cameras." Ma Yunpeng explained to reporters.
According to reports, the ADS3.0 intelligent driving system equipped by Xiangjie includes vehicle centering, and the equipment calibration can be automatically completed within 4 minutes. In this way, a car will complete static calibration, and the vehicle will then dynamic calibration on the road test track. At this point, a car with smart driving, automatic parking and other functions, which will be continuously optimized and updated with the monthly software baseline.
"Compared with traditional car companies, our vehicle inspection, vehicle calibration, problem investigation, and problem solving are all new areas. The traditional models that rely on ordinary testing equipment for diagnosis have been replaced by cloud computing and analysis. Our workers' work has become a moving mouse and looking at the screen, which has completely realized intelligence. It is these new technologies that have created an extraordinary world of enjoyment." Ma Yunpeng is full of confidence in the product.
