Just like people, every car has its own place of birth.
After some cars are "born", they need to travel long distances for several months before they can recognize their "owner". Others only take a few days to come to us.
What we are going to talk about today is a brand new "birthplace", which is very close to us and was born for Volkswagen MEB platform models.
How to talk specifically? Only those "numbers" are the most "intuitive". Next, let's take a look at the "numbers" created by SAIC Volkswagen's new energy vehicle factory that are worthy of attention.
SAIC Volkswagen’s new energy vehicle factory is located in Anting, Shanghai. It is the Volkswagen Group’s first newly built factory in the world specifically for the production of MEB platform models. The SAIC Volkswagen New Energy Vehicle Factory (hereinafter referred to as the SAIC Volkswagen New Energy Factory) started construction in October 2018, with a total investment of approximately 17 billion yuan, with a planned annual production capacity of 300,000 vehicles, and is scheduled to be officially put into production in October 2020.
In November 2019, SAIC Volkswagen’s new energy plant rolled out its first full-process prototype vehicle. The first product to roll off the production line is a pure electric medium-sized SUV on the MEB platform. It is also the first ID. family model to be put into production by SAIC Volkswagen in the future. It will be officially unveiled in the second half of 2020. In the future, the new factory will also be put into production of new pure electric vehicles from multiple brands of the Volkswagen Group.
Keywords: 140
SAIC Volkswagen’s new energy plant uses a number of cutting-edge technologies that are used for the first time by the Volkswagen Group or for the first time in China. It is currently the most advanced and intelligent benchmark factory of SAIC Volkswagen. , further improve the automation rate and production efficiency, and ensure stable production quality. The factory uses more than 1,400 industrial robots, and the body and battery workshops have basically achieved unmanned and fully automatic production. The new factory extensively applies highly automated assembly and automatic measurement technology, and has invested in many new technologies such as automatic tightening, automatic door panel wax spraying, fully automatic assembly platform, fully automatic instrument installation, aerial conveyor lines, AGV trolleys, etc. to replace traditional manual transportation and installation. , improve production stability and ensure product high quality.
Keywords: Cloud Internet
SAIC Volkswagen’s new energy factory adopts RFID artificial intelligence identification technology, optical identification technology, AR/VR technology, paperless factory concept, and energy management system and other advanced technologies and intelligent equipment to realize the intelligence and digitization of the entire manufacturing process. In addition, the new factory is SAIC Volkswagen’s first factory to achieve full coverage of industrial wireless networks. A large number of AP production wireless hotspots are arranged in the workshop, combined with industrial Internet of Things, cloud storage and other Internet technologies to achieve system integration and data collaboration, build a smart factory management platform, open up information flow, and realize interconnection in all aspects from design, production to sales. Interoperability.
Keywords: environmental protection
SAIC Volkswagen’s new energy factory uses solar photovoltaic power generation, combined heat and power, waste heat recovery, rainwater recycling, reclaimed water reuse technology, energy management system, etc. 27 A series of energy-saving and environmentally friendly measures to create an environment-friendly factory for SAIC Volkswagen. At the same time, the new factory's five key environmental indicators of energy, water, carbon dioxide, volatile organic compounds and waste dropped by 20%.
With a number of environmental protection and energy-saving technologies, SAIC Volkswagen’s new energy plant has passed the green building design review of the Ministry of Housing and Urban-Rural Development. The review result was 3 stars (the highest level) and received a green building design certificate issued by the Ministry of Housing and Urban-Rural Development. Green Building Design Label Certificate. From the beginning of the design, the new factory paid special attention to the intensive use of land. The factory covers one third of the area of ??other newly built factories of the same scale. Each workshop spans municipal roads through corridors to achieve complete separation of people and vehicles.
Pressing workshop
SAIC Volkswagen New Energy Factory uses two Schuler servo high-speed press lines with a total tonnage of 6900t. The maximum punch count of both press lines can reach 18 times. /min. In addition, the stamping workshop is also equipped with Crossbar's third-generation crossbar manipulator, KUKA robot and high-speed depalletizing system. It has 24 KUKA robots, the maximum number of mold processes is 5, and uses the most advanced automated mold change and Tooling replacement system, which can complete the entire line of mold changes within 5 minutes, improving production efficiency and accuracy.
In terms of environmental protection and noise reduction, the press line is covered with Schuler’s second-generation overall sound insulation cover, which can reduce noise up to 16dB(A).
The waste recycling room in the workshop uses internal mesh plate sound insulation technology to reduce noise in the waste room and effectively improve the working environment for employees. For the first time, the stamping workshop applies heavy-duty omnidirectional AGV to the off-line transportation of parts. The maximum load capacity is 1.5T. It uses magnetic strip navigation and supports omni-directional car body right-angle turns. The entire process from the stamping line off-line to the parts storage area is seamless. No more forklifts needed.
The workshop uses a three-layer mold crane, which stacks three layers of molds through the gripper, which not only increases the mold storage capacity by 50%, but also increases the running speed and improves the efficiency of mold preparation. At the same time, the mold running position accurately plans the path through automatic positioning, effectively improving the safety during the mold lifting process. The use of automatic operating flatbed trucks can realize automatic operation of transportation between molds, blanks and charging stations across lines; it can reduce the labor intensity of employee operations; it can automatically operate according to fixed routes, improve operating efficiency, and realize intelligent operation of flatbed trucks. At the same time, the workshop uses the TPMS system to achieve integrated and systematic maintenance of molds.
Body shop
The body shop is divided into two floors. The first floor is mainly for door covers, floor 1 and assembly lines. The second floor is mainly the side walls, floor 2, general assembly and delivery lines. The design production capacity of the body shop is 60JPH, which means it can complete 60 bodies in white per hour, with an annual output of 300,000 units.
The workshop adopts a large number of advanced new technologies for intelligent manufacturing, among which At-line online measurement, EMS aerial transportation, robot fully automatic tightening process, and CMT+ cold metal transition welding process are all used by SAIC Volkswagen for the first time. In addition, the workshop also has the highest speed laser welding in the Volkswagen Group factory and the longest workshop assembly line at SAIC Volkswagen to ensure the consistency of parts during transportation.
The workshop has 946 robots and an automation rate of 84%. It is currently the body shop with the highest automation rate among SAIC Volkswagen. In addition, the body shop has 2 At-line online measurement stations, and 8 measurement robots perform 100% visual online inspection of parts and key parts of the body-in-white through laser measurement sensors, image processing, temperature compensation, and computer control. The technology enables precise measurement of the spatial dimensions of objects with a repeatability of up to 0.2mm, ensuring the stability of the quality of the body-in-white production process to the greatest extent.
Compared with traditional measurement stations that require transporting the inspected vehicle from the production line to the measurement area, online measurement stations are connected in series in the production line, and vehicles can be directly extracted from the production line for inspection, effectively saving transportation. time, improve detection efficiency, and also increase the number of detections. At the same time, combined with the factory's intelligent manufacturing system, cloud data verification is realized. The online inspection results are transmitted to the quality assurance control room and released to the system. Technicians can directly see the quality status online, track and optimize in a timely manner, ensuring the stability of the body-in-white production and manufacturing process, and realizing cloud storage and analysis of quality status and automatic network connection. Greatly improve the quality and stability of the final product.
The workshop assembly line is 150m long, and the accompanying belt reduces the walking distance of workers by half. Used together with the aerial EMS, it can realize automatic transportation of parts, reduce the intensity of manual transportation, and ensure the consistency of parts during the transportation process. High-speed laser welding has the advantages of high power density, excellent directionality and high welding speed. Using laser welding can replace the spot welding of the roof and side panels, and there is no need to install sealing strips on the roof. At the same time, the heat input can be accurately adjusted and controlled, resulting in less burning loss of the galvanized layer and reduced deformation of the weldment. The high-speed laser welding used in the body shop currently reaches a speed of 110mm/s, which is the highest speed laser welding in the Volkswagen Group factory. High-density repair welding can be applied to different models, and the welding capacity is increased by 3 times. The workshop currently has 14 welding robots, which can be expanded to 16 in the future.
120JPH paint shop
The 120JPH paint shop is the world's first high-capacity paint shop of the Volkswagen Group. It adopts a number of new technologies, uses new environmentally friendly processes and intelligent technologies, and also supplies MEB The factory and Anting Automobile Factory No. 3 have two factory areas. Compared with the two traditional 60JPH standardized paint workshops, the construction area is saved by 12%. The paint shop has seven major processes: pretreatment, electrophoresis, PVC, sanding, topcoat, submission, and wax injection.
The workshop's production capacity is 120 vehicles per hour, which is twice that of the standardized workshop. After reaching capacity, the annual production volume will be 600,000. The total amount of equipment is 2.5 times that of the standardized paint workshop, the number of robots is 318, and the automation rate reaches 73%. It is the paint workshop with the highest automation rate of SAIC Volkswagen.
In the future, it can produce 12 models of models on the three platforms of MQB\MLB\MEB. It is the paint shop that can produce the largest number of models and the most colors in the world.
In terms of environmental protection, silane film technology is used in the pretreatment process to replace the traditional zinc-based phosphating technology. The silane film does not contain nickel and meets the latest treatment requirements of Shanghai local environmental protection regulations for heavy metal nickel, and the nickel emission indicators have dropped. ten times. Secondly, the process is simple, the process is shortened, and there is basically no residue, low water consumption, and low energy consumption, making it efficient and environmentally friendly. At the same time, a Venturi dry paint mist absorption system is used to eliminate the circulating water system, avoiding the loss of tap water and the generation of waste water. No more chemicals are used and no hazardous waste is produced. The proportion of air circulation usage can be as high as 95%. Compared with traditional wet paint mist treatment, it saves about 60% of energy.
General Assembly Workshop
The designed production capacity of the general assembly workshop is 60JPH, and the annual production volume of 300,000 will be completed after reaching capacity. It is currently the Volkswagen Group's mass-produced model assembly workshop with the highest automation rate, with an automation rate of 26.2%, and a higher degree of modularity and flexibility. The second-floor platform of the workshop has a complete conveyor line. The car body is transported from the paint workshop to the assembly workshop through the corridor; the battery pack reaches the second-floor platform of the assembly workshop through the conveyor chain, and then goes down to the chassis pre-assembly line through the elevator.
The general assembly workshop is characterized by intensive land use and high automation rate, and its area is only 2/3 of the area occupied by the standardized general assembly workshop. The automation rate reaches 26.2%, making it the final assembly workshop with the highest automation rate at SAIC Volkswagen. The workshop uses SAIC Volkswagen's first fully automatic assembly platform. Through automatic tightening and automatic nail feeding technology, as long as the bolts are poured into the equipment, the bolts will automatically be sent to the tightening shaft. The entire process is unmanned, improving production efficiency and installation. Accuracy.
In addition, the fully automatic instrument installation manipulator, compared with the traditional instrument panel installation that requires operators to carry and install manually, the manipulator uses the visual recognition system for fully automatic installation. It is the first technology applied by the Volkswagen Group in the world and is suitable for many people. This model is more accurate and efficient than traditional manual installation. PGD ??all-glass roof installation process, the ID. car that is about to be put into production is SAIC Volkswagen’s first product to adopt an all-glass roof design. The all-glass roof gluing and installation equipment is equipped with 6 visual cameras. It realizes automatic gluing and automatic installation through a central positioning device with both positioning and glass roof recognition functions.
After completing the electrical inspection, the vehicle comes off the assembly line and enters the front toe drum area for inspection. This is the first time that double light box light detection and non-contact laser measurement are used here, combined with a steering wheel leveler to ensure accurate wheel positioning; an open/transparent drum room is also used for the first time, which can conduct multiple tests such as ABS, ESP, braking force, etc. .
Battery Workshop
The battery workshop is SAIC Volkswagen’s first all-aluminum battery case production and battery packaging assembly workshop, with a planned annual production capacity of 300,000 units. The workshop has a two-story building. The second floor is the battery case wire. The finished casing is automatically transported to the battery assembly line on the first floor via an elevator. After the battery pack is assembled, it is automatically transported to the battery pack sequencing center on the second floor via an elevator. After each battery pack is matched with the car shell, it is automatically transported to the final assembly workshop through the corridor.
For the first time in history, SAIC-Volkswagen has made its own aluminum battery casing. It is also the only battery workshop that adopts JIS (Just In Sequence) sorting and the Volkswagen Group's first just-in-time production pull-type battery workshop and battery assembly. For the first time, it is directly coupled with the assembly workshop and delivers battery packs to the assembly workshop at a production speed of 60JPH. The workshop has two production lines: casing and assembly. It produces two types of aluminum battery casings and three battery packs for the MEB platform. It has more than 138 robots. The automation rate of the subject production line reached 88% and the assembly line automation rate reached 78%. .
When the battery module is put into the box, the support design of the bottom water-cooling plate is an example of the "Shanghai Factory Solution" of the MEB project. The workshop adopts a "movable support plate" design scheme to more effectively adapt to the product characteristics of "large-sized and easily deformable parts" of battery cases. This design can better support the bottom water-cooling plate than the German solution (a whole supporting plate). The separation design of the battery pack and AGV trolley in the manual assembly station is another "Shanghai factory solution" for the MEB battery project. In order to meet the ergonomic problems of manual assembly of low-voltage wire harnesses, a 66° inclined roller assembly line is adopted, which is more ergonomic and ensures stable assembly quality.
In the three core processes of welding, gluing, and testing, automatic detection robots are used to monitor and measure welds, dimensions, gluing, air tightness, etc. in real time to ensure the stability and safety of battery pack products. Quality and safety. The battery packs produced in the workshop passed 203 stringent tests, which are far higher than the national standard test requirements. At the same time, in order to cope with China's more stringent battery standards, SAIC Volkswagen has independently designed a complete heat control system. In the event of extreme circumstances, it can control open flames from emerging from the battery case within 5 minutes to protect the safety of drivers and passengers.
MEB platform batteries use a new thermal conductive adhesive process. Compared with the thermal pad process of traditional MQB platform batteries, it has better interface filling capacity, fewer interface bubbles, and better gap applicability. This enables the MEB battery pack to have better thermal management capabilities. The long-life performance design of the battery pack is much longer than 8 years (120,000 kilometers) (the battery charge and discharge cycle test reaches 1,600 times, each cycle is equivalent to the vehicle driving 350 kilometers to 550 kilometers).
Summary: An advanced modern factory? Is the foundation of everything? It is also a good start
When a tall building rises from the ground, the first thing it needs is a rock-solid foundation, which is everything fundamental. For automobiles, an advanced modern factory is like the foundation. It is the foundation of everything and is also a good start.
As an emerging automobile market, new energy is not yet complete and mature, and there are many uncertainties. However, the general trend of new energy has begun to take shape. Volkswagen Group and SAIC Volkswagen have effectively and efficiently taken the lead with their keen insights and mature analysis of the market. The domestic new energy market has gradually become one of the largest new energy markets in the world. The completion of SAIC Volkswagen's new energy vehicle factory also means that Volkswagen Group and SAIC Volkswagen attach great importance to the domestic new energy market.
From the start of construction of SAIC Volkswagen’s new energy vehicle factory to its formal production, in just two years, it can be clearly felt that Volkswagen Group and SAIC Volkswagen’s layout in the new energy field is accelerating. Only in this way can we Can truly catch up with the trend of new energy vehicles.
This article comes from the author of Autohome Chejiahao and does not represent the views and positions of Autohome.