This project aims to comprehensively upgrade the existing Phase I final assembly line to intelligent production. By introducing advanced logistics technologies, optimizing layout, and increasing automation, it will enable efficient and flexible production of new and compatible models, with a design cycle time of 10 JPH and a guaranteed equipment availability rate of ≥95%. This project adopts a turnkey approach, with DUOYUAN fully responsible for the entire process, from process planning, design and manufacturing, procurement and integration, installation and commissioning, to the “Three Guarantees” service, and fully supporting product commissioning.
Core Content and Technical Highlights:
- Intelligent PBS Line Upgrade
High-frequency RFID tag technology enables real-time data transmission throughout the entire lifecycle of vehicle bodies and doors. The skid support mechanical structure has been modified to adapt to the geometry of new vehicle models. Twelve new industrial-grade readers have been added to form a dual-redundant network, ensuring 99.9% recognition accuracy at a high-speed operation of 10 JPH.
- Dual AGV Line Empowerment:
The interior AGV line features a 12-station, 6,500mm pitch layout design, innovatively integrating continuous flow and intermittent operation modes. Deeply coupled with the 5G industrial private network and PLC control system, it enables seamless transfer of vehicle bodies between painting and final assembly, improving transfer efficiency by 40%.
Cockpit AGV line: Using a modular quick-change tooling system, it pioneered the separation technology of AGV carriers and process equipment, compressing the workstation switching time to within 90 seconds, and can support random mixed-flow production of 6 different wheelbase models.
- Optimization of Key Workstations
The final assembly line was extended by 30 meters, adding five intelligent workstations with integrated visual error prevention and torque monitoring systems.
The front suspension sub-assembly line introduced a 360° rotary assembly table, utilizing servo positioning technology to achieve an ultra-high cycle time of 20 JPH.
The torsion beam assembly area utilizes a 240-square-meter double-speed chain layout, coupled with a laser alignment system to maintain assembly accuracy within ±0.15mm.
Project Objectives and Value:
- Capacity Increase: Achieve stable production output of the A100C and its compatible 10JPH model.
- Flexibility Enhancement: Utilizing AGVs, programmable equipment, and modular design, significantly improves the production line’s ability to adapt to changes in multiple vehicle models.
- Intelligent Upgrade: Integrating RFID, 5G communications, and a higher-level control system will enable digitalized logistics, process transparency, and precise traceability.
- Efficient Logistics: AGV continuous/intermittent operation modes and optimized transfer processes reduce waiting times and improve material flow efficiency.
- Turnkey Guarantee: Multinational provides a one-stop solution, ensuring seamless project integration and high-quality delivery from design to after-sales service.
Through systematic transformation and innovative technology application, this project is committed to creating an efficient, flexible, intelligent and reliable modern assembly line, laying a solid foundation for future multi-model strategies and intelligent manufacturing upgrades.
