On the eve of the opening of the 16th China International Machine Tool Exhibition (CIMT2019), good news came from Qinchuan Group: Qinchuan BX robot reducer produced and sold double-increased in the first quarter of this year, operating income increased by 141% year-on-year, and production capacity reached 3500 units per month.
Qinchuan robot reducer
Since the fourth quarter of 2018, Qinchuan Group has further rationalized the reducer production process, optimized the product process, strictly implemented lean production management, reducer production capacity has increased significantly, nearly doubled the speed of growth, and with the gradual completion of the technical transformation of process equipment, the commissioning of digital production lines has been completed, especially the construction of production bases with 180,000 units of capacity is advancing rapidly, and BX reducers are becoming a new growth pole for the high-quality development of Qinchuan Group.
Conquer the core technology to form a series of products
Relying on more than 50 years of experience in technical process research and equipment manufacturing in complex surfaces represented by gears, Qinchuan Group adheres to innovation in Shouzheng, exerts the "spillover" effect of host technology, moderately expands to downstream functional components, does scale, and creates benefits, and BX robot joint reducer is one of the representatives.
"The design of the robot body stems from the custom research and development of different working conditions, which determines the personalized customization characteristics of the joint reducer supporting the robot." Qinchuan Institute of Technology Transmission Institute technical experts said, "Our reducer digital forward design platform is to meet the customized needs of users and built, the role of the platform is to provide users with solutions, so that the design of the reducer can quickly meet the variety of fast changes in the market demand, to achieve the digital production and service of reducer products." ”
Experts from the Institute of Intelligence of Qinchuan Institute of Technology introduced that the digital forward design platform adopts the international advanced level of gear transmission system design software and other means, first of all, according to the load spectrum for digital modeling, assembly and virtual prototype simulation of reducer products, the design, processing, assembly, test and other data analysis and optimization of prototypes, the formation of digital reducer products; the second step is to carry out robot operation tests, vibration analysis, motion simulation, attitude adjustment and other work, and obtain relevant data of reducers The third step is to re-optimize and re-adjust the digital forward design virtual prototype through the test test results, so as to reduce the number of tests, shorten the test process, and improve the level of new product research and development. "The reducer of the same model takes 3 months if the traditional design method is used, and the use of the platform can be shortened to 1 week." The expert said.
The technical team of Qinchuan Group has overcome a number of key core technologies such as high transmission accuracy, high torsional rigidity, high overload capacity, over-positioning structure and interference transmission of the reducer, and developed 3 series of BX-E/C/F and other 19 models and 85 specifications of the product, to meet the optional needs of 5kg to 800kg robots, the products have realized digital production, forming a digital twin, that is, "physical + data packet" service.
"The Qinchuan joint reducer packet contains both internal packets and external packets, and the internal packets are optional component geometry or geometric tolerance dimensions to meet the performance of the reducer; the external packets are provided to the user for robot tuning, testing, simulation and other related data." The company's gear technology experts said, "Qinchuan's data package can be used by users (robot machine factories) to carry out structural mechanics simulation, modal analysis and dynamic response analysis and feed-forward compensation, and robot calibration. ”
At the same time, with the Qinchuan robot joint reducer standing out in the market, Qinchuan Group, which has mastered the right to speak in the field, was responsible for drafting the "Precision Cycloid Planetary Gear Reducer for Robots" standard, and the formulation of this standard further laid the company's industry leadership.
Research and development of complete sets of equipment to help rapid development
The data shows that the total demand for industrial robot reducers in China exceeded 470,000 units in 2018, and the incremental demand is expected to exceed 600,000 units in 2019. During the two sessions this year, the government work report mentioned "intelligence +", indicating that the combination of artificial intelligence and robots was further deepened, once again providing favorable conditions for the development and growth of domestic robots.
As the commanding height of the core technology that is the most concerned about localization, the robot reducer has always been a place where Chinese enterprises must compete, but at present, there are only a few enterprises that can achieve mass production among the domestic production reducers.
In order to meet the market demand and break down technical barriers, Qinchuan Group gives full play to the advantages of the company's complex surface digital manufacturing process equipment, and develops MK2336, VG80, QYF007, QYF007T, QMK017 and other special processing equipment for the key processes of 5 major components of cycloid wheel, needle tooth shell, eccentric shaft, planetary frame and planetary gear. Independently designed and manufactured a test bench for testing the transmission accuracy, differential return, efficiency, temperature rise, and vibration, noise, torsional stiffness, life and other major indicators of the reducer. At the same time, Qinchuan Group cooperated with Bosch Rexroth in Germany to jointly design and manufacture the BX5+1 intelligent production line (that is, 5 key parts production lines and a digital machine assembly line), of which the key equipment of the production line was independently developed and manufactured by Qinchuan.
For example, the digital machine assembly line is composed of several workstations and wire feeding systems, which integrates the application of sensor detection technology, FRID technology, error-proofing technology, network communication technology, etc., which not only enables the reducer to achieve lean production, but also forms personalized data packages such as product parameters and performance, which can provide users with a complete service of "physical + data package". Qinchuan intelligent manufacturing technicians introduced, "Combined with the quality traceability system, pallet conveyor system, actuator, production information display, etc., the use of distribution assembly, distribution testing, workpiece fixed storage and other control means, so that the production line has obvious flexible assembly characteristics." ”
Recently, the national "strong foundation" engineering experts said after visiting the survey: "It is difficult to find an enterprise like Qinchuan in China that has many specifications, high precision, and strong comprehensive strength in mass production and service in terms of robot reducers. ”
Promote lean production to meet market demand
Since the successful development and manufacture of BX robot joint reducer, Qinchuan BX reducer has been in short supply. In order to improve efficiency, expand production capacity, and continuously meet market demand, the company strictly implements lean management, adheres to goal orientation, continuously improves the manufacturing process flow, refines the process cost management, improves the level of equipment management and use, and ensures that the product achieves a significant improvement in output and quality.
Process planning and value stream analysis based on lean management are the characteristic advantages of Qinchuan BX robot reducer production management, around this advantage, the company implemented capacity planning and upgrading projects. At the production site, a deputy factory of Qinchuan Robot Factory introduced that the first is to implement a number of advanced processes in the processing technology of key parts, set up a number of key project teams, and increase the efficiency by 3-4 times under the premise of ensuring quality; secondly, optimize the workshop logistics to ensure the orderly flow of parts in the processing process and be in place on time to improve the flow speed of parts; the third is to centralize management of finishing equipment, improve equipment utilization, and also accelerate the turnover speed of parts and achieve production capacity improvement.
With mass production and quality double improvement as the goal orientation, management forced, the company to refine the process cost management, control the cost between the process, improve the efficiency of the process as the starting point, continue to improve production capacity and quality. Only by optimizing the processing margin, adjusting the assembly process self-inspection and special inspection items, and reducing the inspection and other working hours, the process efficiency is improved by an average of 35%.
In the process of meeting market demand, the company has also established a rapid response mechanism, formulated and implemented the "Workshop Rapid Response, Upgrade Reporting Process", formulated the "Monthly Commodity Production Plan", "Monthly Parts Processing Plan" and "Monthly Production Preparation Plan" according to market demand within the scope of "Production Operation Plan Indicators", organized production to strictly control the input of rough blanks and wiped stocks, improved turnover rate, reduced semi-finished product inventory, and gradually changed to the mode of demand-driven production.
Qinchuan brand BX reducer has won the "Best Robot Parts Award" and "Robot Reducer Good Product" award of China Robot Industry Alliance for many times. At present, the number of domestic and foreign users has exceeded 260, and the batch orders of some important customers continue to increase. According to industry experts, Qinchuan robot joint reducer business carries and extends the company's traditional technology and technology at the same time, but also feeds and leads the innovation and upgrading of the core technology of the enterprise, and will surely become the forerunner of the high-quality development of the robot reducer industry.
Excerpt: China Industry News Network