In order to further improve the efficiency of FTL production and adapt to the market faster, the agile flexible automatic line AFTL was developed. The goal is to quickly respond to changing market demands; to meet the needs of modern car engines "multi-variety, large and medium-volume, high efficiency, low cost"; in line with the "lean production" principle, that is, to obtain maximum economic benefits with minimum investment.
The main features of AFTL are:
(1) Hybrid type automatic line consisting of a general-purpose high-speed machining center and a dedicated/combined machine tool (HSMC+SPM/TM).
The equipment is arranged according to the process flow and connected by an automatic conveying device.
(2) Using agile fixtures (flexible fixtures - controllable, adjustable fixtures).
(3) Adopting “Smart Tools†(special high-efficiency tool) with electromechanical and hydraulic integration features.
The advantage of AFTL is that it has high production efficiency and considerable flexibility, and can be suitable for mass production and production of variant products with a small investment. The disadvantage is that the flexibility is limited and it is not possible to process unforeseen parts of any type. At present, hybrid flexible automatic lines are widely used in the domestic and international automotive industries. Especially in the design and manufacture of combination/special machine tools, China has a huge comparative advantage, that is, the price of China's combination/special machine tools is lower than that of high-speed machining centers, while foreign countries are just the opposite. Hybrid flexible automatic lines should be strongly promoted. The following is a list of fully flexible (machining center), special aircraft and hybrid flexible automatic line cost data as shown in Table 1 (delivered by Dalian Ingersoll).
2. The third revolution in engine manufacturing technology
The background of the third revolution in engine manufacturing technology has two aspects.
On the one hand, with the advancement of technology, engine development speed is getting faster and faster, and the new product development cycle has been shortened from 30 months to 13 months. At the same time, the increasing diversity of demand has led to a sharp increase in the number of models. For example, China's First Automobile Group developed 920 new models from 2000 to 2004; Japan's Toyota Corporation has doubled its number in the past 10 years.
On the other hand, in the increasingly fierce competition in the engine market, the uncertainty of engine production volume increases. Currently popular flexible automatic lines, due to the high price, the investment risk is increased. At the same time, the contradiction of overcapacity is increasingly prominent. In recent years, people have been exploring the contradictions that are increasingly addressing diversity and economics. To meet the needs of variable varieties and variable batches, and to meet the requirements of high flexibility, high efficiency, low investment, and rapid market response; at the same time, we are also exploring the century-old contradiction of overcapacity by the revolution of manufacturing systems.
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