The staff used AR glasses to control the virtual electronic screen in the intelligent CNC workshop of China Commercial Aircraft Corporation's final assembly manufacturing center.
Editor's note:
With the advent of the new industrial revolution, countries have cut through their own areas of strength in order to seek a favorable position in the new industrial division of labor. The Shanghai-based industrial belt with Shanghai as the leader has a unique global comprehensive advantage in terms of industrial base, capital cost and accessibility, and will become the geographical hub of the fourth industrial revolution.
From a global perspective, the Pan-Shanghai Industrial Belt has the most complete industry categories. This layout enhances the interconnectivity between the categories. The efficiency of cross-learning is higher, and the overall change of all categories can be realized in a short period of time. More importantly, the Pan-Shanghai Industrial Belt has also formed close upstream and downstream clusters around different industries, enabling industrial support in a very short period of time.
Therefore, the launch of the “Made in Shanghai†brand not only polishes the Shanghai brand, but also enhances Shanghai's ability to participate in global cooperation and competition and allocate global resources.
Large domestic aircraft lifted Shanghai to create "industrial endogenous force"
Wearing AR glasses to manipulate virtual electronic screens, and carrying the camera to stereo scan the parts... This scene is like playing an augmented reality game, but in fact they are manufacturing and testing aircraft parts.
A few days ago, the reporter saw in the intelligent CNC workshop of domestic large-scale aircraft production and processing parts, the most popular technologies such as Internet of Things, AR, cloud computing, etc. are all used in this workshop.
It is understood that the manufacture of large passenger aircraft is a highly integrated system engineering, known as the "crown of modern industry." A C919 large passenger aircraft with 724 cables, 2328 ducts, and a total length of nearly 80 kilometers of pipelines, with a total of 2.5 million parts, is undoubtedly a fine work.
Is the smart workshop making the plane reliable?
Into the intelligent CNC workshop of Shanghai Aircraft Manufacturing Co., Ltd., the busiest is an unmanned parts production line. CNC machine tools, carrier robots, AGV trolleys, and even material racks and pallets, all of which are equipped with a “neural†to enable information interaction between devices.
The CNC machine tool processes the parts, and the carrier robot picks up the information before receiving the information, automatically “wakes up†the water tank to ultrasonically clean the parts, and then places them on the brackets, which are transported out of the workshop by the AGV trolley. The entire process is unmanned.
Xu Jiangwei, secretary of the Party branch of the CNC Machine Shop in Shanghai Aircraft Manufacturing Co., Ltd. said: "Operation workers are freed from linear work, from oil pollution to refreshing, and work efficiency is greatly improved."
The automated production line has already been applied on a large scale in the equipment manufacturing industry such as automobiles. What is special about this intelligent production line?
Although there are hundreds of thousands of parts on a plane, the types of parts are complicated, and many parts are not used much, but the processing is very difficult.
Xu Jiangyan picked up an irregularly shaped part and told reporters that the part called "corner piece" was used for the flat tail of the plane. One plane used only one piece and produced about 30 pieces per month, because the demand is small, if adopted Similar to the automated pipeline mode of automotive manufacturing, production costs are too high. To meet the special needs of high precision and small quantity of aircraft manufacturing, only flexible and intelligent production mode can be adopted.
Simply put, this production mode is the “proofing†of the craftsman and the “copying†of the machine. According to the design requirements, the craftsman will create the first part that meets the requirements. The data processing method will let the processing and inspection requirements of this part enter the production management system, and then the robot will carry out the same standard according to the production system instructions. Batch automated parts production.
“In the intelligent CNC workshop, as long as the size of the machine tool is correct, there is no need to worry about deviations and reduce the error and interference caused by human factors.†Chen Haiming, a senior milling engineer who entered Shanghai Aircraft Manufacturing Co., Ltd. in 2010.
The robot is coming, what are people going to do?
In the product inspection area, a robot with more than a dozen "eyes" is scanning all parts in one part. The image of the parts under the robot shooting is directly input into the computer and compared with the design drawings in the computer. Whether the manufacture of this part meets the design requirements. Tests that have been completed in the last two or three hours are now completed in two or three minutes.
The machine is so "smart", is it no longer necessary for workers?
In fact, in this smart workshop, in addition to the production line, there is also a hidden “flowâ€, that is, information flow, the operation information of the entire workshop is aggregated to the real-time monitoring platform, so that the workshop is “transparentâ€, and all the information is summarized to the controllers. The role can be better played.
For example, how is the processing equipment implanted with “nerve†working, how to check? A staff member wears AR glasses and his fingers move in the air. This is how the staff monitors the operation of the equipment in real time. Using AR technology, the electronic screen projected by the glasses can reflect the working status, historical data and design drawings of the equipment. If you need any information, you can directly click on the virtual screen to retrieve the data, eliminating the need to repeatedly retrieve data on the computer. The trouble of data comparison. “Working here, full of technology, cool!†The operator introduced the interest.
“The intelligent transformation of the workshop is not to replace the machine, but to put forward higher requirements for people. Now our craftsmen must understand the design, understand the production, and understand the quality inspection to ensure the safety of the whole system. run. "Minister of Science and Technology Co., Ltd. Shanghai aircraft manufacturing management Department Wangshun Li said.
With intelligent equipment, traditional arts is not is not required? Surprisingly, the 30 years have not been out of a defective national model worker Hu double the money in this workshop. "We learn from model worker who is not only the spirit, and his operational experience, we need to do is to these empirical data, structuring, inheritance and easier to upgrade technology." Xu Jiang Wei said.
Intelligent transformation is also a testing ground for incubator
NC workshop of the entire staff of 300 people, 35 years of age accounted for 90%, "90" accounted for 50%. The times have changed and the production model has to change.
In addition to the mechanical processing workshops that have been intelligently transformed, the intelligent transformation of the assembly, tooling and assembly shops for aircraft manufacturing is the future direction.
Since September 2017, Shanghai Aircraft Manufacturing Co., Ltd. has decided to carry out intelligent transformation of the processing workshop. The production of parts within 800 mm has achieved intelligent production. The next goal is to realize the intelligent manufacturing of parts over 800 mm.
“We have realized the production of mixed batches of small batches, multi-variety and multi-processes. The next step will be to work in the direction of single-piece flow and complete customization. That is to say, any parts in the future can be customized and only one piece can be produced. Not to raise costs, not subject to mass production restrictions." Xu Jiangyan said.
The hard part is not to do it, but to think of it. The intelligent CNC workshop is a test field and an incubator. The future intelligent transformation will also develop into green, energy-saving, environmental protection and Internet.
For example, CNC machine tools require coolant, and now the coolant is replaced by filling. In the future, intelligent liquidification can realize the recycling of coolant, reduce costs and protect the environment.
Another example is that the aircraft parts are complex in shape, and the finished products only account for one-third of the original materials. Two-thirds of the materials are cut off. Through intelligent design, the discarded aluminum chips are directly recovered and pressed to reduce waste. Logistics costs of processing.
For another example, in the era of mobile Internet, the information system of the intelligent workshop can be connected with the mobile phone of each employee, so that employees can see their production tasks, design drawings and production difficulties through the mobile phone on the way to work.
To complete the mass production tasks of aircraft manufacturing, it is difficult to achieve without intelligent manufacturing, and it is difficult to guarantee product quality. Through intelligent transformation, looking for production models with higher efficiency, higher reliability and lower cost, China's aircraft manufacturing industry is constantly exploring and upgrading.
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