Automobile Industrial Park, South Section of West Ring Road, Zhongmou County, Zhengzhou City
New Energy Vehicle Final Assembly Production Line Project
Release time:
2025-10-29 11:19
Source:
duoyuan
| To meet the customer's demand for efficient production of new vehicle models and future multi-platform models, Zhengzhou Duoyuan Vehicle Equipment Co.,Ltd undertook the systematic upgrade project for the Phase I general assembly production line. Based on the core concepts of Industry 4.0, the project was delivered as a complete "turnkey project," covering the entire process from process planning and equipment integration to system construction and production validation. After the upgrade, the production line will achieve a standardized high-efficiency cycle time, with overall equipment effectiveness (OEE) increasing to over 95%, establishing a flexible smart manufacturing system capable of mixed-flow production for multiple models. | |
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| Core Construction Content | |
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PBS Line Intelligent Upgrade A high-frequency RFID tag system was introduced to enable real-time tracking of vehicle bodies and doors throughout the entire process. The skid support point structure was optimized to adapt to the geometric parameters of new vehicle models. Twelve industrial-grade reader-writers were deployed to form a dual-redundant network, ensuring a recognition accuracy rate of no less than 99.9% under a high cycle time of 10 JPH. Dual AGV System Collaborative Operation - The interior AGV line adopts a 12-station equidistant layout, integrating both continuous flow and intermittent operation modes. Leveraging deep integration of a 5G private network and the PLC control system, it achieves seamless transfer of car bodies from the painting to the general assembly section, increasing overall transfer efficiency by 40%. - The cockpit AGV line utilizes modular tooling with carrier separation technology, enabling rapid station changeovers. It supports random mixed-flow production for models with six different wheelbases, with changeover times controlled within 90 seconds. Automatic Glass Gluing Workstation This workstation integrates storage and handling, gluing, inspection, positioning, and a human-machine collaboration system. It is capable of adapting to glass types for multiple vehicle models, covering over ten types including front and rear windshields and side windows, and supports future model expansion. Key Station System Optimization - The final assembly line was expanded with five smart stations, integrating vision-based error-proofing and torque monitoring systems. - The front suspension sub-assembly line introduced a 360° rotary servo positioning table, achieving an ultra-high cycle time of 20 JPH. - The torsion beam assembly area applied a roller conveyor with laser alignment technology, maintaining assembly accuracy within ±0.15mm. |
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| Technical Highlights | |
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| The upgraded production line achieves systematic improvements in flexible manufacturing, full-process quality traceability, and predictive maintenance. It is projected to increase production efficiency by 30%, reduce the product defect rate by 40%, and boost annual production capacity to over 150,000 units, fully meeting the customer's current and future demands for efficient vehicle production. | |
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Address：Automobile Industrial Park, South Section of West Ring Road, Zhongmou County, Zhengzhou, China
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