1. Overview of flexible manufacturing systems
With the integration of economy, the era of competition globalization, diversification of demand and differentiation of competition, the traditional manufacturing system can no longer meet the market demand for multi-variety and small-volume products. Forcing traditional large-scale production methods to change, the mass production era is gradually being replaced by production systems that adapt to the dynamic changes of the market, which makes the flexibility of manufacturing systems more and more important.
The flexible manufacturing system is an automated manufacturing system that is managed and controlled by computer and efficiently manufactures a variety of small and medium-sized parts and components. It can be quickly adjusted according to changes in manufacturing tasks or production environments, so as to be suitable for multi-variety, medium and small batch production. When the manufacturing object changes, it can produce the required parts by simply changing the software, tooling, and tools.
It is mainly composed of three parts: (1) multiple CNC machining equipment; (2) a storage system that can transport and store workpieces between the clamping station, processing equipment, and exchange workstations; (3) corresponding computer control system . At the same time, it can also be equipped with supporting equipment such as chip collection and workpiece cleaning.
The flexible manufacturing system IEJ according to the size can be divided into the following four categories:
(1) The flexible manufacturing unit (FMC) usually consists of a single CNC machining equipment and a loading and unloading mechanism. FMC can be regarded as the smallest FMS, which is characterized by single machine flexibility and automation.
(2) Flexible Manufacturing System (FMS) usually includes multiple CNC machine tools, which are connected by centralized control system and material handling system to realize multi-variety, medium and small batch processing and management without stopping the machine.
(3) Flexible Manufacturing Line (FML) It is a production line between single or small variety large quantities of non-flexible automatic lines and small and medium batches of multi-species IEJ. The processing equipment can be a general-purpose machining center or a CNC machine tool. It can also use a special machine tool or a NC-specific machine tool. The flexibility of the material handling system is lower than that of the FMS, but the productivity is higher. It is represented by a flexible manufacturing system in discrete production and a distributed control system (DCS) in a continuous production process, which is characterized by flexibility and automation of the production line.
(4) Flexible Manufacturing Factory (FMF) is a computer system and network that connects all flexible units FMC and flexible line FMS of design, process, production management and manufacturing process through manufacturing execution system MES, and is equipped with an automated warehouse. Complete digital manufacturing process from ordering, design, processing, assembly, inspection, shipping to delivery. It integrates the automation of manufacturing, product development and operation management into a whole. It is represented by the Intelligent Manufacturing System (IMS), which controls the flow of information flow. It is characterized by the flexibility and automation of the entire plant.
The above four types of flexible manufacturing systems, in addition to FML; the rest of the system has been widely applied and fully embodied in Little Giant Machine Tool Co., Ltd. The following is a detailed introduction to the specific application of the Little Giant Company.
2. Application of flexible manufacturing unit FMC
At present, there are 6 types of flexible units in the Little Giant Company.
(1) Flexible processing unit with bar conveyor (QTN200M/500U)
The bar conveyor feeds a long bar through the hollow chuck into the machine. The turning and milling machine is machined according to a predetermined procedure. The machined workpiece is collected by the workpiece collector and placed in a storage bin or conveyor. The bar conveyor continues to feed according to the action signal sent by the machine numerical control system, and starts the machining of the second workpiece.
(2) Flexible processing unit with automatic cutting machine (INT200SY)
The machine tool itself is equipped with a parallel arrangement of the cutting machine and the machine tool. The machine tool cuts a long bar according to the programmed program, cuts it into the required raw materials, automatically feeds it into the machine tool, and then the machine tool processes the workpiece according to the established program ( Turning and milling composite, using the main and auxiliary twin-spindle multi-process simultaneous processing), after all the processing is completed, the cutting and unloading device of the cutting machine takes out the processed workpiece, put it on the conveyor belt, and then feeds the raw materials, and so on, to achieve continuous Automatic processing. The automatic machining efficiency of the machine tool is high, the machine starting rate can reach 75%, and the unmanned running time is more than 8h.
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