reborn industrial empire

Chapter 429 Manufacturing Process and Talent Training

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The main honing machines are vertical honing machines imported from Kohler, Germany. The main purpose of these machines is to perform the most basic grinding process on the engine cylinder block and cylinder head.

The rough embryo is put into the honing machine and is polished and cleaned hydraulically. The material used for cleaning is not water, but a special engine oil.

The honing body used by the honing machine is also a special stone material. These materials are combined together to perform the preliminary grinding of the engine cylinder block and cylinder head and other equipment, and to remove the metal on the cylinder block and cylinder head castings.

The main purpose of removing burrs and metal debris is to make the workpiece flatter and smoother.

Then the initial processing workpieces of these cylinders will be placed on the conveyor belt and sent to the second machining center for further finishing, which is actually the second polishing and cleaning.

This step is even more critical, because after completing this process, the cylinder will be ready for assembly. Part of the machinery used for polishing this time was secretly smuggled in from Japan, and

Some of them were later purchased from Germany.

In the past, when it came to this part of finishing grinding and ball grinding, Japan and Germany had very strict export controls on such machinery.

But in the past two years, especially after Huayang Power used some grinders and ball mills smuggled in from Japan to improve the finishing level of their engines by several levels, they can be on par with German and Japanese products.

The Germans and Japanese thought that the Chinese people had made a breakthrough in this part of the field of finishing and were able to produce high-precision ball mills and grinders, so the two countries relaxed their technology export controls in this area.

Although such machinery is still included in Batumi's embargo list to China, since people now have such technology, there is no need to block it.

Therefore, while the Americans turned a blind eye, the two countries began to use side kicks and secretly exported machinery like China under various names.

Following this opportunity, Huayang Power brought back a lot of machinery from Germany and a lot from Japan. In this trend, those who got the biggest bargains were of course other domestic companies.

Own brand enterprise.

Originally, their engine cylinder processing accuracy was not as good as that of foreign-funded enterprises, or even as good as Huayang Power. Now that the Germans and Japanese have opened up their technology to them, how can anyone wait and wait? So everyone started to wait.

In the second half of last year alone, Chinese companies imported thousands of such high-precision grinders and ball mills from abroad.

Of course, this is all thanks to the east wind that Huayang Power pierced through the window.

After the second finishing, grinding and cleaning, the cylinder workpieces will be turned over for inspection after they come off the assembly line. Some workers will conduct preliminary inspections of these cylinders at one station.

These workers all belong to the quality supervision department and require very rich experience. They must be familiar with the operation process and inspection items of the work area. They work in pairs to conduct initial inspection of the produced workpieces.

On several other production lines, workers are also testing important engine components such as cylinder heads, crankshafts, crank connecting rods, pistons, timing chains, etc.

After all the tests pass, these parts will be transported to the assembly workshop on the assembly line for assembly. Workers will assemble all the workpieces according to the production process of their shift today. Of course, most of the work is done by the assembly line.

The robot on it will do it.

There are many processes that are assisted by computers. For example, when assembling connecting rods and pistons, computers will be available for comparison at any time.

After each workpiece combination is produced, it will be compared with the previous standard parts after computer photography or industrial X-ray photography. It is allowed within a certain error range, but if it exceeds the error range

, and will eventually be reworked.

Before the assembly work begins, workers at each station must check whether there are foreign objects inside the components they are facing. A mirror is placed diagonally above each station to allow workers to

From different angles, notice whether there are any foreign objects inside the components in front of them.

The entire assembly process is extremely strict, and even the workers are verifying it like robots. Only in this way can the quality of Huayang Power products be ultimately guaranteed.

After the cylinder block and cylinder head are assembled together, a leakage prevention process will be carried out, and the assembled workpieces will be placed on the assembly line and transferred to the front of a robot.

This robot will perform leak-proof treatment on this component. In fact, it means injecting special glue containing silicon into the joint part of the workpiece. This will ensure that when the engine is working later, after the cylinder block and cylinder head are combined,

The water channels and oil channels are completely leak-free.

Then there are steps such as installing an oil pump to the engine, and then continuing with the installation of the variable valve timing system, such as timing chains and other accessories.

If it is an engine equipped with a turbine, you must also start installing the turbocharger and other steps after this process.

After the installation is completed, the engine components will be sent to an inspection station. The principle of this inspection station is similar to a blower, but the air outlet is upward. The engine is placed on this air outlet, and then the blower starts blowing upward to check whether the oil pipe is leaking.

Wait for the program.

The last step is to install the ignition coil on the engine. Today's technology is very advanced and the ignition coil is made very small. Therefore, the placement and size of the ignition coil before it is recognized by the robot are very particular and must not appear.

Any mistakes, because once placed improperly, the robot may not be able to recognize these ignition coils.

This robot uses Yaskawa's two-arm robot. The assembly speed can be said to be very nb. He first swept the ignition coil into the arm pocket in front of him, and then moved it at a speed of more than ten per second.

These ignition coils are installed into the cylinder head.

Then even if an engine is assembled, it is time to go to the last process of the engine, quality inspection!

For this last part, because the entire engine has been assembled, the inspection method is intuition and touch, which requires very high experience of the workers.

Because Zeng Jianxin recruited a lot of masters in engine manufacturing before, and then specially made these people familiar with the production line process and conducted production for a period of time. After that, they asked these masters to come to the last part to do quality work.

Check.

After they were thoroughly familiar with this set of processes, they were assigned two apprentices to each person. These apprentices were all technically qualified employees specially selected from the production line.

The quality inspector will take out photos of the previous standard engine and compare them with the assembled engine from all angles. If it passes, they will put a green label on the engine.

If they fail, they will put a red label on the engine, and then a forklift will send these engines to different work areas for placement.

Qualified engines are placed in zoned warehouses, waiting for the production department to transport them away, while unqualified engines stay in the recycling area, waiting for rework and inspection.

In this way, a complete set of engine production process was completed. After Jin Xiaoqiang followed Zeng Jianxin and walked around the large work area, he felt very satisfied with this machining center.

It has only been less than a month since the entire new engine production and processing center was completed and put into operation, but the mood of the workers in the center is not bad.

The age level of the workers is also a combination of old, middle and young generations. Those who are old enough are generally experienced masters. Now they usually work in quality inspection positions and then lead apprentices.

Middle-aged masters generally work in the production department and on the assembly line, while young apprentices are found in various departments, both on the assembly line and in the quality supervision department.

There are also engineers from various professions who are also working on the front line of production and accumulating practical experience.

Of course, these are the regulations set by Jin Xiaoqiang. He is very clear about the training mechanism of our university in China. There are many talents trained who can take exams, but their practical ability can be said to be basically non-existent or very poor.

These engineers are the talents that the company will make great efforts to cultivate in the future. However, if they do not have enough front-line production experience, Jin Xiaoqiang believes that it will be difficult for them to become qualified designers and engineers.

Of course, he learned this from Japanese automobile manufacturing companies. After graduating from university with a mechanical major, engineers from Toyota and Honda, without exception, would often go to the production line to understand the actual situation in the first year after entering the company.

, and even participate in machining and finishing work, so that they can have a fuller understanding of the knowledge learned in previous books, and lay a solid foundation for their future design work.

However, our mechanical graduates, not to mention the knowledge they learned in school, are more than a generation behind international students. Many of them are students who have never even seen an assembly line.

If you don't let them understand the production process and process in detail and start designing drawings at the beginning, it will only be counterproductive and talk on paper.

If he, Jin Xiaoqiang, had not had actual operating experience in a factory in his previous life, he would probably not know these things, so he has the same requirements for his engineers.

Everyone must have practical experience before they can start working.

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