The workshop process improvement of Zoomlion Heavy

2022-08-23
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Zoomlion crane engineering Co., Ltd. has achieved remarkable results in the improvement of workshop processes

Zoomlion crane engineering Co., Ltd. has achieved remarkable results in the improvement of workshop processes

China Construction machinery information

Guide: to prove whether the design has shortcomings. In the second span of Changsha truck crane structure factory of engineering crane company, when the turntable of 25~80t was previously produced, the base plate and large flange ring were produced by manual welding. Manual welding after setting up the turntable, it needs to be hoisted to the positioner to burn and weld the base plate and flange ring, which is not only heavy workload, but also welding

in the second span of Changsha truck crane structure plant of engineering crane company, when 25~80t turntables were previously produced, the base plate and large flange ring were produced by manual welding. When cooking and buying vegetables manually, plastic bags should be used as little as possible. After setting up the turntable, it needs to be hoisted to the positioner to burn and weld the base plate and flange ring. Not only does it have a large workload, but also the utilization rate of the welding robot can only reach 73%, which is not cost-effective

the problem of manual welding has always been an obstacle to the speed-up of workshop production, and it is also a headache for our welders. When we looked at the advanced robot welding equipment, we came up with the idea: "can we make full use of these advanced equipment and let the robot program instead of manual welding of the base plate and large flange ring, so as to reduce the labor intensity?" After we put forward suggestions, the technicians of the turntable group began to study solutions: such as making special tooling, changing processes, etc

during the research, it was found that the deformation of the large flange ring on the base plate of the turntable had no harmful organisms carried by the imported wooden packaging, and the prominent method was guaranteed to be within the controllable range, so it might not meet the design requirements. After the discussion and demonstration of the process personnel, everyone unanimously decided to innovate and try to change the process. The front-line staff and technicians in our workshop decided to produce a 55v532 product in the experiment. The welding procedure of the base plate and the large flange ring was programmed by the welding robot first, and then placed in the front section of the turntable, then welded by the overall robot, and finally metallized. The flatness of the large flange ring can be controlled within the range of production and design requirements when the deformation data after welding is detected by the three-dimensional scriber in this way. At the same time, the welding deformation of the bottom plate and the post welding metal processing in the experiment can be well controlled in each process. The success of the experiment gives us great confidence, because it means that it is expected to realize full robot welding on the structural parts of 25~80v products. By then, it will not only bring "benefits" to the front-line operators in our workshop - reduce the labor intensity of manual welding of large flange rings; At the same time, it also makes the welding robot in the workshop more efficient, shortens the production pace, ensures the weld quality, and fundamentally eliminates the quality accidents caused by the manual welding defects of the large flange ring of the turntable

this is only a small step taken by the workshop staff in implementing the strategic decision of "quality is king" of the engineering crane company. Next, the workshop will carry out more in-depth product research and development and other activities aimed at improving production efficiency

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