en.Wedoany.com Reported - To deeply implement the "Four Modernizations Factory" construction requirements of the Forging Division and consolidate the foundation of lean production, the Front Crank Workshop of FAW Foundry and Forging Forging Division recently completed the automation upgrade of the trimming process on the 301 production line and the optimization of the T2 and T3 transfer trolley systems. This technical transformation has achieved significant results, with overall equipment efficiency increasing by 8% and cumulative cost savings reaching 150,000 yuan.
This transformation focused on pain points of the traditional trimming process, such as low efficiency, high investment, and insufficient space utilization. It adopted an optimized "dual-action clamp" design, enabling a single robot to simultaneously perform forging part gripping and flash removal operations. Compared to the commonly used dual-robot split operation mode in the industry, this innovative solution effectively reduces equipment investment, saves on-site space, and significantly lowers comprehensive production costs including equipment maintenance, energy consumption, and labor, achieving a comprehensive improvement in process operation efficiency.
The workshop completely restructured the workflow, eliminating the oil cylinder ejection structure under the die. It adopted a new robot combined with a specialized clamp for contactless material feeding. Through precise positioning of the clamp, accurate placement of the forging into the die is ensured without manual intervention. Additionally, the workshop modified the die base and installed a hydraulic die-pulling mechanism to replace forklift die changes, while also installing fully enclosed safety fences to create a physical isolation barrier, significantly improving the working environment.
The workshop simultaneously improved the T2 and T3 transfer trolleys, upgrading the drive motor from the original variable frequency system to a servo system. This significantly enhanced positioning accuracy, resulting in more responsive operation and more stable control. Furthermore, by changing the guide rail type, optimizing the overall trolley structure, and leveraging the team's self-maintenance capabilities, operational stability was significantly improved, with equipment failure rates decreasing by over 40% year-on-year.
In the next step, the Front Crank Workshop of the Forging Division will take this transformation as an opportunity to continuously focus on the core goal of the Division's "Four Modernizations Factory" construction, promote intelligent equipment upgrades, continuously strengthen the core competitiveness of the enterprise's production, and build a solid production technology foundation for creating a world-class forging enterprise.
