消费性电子具有体积小、**、迭代快、规模大、效率高的特点,因此对于制造装备的可靠性有着严格的要求。虽然长期以来我国数控机床产业的发展不尽人意,但在3C(电脑、通讯和消费性电子)产业却独放异彩,不仅在整机上有了很大突破,在核心的数控系统领域也斩获颇丰,入选国家智能制造试点示范的东莞劲胜精密组件股份有限公司(以下简称东莞劲胜)“移动终端金属加工智能制造新模式”项目,就是一个缩影。
“十八罗汉”剑出鞘
众所周知,3C产品的组成零部件数量众多,如手机就包含触摸屏、显示面板、主板PCB等较大的零部件,以及摄像头、结构件等其他细小零部件,且基本都是非标产品,体积小、**精度要求高,因此生产组装的自动化改造难度也较高。
但与此同时,包括外壳、盖板等在内3C产品零部件制造技术以及整机装配技术工艺和设备都相当成熟,加工内容重复度高,劳动强度高,符合自动化改造的特征。由此,东莞劲胜确定了智能制造项目的实施目标:实现生产效率提高20%以上,运营成本降低20%,产品研制周期缩短30%,产品不良品率降低30%,能源利用率提高15%。
历时1年,目前东莞劲胜已建成拥有10条自动化钻攻生产线的智能车间,建立了智能工厂设备大数据平台,通过对设备实时大数据的采集、分析,实现了机床健康保障、G代码智能优化、断刀监测等智能化操作。另外,项目还建有普及型自动化钻攻推广线(20台钻攻中心机床和12台工业机器人)、机器人自动抛光打磨生产线(12台工业机器人)、用于智能制造人才培训的智能生产线等。
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