一、前言
随着汽车生产规模的日益扩大，人们对于汽车的生产效率也提出了更高的要求。为了提高生产质量，需通过技术手段的创新促进订单的迅速下达，对车辆生产情况进行动态化的跟踪，帮助相关人员了解各类车型的位置和状态，避免由于各类客观和主观因素引起的误装、缺料问题。汽车的整车生产中有多个流程，如冲压、焊装、涂装、总装，为了满足自动化、智能化的生产要求，需对传统的汽车生产线进行适度的改造。
二、Y 企业生产线现状
1. 焊装生产线
Y 企业是一家历史悠久的汽车企业，由于车间的使用时间较长，面对现代化的生产要求，亟待进行转型。具体来看，Y 企业的焊装车间存在几个突出问题：a. 生产线的柔性不足，不支持灵活生产，由于生产线的建设时间不同，设备的规格以及产业的布局具有差异，无法兼顾目前的车辆生产要求，不仅浪费了资源，也会增加生产成本；b. 厂房面积较小，不支持新车型的生产，一些新设备受到厂房面积的制约无法顺利投入，影响了 Y 企业的经济效益；c. 自动化水平较为滞后，在传统的厂房之中是采用人工的作业方式，没有实现数字化、自动化的生产。在科技的不断发展下，当前的新车型广泛采用了新技术，加之劳务成本的逐年上涨，严重影响 Y 企业的效益，因此对现有的生产线进行提质改造，既可以降低人工成本，还可发挥品牌效益，提高生产质量。 数字化转型网（www.szhzxw.cn）
2. 冲压生产线
Y 企业的冲压生产线已经建立了多年，迄今为止已有 10 余年的时间，已经与当前时代的发展表现出了一些不适应性。a. 传统冲压生产线需要多个操作人员的共同参与，也增加了 Y 企业的成本；b. 传统冲压生产线的设备老化问题严重，信息化发展水平之后，在 10 余年前，Y 企业受到技术因素、企业规模的限制，冲压生产线的建设也是遵循简洁性、集约性原则，生产线是以人工操作为主，生产设备有双梁行车、配油压机、曲柄压力机、板材清洗机等，由于长时间的运行，部分设备已经老化，常常发生故障，且信息化、自动化程度较多。另外，冲压生产线附近还有不少危险源，人们需要交叉作业，由于人员因素引起的不安全事件频发，且车间采用的是开放式的作业布置模式，环境比较复杂，存在一些危险因素，这是后续自动化改造中需关注的重点内容。
三、Y 企业焊装车间的自动化改造方向与对策
1. 焊装生产线的自动化改造
（1）改造方向
鉴于 Y 企业焊装车间生产线存在的各类问题，对于焊装车辆的自动化改造，从如下几个方向进行：
a. 减小生产线的损失。在自动化改造的过程中，不能影响正常的生产活动，为了保障新、旧生产线之间可以紧密衔接起来，最大限度发挥出资金的利用效率，需要科学制定总体规划方案，为自动化改造提供精准的支持。在具体改造过程中，采用“分步走”的方式，先拆除一条生产线，建立新的自动化生产线，在生产稳定之后再逐步拆除其他的生产线，在不影响正常生产的前提条件下进行自动化改造。
b. 以技术手段提高生产质量。在自动化改造的过程中，融入自适应等焊接技术，这可以提高焊接质量，还可记录焊接数据，支持焊接的可追溯。同时，应用涂浇自动化与视觉检测技术，利用 CV 技术、AI 技术等精准评估生产品质。引入最新的设备备件，推广通用化部件，减少备件库存，让备件库存的管理可以实现灵活化。 数字化转型网（www.szhzxw.cn）
（2）改造对策
a. 新建车间：考虑到原有的车间面积较小，在改造时需要扩大车间面积，新建厂房，厂房选址与旧厂房距离相近，在改造前提前做好规划，根据投产计划来确定，严格遵循相关法律法规的要求。根据 Y 企业的情况，采用门式钢架结构，屋面使用岩棉夹芯板，按照要求设置好水、电、气以及消防参数，根据后续发展趋势预留好区间。对于车间照明、排烟、消防通道的设计需关注到环保、便利要求。
b. 合理设置布局：一是优化输送线体，提高物流效率，减少机器与设备的占地面积；二是改进工件投入模式，采用自动化的传送方式，引入机器人搬运；三是科学优化生产线，将以往的人工总拼夹具改为自动模式，提高夹具对位精准度；四是优化设备，满足整体切换、自动切换要求；五是应用轻量高压力焊枪以及小型高速机器人；六是引入自诊断机器人，满足设备实施监控的要求，实现“零停机”。通过上述举措有效提高了生产的达成率以及涂胶自动化率。
c. 革新工艺：为了满足自动化的生产要求，还需要对传统工艺进行革新，传统的生产工具定位的精度不理想，常常会影响车身精度，鉴于这一不足，在自动化改造上采用定位搬运一体化设备，对焊装的关键工序进行了改进，也促进了涂胶、焊接的自动化，可对涂胶与焊接品质进行自动化的全程控制。另外，传统的人工切换台车方式会造成一定的停链损失，在自动化改造时应用了伺服切换技术，大大提高了定位的精度和准确性。 数字化转型网（www.szhzxw.cn）
2. 冲压生产线的改造
（1）改造方向
冲压生产线是 Y 企业生产的重点内容，在自动化的改造上，对标目前先进的制造标准，使冲压生产线可表现出柔性化、智能化、自动化的特点。一方面，减少生产线的员工数量，对生产线的自动化改造中可用 PLC 系统、工业机器人、高速压力机替代以往的人工操作，可以减少人力投入，帮助企业节约成本。为了满足生产线的操作要求，还需优化人才的培育，引入一专多能型的技术人才，加强对人才的培训和教育，使人员可从以往的制造型转化为复合技能型；另一方面，采用高度信息化、智能化的生产设备，将监控系统、信息系统、自动化设备结合起来，支持对生产的全过程管理，还支持对生产活动数据的实时采集，确保生产活动的稳定性和高效性，让管理活动变得更加智能、透明。在应用了数字化、技能化技术之后，可以减少现场的危险因素，此次自动化改造采用了全封闭的设计方式，此类设计实现了低噪音、高安全性，促进了“人”“机”之间的互动交流，进一步减少生产线的人员、环境危险因素。
（2）改造对策
a. 改进瓶颈工艺，提高工序能力，收集分钟冲次工序能力、换模效率以及工序平衡率等内容，通过价值流图的分析明确需要改进的内容，对设备进行升级与改造，优化设备升序，改善业务流程，引入大众 SUDIT 评审机制与过程审核标准，及时识别出过程中存在的各类质量问题，优化工序能力。
b. 建立智能生产控制中心，确保整个生产环节的高效性与稳定性，建立智能化的生产控制中心，采集现场作业流程、产品质量、人员、设备等信息数据，对生产活动进行全过程的监控，实时评估、核算生产要素，为管理人员提供精准的数据支持，使整个生产车间可做到智能化、数据化的运行。
c. 积极推进 SMED，通过外部操作、内部区分的方式提高换模效率，采用人机联合分析法，在进行了改造之后，换模作业可以做到精准定位，有效缩短了换模时间，进一步提高生产效率。
d. 增加安全技术投入，提升设备的可靠性，通过数据分析、评审、试点评估的流程来推广，确保技术应用的有效性。在进行改造的过程中，增加安全技术的投入，包括安全护网、安全地垫、安全挂锁、自动感应、警示警报、安全光栅等。
e. 实现用能平衡，建立信息化生产平台，支持水、电、气数据的自动采集，优化能源消耗数据系统，支持能耗报表的自动化合成，可根据生产要求设定设备和生产线的能源指标，对能耗消耗情况进行实时分析，提高资源的利用率。 数字化转型网（www.szhzxw.cn）
f. 优化现场管理模式，根据《企业现场管理准则》的要求优化管理模式，建立与自动化改造相适应的管理机制，从人、场、物几个要素进行管理，对其进行统一的组织、控制和改进，改进传统的设备管理、人员管理以及布局设计模式。在管理层面，不仅会关注现场的显性因素，也会注重隐性要素，提高各类资源的利用率，充分发挥出标准、制度和流程的作用，建立起适合自动化改造后的管理机制。
3. 生产线自动调度系统的改造
在生产线自动调度系统的改造上，将 SCADA 系统监控与 MES 系统实时生产管理结合起来，满足 WBS 的要求，其中，MES 系统支持品质管理、计划编制、计划管理、统计报表、系统集成、异常处理等功能，可支持 Y 企业的各类生产与管理工作，满足了管理层、车间之间的互通。改造后的生产线自动调度系统包括企业层、生产管理层、数据采集层、现场控制层组成，系统包括 4 个子系统：
a. 生产管理子系统，主要为 MES 系统，可从企业层中接收信息，对信息进行自动分解，可将生产信息反馈至系统，满足车辆管理工作的要求。
b. 数据采集系统，可监视设备的生产情况与运行状态，如果数据中存在异常，系统会发出警报。
c.RFID 车体跟踪子系统，利用 RFID 标签建立动态数据链，可以与车间直接进行通讯，做到了数据信息的全程跟踪。
d. 现场控制子系统，包括机器人系统、智能化设备、PLC 系统以及传感器组成。
（1）系统网络结构
系统的 MES 层使用的是 B/S 架构，数据采集层可将各个设备、车间的机器人系统、RFID 系统以及 PLC 体通过互联网连接起来，支持数据的通信协议转换。 数字化转型网（www.szhzxw.cn）
（2）生产管理子系统
生产管理子系统可为管理层、生产计划、物流、车间等提供支持。a. 在管理层方面，利用生产管理子系统可以满足柔性生产的要求，支持订单计划的追踪和报表的自动生成；b. 在生产计划方面，支持精益化生产，可帮助管理者掌握各类一线数据，根据数据情况修订生产计划，调整生产顺序；c. 在物流方面，可帮助 Y 企业降低物流成本的支出，支持缺料的自动报警；d. 在车间方面，利用 RFID 技术可以将车辆生产数据反馈给车间调度员，有效避免了人为因素造成的漏装、错装问题。
（3）车间 MES 管理系统
车间 MES 管理系统包括生产管理、质量管理、绩效管理模块，子模块包括品质管理、统计报表、计划管理、缺陷情况的处理以及作业指示。车间 MES 管理系统能够与 SCADA 系统之间进行数据的传输，可以监控各个单元的工作情况，有效避免了颜料浪费、减少了车辆停机时间。同时，库区还增加了查询功能与报警功能。
（4）MES 子系统数据接口
MES 子系统是利用数据缓冲区来交换数据，外部系统不会直接与内部系统进行交互，在系统内部设置了缓冲区，缓冲区可支持生产任务、工艺流程、基础数据、物料清单的交互，保障几个区域的独立性，也可有效提高系统的安全性。同时，配备了冗余 OPC 服务器，OPC 通信数据涵盖生产状态数据、生产指导数据、生产视图数据等。 数字化转型网（www.szhzxw.cn）
（5）3.3.5 SCADA 数据采集子系统
SCADA 数据采集子系统可将总装车间、焊装车间、涂装车辆通过控制设备与网络连接，系统可展示车身存储、工艺运行、工位情况、车型信息。在 SCADA 数据采集子系统中还设置了冗余服务器、历史数据服务器，这是系统的核心所在，负责 Alarm Server、Report Server、IOServer 的运行。
（6）RFID 车身跟踪子系统
RFID 车身跟踪子系统应用了 RFID 标签，这是利用射频信号满足信息传递要求，有着非接触、储存量大、远距离、保密性能好、识别速度快等优势，在工业生产中有广泛使用。其中，标签对应的信息有产品编码、计划号、状态位置、订单号、生产线编码、车型编码等内容。
四、结语
经过自动化改造之后，Y 企业在工艺规划、总体布局上已经形成了标准化流程，产生了良好的经济效益与社会效益，具有良好的应用价值和推广意义。
翻译：
Analysis of auto production line automation transformation
I. Introduction
With the increasing scale of automobile production, people have put forward higher requirements for the production efficiency of automobiles. In order to improve the production quality, it is necessary to promote the rapid delivery of orders through the innovation of technical means, track the dynamic production of vehicles, help relevant personnel understand the location and status of various models, and avoid the problem of misloading and shortage of materials caused by various objective and subjective factors. There are many processes in the vehicle production, such as stamping, welding, painting, final assembly, in order to meet the requirements of automatic and intelligent production, it is necessary to modestly transform the traditional automobile production line. 数字化转型网（www.szhzxw.cn）
Second, Y enterprise production line status
- Welding production line
Y enterprise is an automobile enterprise with a long history. Due to the longer use time of the workshop, it is urgent to transform in the face of modern production requirements. Specifically, there are several prominent problems in the welding workshop of Y enterprise: a. The flexibility of the production line is insufficient, and it does not support flexible production. Due to the different construction time of the production line, the specifications of the equipment and the layout of the industry are different, and the current vehicle production requirements cannot be taken into account, which not only wastes resources, but also increases the production cost; b. The small plant area does not support the production of new models, and some new equipment cannot be smoothly invested due to the restriction of the plant area, which affects the economic benefits of Y enterprise; c. The level of automation is lagging behind, and manual operation is used in traditional factory buildings, without realizing digital and automated production. With the continuous development of science and technology, the current new models have widely adopted new technologies, coupled with the increase of labor costs year by year, which seriously affects the efficiency of Y enterprise. Therefore, the improvement of the existing production line can not only reduce labor costs, but also play a role in brand benefits and improve production quality.
- Stamping production line
The stamping production line of Y enterprise has been established for many years, so far it has been more than 10 years, and has shown some inadaptability with the development of the current era. a. The traditional stamping production line requires the participation of multiple operators, which also increases the cost of Y enterprise; b. The traditional stamping production line equipment aging problem is serious, after the level of information development, more than 10 years ago, Y enterprise is limited by technical factors, enterprise scale, the construction of the stamping production line is also follow the principle of simplicity, intensive, the production line is mainly manual operation, production equipment has double beam truck, oil press, crank press, plate cleaning machine, etc. Due to long-term operation, some equipment has been aging, often failure, and information, automation degree is more. In addition, there are many dangerous sources near the stamping production line, people need to cross operations, unsafe incidents caused by human factors are frequent, and the workshop uses an open work arrangement mode, the environment is more complex, there are some risk factors, which is the focus of attention in the subsequent automation transformation. 数字化转型网（www.szhzxw.cn）
Third, Y enterprise welding workshop automation transformation direction and countermeasures
Automatic transformation of welding production line
(1) Transformation direction
In view of the various problems existing in the welding workshop production line of Y enterprise, the automatic transformation of welding vehicles is carried out from the following directions:
a. Reduce the loss of the production line. In the process of automation transformation, normal production activities can not be affected, in order to ensure that the new and old production lines can be closely connected, and maximize the efficiency of the use of funds, it is necessary to formulate a scientific overall planning program to provide accurate support for automation transformation. In the specific transformation process, the “step by step” method is adopted, first dismantle a production line, establish a new automatic production line, and gradually dismantle other production lines after the production is stable, and carry out automatic transformation under the premise of not affecting normal production.
b. Improve production quality by technical means. In the process of automatic transformation, adaptive welding technology is incorporated, which can improve the quality of welding, but also record welding data to support the traceability of welding. At the same time, the application of casting automation and visual inspection technology, the use of CV technology, AI technology and other accurate assessment of production quality. Introduce the latest equipment spare parts, promote universal parts, reduce spare parts inventory, so that spare parts inventory management can achieve flexibility.
(2) Reform countermeasures
A. New workshop: Considering the small area of the original workshop, it is necessary to expand the workshop area and build a new plant during the renovation. The site selection of the plant should be close to the old plant, and the plan should be made in advance before the renovation, determined according to the production plan, and strictly follow the requirements of relevant laws and regulations. According to the situation of Y enterprise, the portal steel frame structure is adopted, and rock wool sandwich panels are used for the roof. Water, electricity, gas and fire protection parameters are set according to the requirements, and a good section is reserved according to the subsequent development trend. The design of workshop lighting, smoke exhaust and fire channels should pay attention to environmental protection and convenience requirements.
b. Reasonable layout: First, optimize the conveying line body, improve logistics efficiency, and reduce the floor area of machinery and equipment; The second is to improve the workpiece input mode, adopt automatic transmission mode, introduce robot handling; The third is to scientifically optimize the production line, change the previous manual total fixture to automatic mode, improve the fixture alignment accuracy; Fourth, optimize the equipment to meet the overall switching and automatic switching requirements; Fifth, the application of light weight high pressure welding gun and small high-speed robot; The sixth is the introduction of self-diagnostic robots to meet the requirements of equipment implementation monitoring and achieve “zero downtime”. Through the above measures, the production achievement rate and the automatic rate of gluing are effectively improved.
c. Innovation process: In order to meet the requirements of automated production, it is also necessary to innovate the traditional process, the accuracy of the positioning of the traditional production tools is not ideal, often affect the accuracy of the body, in view of this shortage, the use of positioning and handling integrated equipment in the automatic transformation, the key process of welding has been improved, but also promote the automation of gluing and welding. Automatic whole-process control of gluing and welding quality. In addition, the traditional manual switching of the car will cause a certain loss of chain stop, in the automatic transformation of the application of servo switching technology, greatly improve the accuracy and accuracy of positioning. 数字化转型网（www.szhzxw.cn）
Transformation of stamping production line
(1) Transformation direction
Stamping production line is the key content of Y enterprise production, in the transformation of automation, the standard of the current advanced manufacturing standards, so that the stamping production line can show the characteristics of flexibility, intelligence and automation. On the one hand, reduce the number of employees in the production line, and replace the previous manual operation with PLC system, industrial robots and high-speed presses in the automatic transformation of the production line, which can reduce human input and help enterprises save costs. In order to meet the operation requirements of the production line, it is also necessary to optimize the cultivation of talents, introduce specialized and versatile technical talents, strengthen the training and education of talents, so that personnel can be transformed from the previous manufacturing type into a composite skill type; On the other hand, the use of highly informationized and intelligent production equipment, the monitoring system, information system, automation equipment combined to support the whole process of production management, but also support the real-time collection of production activity data, to ensure the stability and efficiency of production activities, so that management activities become more intelligent and transparent. After the application of digital, technical technology, can reduce the risk factors of the site, the automatic transformation adopts a completely closed design, such design to achieve low noise, high safety, promote the interaction between “people” and “machines”, and further reduce the personnel and environmental risk factors of the production line.
(2) Reform countermeasures
a. Improve the bottleneck process, improve the process capacity, collect the process capacity of minute stroke, die change efficiency and process balance rate, identify the content to be improved through the analysis of value stream map, upgrade and transform the equipment, optimize the equipment ascending order, improve the business process, introduce Volkswagen SUDIT review mechanism and process audit standards. Identify all kinds of quality problems in the process in time and optimize the process capacity.
b. Establish an intelligent production control center to ensure the efficiency and stability of the entire production process, establish an intelligent production control center to collect information and data such as on-site operation process, product quality, personnel and equipment, monitor the whole process of production activities, evaluate and calculate production factors in real time, and provide accurate data support for managers. So that the entire production workshop can be intelligent, data operation.
c. Actively promote SMED, improve mold change efficiency through external operation and internal differentiation, adopt man-machine joint analysis method, after the transformation, mold change operation can achieve accurate positioning, effectively shorten the mold change time, and further improve production efficiency. 数字化转型网（www.szhzxw.cn）
d. Increase the investment in safety technology, improve the reliability of equipment, and promote it through the process of data analysis, review and pilot evaluation to ensure the effectiveness of technical application. In the process of transformation, the investment in safety technology is increased, including safety nets, safety pads, safety padlocks, automatic induction, warning alarms, safety grating, etc.
e. To achieve energy balance, establish information production platform, support automatic collection of water, electricity and gas data, optimize energy consumption data system, support automatic synthesis of energy consumption reports, set energy indicators of equipment and production lines according to production requirements, real-time analysis of energy consumption, improve resource utilization.
f. Optimize the site management mode, according to the requirements of the “Enterprise Site Management Standards”, optimize the management mode, establish a management mechanism suitable for automatic transformation, manage the elements of people, field and material, conduct unified organization, control and improvement, and improve the traditional equipment management, personnel management and layout design mode. At the management level, it will not only pay attention to the explicit factors of the site, but also pay attention to the hidden elements, improve the utilization of various resources, give full play to the role of standards, systems and processes, and establish a management mechanism suitable for automated transformation.
Transformation of automatic scheduling system of production line
In the transformation of automatic production line scheduling system, SCADA system monitoring and MES system real-time production management are combined to meet the requirements of WBS. Among them, MES system supports quality management, planning, planning management, statistical reports, system integration, exception handling and other functions, which can support all kinds of production and management work of Y enterprise. Meet the communication between management and workshop. The modified automatic scheduling system of the production line consists of enterprise layer, production management layer, data acquisition layer and field control layer. The system consists of four subsystems:
a. Production management subsystem, mainly MES system, can receive information from the enterprise layer, automatically decompose the information, and feedback the production information to the system to meet the requirements of vehicle management.
b. Data acquisition system, can monitor the production and operation status of the equipment, if there is an anomaly in the data, the system will issue an alarm. 数字化转型网（www.szhzxw.cn）
c.RFID vehicle body tracking subsystem, using RFID tags to establish a dynamic data link, can communicate directly with the workshop, to achieve the full track of data information.
d. Field control subsystem, including robot system, intelligent equipment, PLC system and sensor composition.
(1) System network structure
The MES layer of the system uses the B/S architecture, and the data acquisition layer can connect each device, the robot system of the workshop, the RFID system and the PLC body through the Internet to support the communication protocol conversion of data.
(2) Production management subsystem
The production management subsystem supports management, production planning, logistics, shop floor, etc. a. At the management level, the production management subsystem can meet the requirements of flexible production and support the tracking of order plans and the automatic generation of reports; b. In terms of production planning, support lean production, help managers master various front-line data, revise production plans and adjust production sequence according to the data; c. In terms of logistics, it can help Y enterprise reduce the expenditure of logistics costs and support the automatic alarm of material shortage; d. In the workshop, the use of RFID technology can feed back the vehicle production data to the workshop dispatcher, effectively avoiding the problem of missing and misinstalling caused by human factors. 数字化转型网（www.szhzxw.cn）
(3) Workshop MES management system
Workshop MES management system includes production management, quality management and performance management modules, and sub-modules include quality management, statistical reports, plan management, defect processing and operation instructions. Workshop MES management system can transmit data between the SCADA system, and can monitor the work of each unit, effectively avoiding pigment waste and reducing vehicle downtime. At the same time, the reservoir area has also increased the function of inquiry and alarm.
(4) MES subsystem data interface
MES subsystem is the use of data buffer to exchange data, the external system will not directly interact with the internal system, set a buffer in the system, the buffer can support the production task, process flow, basic data, bill of materials interaction, to ensure the independence of several areas, but also effectively improve the security of the system. At the same time, it is equipped with redundant OPC server, and OPC communication data covers production status data, production guidance data, production view data, etc. 数字化转型网（www.szhzxw.cn）
3.3.5 SCADA data acquisition subsystem
The SCADA data acquisition subsystem can connect the assembly workshop, welding workshop and painting vehicle to the network through the control equipment, and the system can display the body storage, process operation, station situation and model information. In the SCADA data acquisition subsystem, redundant Server and historical data Server are also set up, which is the core of the system and is responsible for the operation of Alarm Server, Report Server and IOServer.
(6) RFID body tracking subsystem
RFID body tracking subsystem applied RFID tags, which is the use of radio frequency signals to meet the requirements of information transmission, with non-contact, large storage, long distance, good security performance, identification speed and other advantages, widely used in industrial production. The information corresponding to the label includes product code, plan number, status location, order number, production line code, and model code. 数字化转型网（www.szhzxw.cn）
Iv. Conclusion
After the automatic transformation, Y enterprise has formed a standardized process in process planning and overall layout, which has produced good economic and social benefits, and has good application value and promotion significance.
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