小零件精密裝配與產(chǎn)線智能化：制造業(yè)的未來趨勢

小零件精密裝配的挑戰(zhàn)與需求

在制造業(yè)中，小零件精密裝配是一項**挑戰(zhàn)性的任務(wù)。以小型電磁閥線圈裝配為例，在傳統(tǒng)的人工流水線作業(yè)中，存在諸多弊端。人工流水作業(yè)產(chǎn)線需要大量人員，然而人員流動性大，管理難度高。新員工由于經(jīng)驗不足，效率低下，且產(chǎn)品質(zhì)量不穩(wěn)定，這往往導(dǎo)致訂單無法按時完成。像全力科技的客戶之前就面臨這樣的問題，人工裝配不僅耗費(fèi)大量人力成本，還難以滿足市場對產(chǎn)品質(zhì)量和交付時間的要求。

小零件精密裝配對精度和穩(wěn)定性的要求極高。例如在電子設(shè)備、航空航天等領(lǐng)域，一個小零件的裝配失誤可能會導(dǎo)致整個產(chǎn)品的性能下降甚至失效。這就要求在裝配過程中，每個環(huán)節(jié)都要做到精準(zhǔn)無誤。同時，隨著市場需求的不斷變化，產(chǎn)品的更新?lián)Q代速度加快，企業(yè)需要能夠快速調(diào)整生產(chǎn)工藝，以適應(yīng)不同產(chǎn)品的裝配需求。因此，傳統(tǒng)的人工裝配方式已經(jīng)難以滿足現(xiàn)代制造業(yè)的發(fā)展需求，產(chǎn)線智能化成為必然趨勢。

產(chǎn)線智能化的發(fā)展背景與現(xiàn)狀

隨著工業(yè) 4.0 和智能制造的興起，傳統(tǒng)裝配生產(chǎn)線面臨著效率低下、成本高、靈活性差等問題。勞動力成本的上升和市場需求的多樣化，推動企業(yè)尋求生產(chǎn)方式的變革。智能化裝配生產(chǎn)線應(yīng)運(yùn)而生，旨在通過集成自動化、信息化和智能化技術(shù)，提升生產(chǎn)效率和產(chǎn)品質(zhì)量。

目前，許多企業(yè)已經(jīng)開始積極推進(jìn)產(chǎn)線智能化升級。如貴州貴安新區(qū)東江科技有限公司，投入大量資金用于智能化升級，自主研發(fā)了一套智能生產(chǎn)管理系統(tǒng)。該系統(tǒng)將生產(chǎn)計劃排程、設(shè)備監(jiān)控、質(zhì)量檢測等多個環(huán)節(jié)進(jìn)行整合，實現(xiàn)了從訂單接收、產(chǎn)品生產(chǎn)、貨物發(fā)運(yùn)、交貨交付，再到開具發(fā)票以及回款的全流程管理。在其生產(chǎn)車間，除了部分定制化以及精細(xì)化的加工環(huán)節(jié)需要人工參與外，絕大多數(shù)生產(chǎn)環(huán)節(jié)均由機(jī)器獨(dú)立運(yùn)作完成，工人主要承擔(dān)檢查、調(diào)試與維護(hù)工作，保障了產(chǎn)品質(zhì)量。

智能化裝配生產(chǎn)線的關(guān)鍵技術(shù)

自動化設(shè)備

自動化設(shè)備是智能化裝配生產(chǎn)線的基礎(chǔ)。包括機(jī)器人、自動化機(jī)械手、數(shù)控機(jī)床等，它們能夠?qū)崿F(xiàn)生產(chǎn)過程的自動化操作。以小型電磁閥線圈自動化裝配線為例，前段采用轉(zhuǎn)盤載具結(jié)構(gòu)完成線圈、靜鐵芯、大、小 O 型圈的裝配，后段采用環(huán)形載具結(jié)構(gòu)完成支架、線圈組件、左、右塑料擋塊、支架側(cè)板的裝配。這些載具結(jié)構(gòu)系統(tǒng)能夠精確地完成各個物料的裝配，提高了裝配的效率和精度。

信息集成系統(tǒng)

信息集成系統(tǒng)通過工業(yè)互聯(lián)網(wǎng)、物聯(lián)網(wǎng)等技術(shù)，實現(xiàn)生產(chǎn)數(shù)據(jù)的實時采集、傳輸和分析。在平高的 126 產(chǎn)線隔離開關(guān)裝配流水線智能化改造項目中，結(jié)合精益生產(chǎn)的配餐模式、工位制及數(shù)據(jù)采集需求進(jìn)行 MES 系統(tǒng)的拓展應(yīng)用。工序流轉(zhuǎn)路徑更加清晰，生產(chǎn)效率得到顯著提升。同時，配置具備數(shù)據(jù)傳輸功能的生產(chǎn)過程測量設(shè)備及出廠試驗設(shè)備，實現(xiàn)了制造過程質(zhì)量數(shù)據(jù)及出廠試驗數(shù)據(jù)的自動采集，為生產(chǎn)決策提供了有力支持。

智能控制系統(tǒng)

智能控制系統(tǒng)運(yùn)用人工智能、大數(shù)據(jù)分析等技術(shù)，實現(xiàn)生產(chǎn)過程的智能化決策和優(yōu)化。堅豐公司推出的 Z 型自動扭力電批（DP - HL - 003 - Z）就是智能控制系統(tǒng)在小零件裝配中的典型應(yīng)用。其內(nèi)置的智能控制系統(tǒng)能夠自動識別螺絲類型，并根據(jù)預(yù)設(shè)的扭矩參數(shù)進(jìn)行精確控制，實現(xiàn)自動擰緊功能。這種自動化操作不僅提高了工作效率，還減少了因人為因素導(dǎo)致的誤操作和質(zhì)量問題，確保每個螺絲都能被均勻、穩(wěn)定地擰緊。

小零件精密裝配產(chǎn)線智能化的成功案例

小型電磁閥線圈自動化裝配線

根據(jù)客戶需求，研發(fā)、設(shè)計、制造的小型電磁閥線圈自動化裝配線，實現(xiàn)了送料、涂油、成型、裝配以及出成品裝盤全自動化作業(yè)。該設(shè)備具有多個特點(diǎn)，如實現(xiàn) O 型圈涂油，支架整型及各個物料裝配，成品裝盤全自動化作業(yè)；實現(xiàn) 8 個物料的涂油、整型、裝配以成品裝盤。其智能數(shù)字化能力強(qiáng)，能夠數(shù)字化管控每一個裝配環(huán)節(jié)，整個裝配過程實現(xiàn)數(shù)字化視覺智能引導(dǎo)且可追溯，有效保證了產(chǎn)品質(zhì)量的一致性和標(biāo)準(zhǔn)化。產(chǎn)能達(dá)到 15 - 20 次/MIN，相比人工裝配，大大提高了生產(chǎn)效率。

平高 126 產(chǎn)線隔離開關(guān)裝配流水線智能化改造項目

為響應(yīng)平高公司戰(zhàn)略，提升裝配產(chǎn)線智能化、數(shù)字化水平，從 2022 年開始實施自動化輸送線建設(shè)、配備自動擰緊裝置、電子檢查卡全面應(yīng)用等改造措施。改造成果顯著，完成智能生產(chǎn)管理場景建設(shè)后，結(jié)合精益生產(chǎn)的配餐模式、工位制及數(shù)據(jù)采集需求進(jìn)行 MES 系統(tǒng)的拓展應(yīng)用，工序流轉(zhuǎn)路徑更加清晰，生產(chǎn)效率提升 23.3%。完成管理場景建設(shè)，實現(xiàn)了制造過程質(zhì)量數(shù)據(jù)及出廠試驗數(shù)據(jù)自動采集的目標(biāo)，生產(chǎn)周期縮短 13.2%。完成智能化裝配場景建設(shè)，配備自動化、智能化裝配及轉(zhuǎn)運(yùn)裝置，實現(xiàn)新一代 126、輕量化 126、無氟環(huán)保三種產(chǎn)品三工位隔離開關(guān)半自動化裝配，在制品數(shù)量降低 16.7%，產(chǎn)品一次提檢合格率顯著提高。

產(chǎn)線智能化帶來的效益與優(yōu)勢

提高生產(chǎn)效率

產(chǎn)線智能化能夠大幅提高生產(chǎn)效率。通過自動化設(shè)備的應(yīng)用，減少了人工操作的時間和誤差。如小型電磁閥線圈自動化裝配線，實現(xiàn)了全自動化作業(yè)，產(chǎn)能達(dá)到 15 - 20 次/MIN，相比人工裝配，效率提升明顯。平高的 126 產(chǎn)線隔離開關(guān)裝配流水線智能化改造后，生產(chǎn)效率提升了 23.3%，能夠更快地滿足市場需求。

提升產(chǎn)品質(zhì)量

智能化裝配生產(chǎn)線能夠精確控制每個裝配環(huán)節(jié)，確保產(chǎn)品質(zhì)量的一致性和穩(wěn)定性。在小零件精密裝配中，精確的自動化設(shè)備和智能控制系統(tǒng)能夠減少人為因素對產(chǎn)品質(zhì)量的影響。例如堅豐 Z 型自動扭力電批（DP - HL - 003 - Z）能夠根據(jù)不同螺絲的規(guī)格和要求，施加恰到好處的扭矩，確保每個螺絲都能被均勻、穩(wěn)定地擰緊，提高了裝配質(zhì)量。平高的改造項目中，產(chǎn)品一次提檢合格率顯著提高，說明產(chǎn)線智能化對產(chǎn)品質(zhì)量的提升起到了重要作用。

降低成本

產(chǎn)線智能化可以減少對人工的依賴，降低勞動力成本。同時，通過提高生產(chǎn)效率和產(chǎn)品質(zhì)量，減少了次品率和返工率，降低了生產(chǎn)成本。以小型電磁閥線圈自動化裝配線為例，大幅度節(jié)省了人員需求數(shù)量，降低了人力成本。平高的改造項目中，生產(chǎn)周期縮短 13.2%，在制品數(shù)量降低 16.7%，也有效降低了生產(chǎn)成本。

小零件精密裝配與產(chǎn)線智能化的未來展望

隨著科技的不斷進(jìn)步，小零件精密裝配與產(chǎn)線智能化將迎來更廣闊的發(fā)展前景。未來，智能化裝配生產(chǎn)線將更加智能化、柔性化和綠色化。

智能化方面，人工智能、機(jī)器學(xué)習(xí)等技術(shù)將在生產(chǎn)過程中得到更廣泛的應(yīng)用。智能控制系統(tǒng)將能夠根據(jù)生產(chǎn)數(shù)據(jù)實時調(diào)整生產(chǎn)工藝，實現(xiàn)自適應(yīng)生產(chǎn)。例如，當(dāng)檢測到某一零件的裝配出現(xiàn)異常時，系統(tǒng)能夠自動調(diào)整裝配參數(shù)，確保產(chǎn)品質(zhì)量。

柔性化方面，生產(chǎn)線將能夠快速適應(yīng)不同產(chǎn)品的裝配需求。通過模塊化設(shè)計和可重構(gòu)技術(shù)，生產(chǎn)線可以在短時間內(nèi)進(jìn)行調(diào)整和切換，生產(chǎn)不同類型的小零件。這將滿足市場對產(chǎn)品多樣化的需求，提高企業(yè)的市場競爭力。

綠色化方面，產(chǎn)線智能化將更加注重節(jié)能減排。采用先進(jìn)的節(jié)能技術(shù)和環(huán)保材料，降低生產(chǎn)過程中的能源消耗和環(huán)境污染。例如，優(yōu)化設(shè)備的運(yùn)行參數(shù)，提高能源利用效率；使用可回收材料，減少廢棄物的產(chǎn)生。

總之，小零件精密裝配與產(chǎn)線智能化是制造業(yè)發(fā)展的必然趨勢。企業(yè)應(yīng)積極推進(jìn)產(chǎn)線智能化升級，提高自身的競爭力，以適應(yīng)未來市場的變化。

Precision assembly of small parts and intelligent production lines: the future trend of manufacturing industry

The challenges and demands of precision assembly of small parts

In the manufacturing industry, precision assembly of small parts is a highly challenging task. Taking the assembly of small solenoid valve coils as an example, there are many drawbacks in traditional manual assembly line operations. The manual assembly line requires a large number of personnel, but the personnel turnover is high and the management difficulty is high. Due to lack of experience, low efficiency, and unstable product quality, new employees often fail to complete orders on time. Customers like Quanli Technology have faced such problems before, where manual assembly not only consumes a lot of labor costs, but also struggles to meet market demands for product quality and delivery time.

Precision assembly of small parts requires extremely high precision and stability. For example, in fields such as electronic devices and aerospace, an assembly error of a small component may lead to a decrease in the performance or even failure of the entire product. This requires precision and accuracy in every step of the assembly process. At the same time, with the continuous changes in market demand and the acceleration of product updates, enterprises need to be able to quickly adjust their production processes to meet the assembly needs of different products. Therefore, traditional manual assembly methods are no longer able to meet the development needs of modern manufacturing, and intelligent production lines have become an inevitable trend.

The development background and current situation of intelligent production line

With the rise of Industry 4.0 and intelligent manufacturing, traditional assembly production lines are facing problems such as low efficiency, high costs, and poor flexibility. The rise in labor costs and the diversification of market demand are driving enterprises to seek changes in their production methods. The emergence of intelligent assembly production lines aims to improve production efficiency and product quality by integrating automation, information technology, and intelligent technologies.

At present, many enterprises have begun to actively promote the intelligent upgrading of their production lines. Guizhou Gui'an New Area Dongjiang Technology Co., Ltd. has invested a large amount of funds in intelligent upgrading and independently developed an intelligent production management system. This system integrates multiple aspects such as production planning and scheduling, equipment monitoring, and quality inspection, achieving full process management from order receipt, product production, goods shipment, delivery, to invoice issuance and payment collection. In its production workshop, except for some customized and refined processing steps that require manual participation, the vast majority of production processes are independently operated by machines, and workers mainly undertake inspection, debugging, and maintenance work to ensure product quality.

Key technologies of intelligent assembly production line

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automation equipment

Automated equipment is the foundation of intelligent assembly production lines. Including robots, automated robotic arms, CNC machine tools, etc., they can achieve automated operation of the production process. Taking the automatic assembly line of small solenoid valve coils as an example, the front section uses a turntable carrier structure to complete the assembly of coils, static iron cores, large and small O-rings, while the rear section uses a circular carrier structure to complete the assembly of brackets, coil components, left and right plastic stoppers, and bracket side plates. These vehicle structural systems can accurately complete the assembly of various materials, improving the efficiency and accuracy of assembly.

information integration system

The information integration system realizes real-time collection, transmission and analysis of production data through industrial Internet, Internet of Things and other technologies. In the intelligent transformation project of the isolation switch assembly line of Pinggao's 126 production line, the MES system is expanded and applied in combination with the catering mode, workstation system, and data acquisition requirements of lean production. The process flow path is clearer, and production efficiency has been significantly improved. At the same time, production process measurement equipment and factory testing equipment with data transmission capabilities are configured to achieve automatic collection of manufacturing process quality data and factory testing data, providing strong support for production decision-making.

intelligence control system

The intelligent control system utilizes technologies such as artificial intelligence and big data analysis to achieve intelligent decision-making and optimization of the production process. The Z-type automatic torque electric batch (DP-HL-003-Z) launched by Jianfeng Company is a typical application of intelligent control systems in small part assembly. Its built-in intelligent control system can automatically identify the type of screw and perform precise control based on preset torque parameters, achieving automatic tightening function. This automated operation not only improves work efficiency, but also reduces errors and quality issues caused by human factors, ensuring that each screw can be tightened evenly and stably.

Successful case of intelligent small parts precision assembly production line

Automated assembly line for small solenoid valve coils

Based on customer needs, we have developed, designed, and manufactured an automated assembly line for small solenoid valve coils, which achieves fully automated operations such as feeding, oiling, forming, assembling, and loading finished products onto trays. This device has multiple features, such as achieving O-ring oiling, bracket shaping, and assembly of various materials, as well as fully automated operation of finished product plating; Realize the oiling, shaping, and assembly of 8 materials to form finished products for palletizing. It has strong intelligent digital capabilities and can digitally control every assembly process. The entire assembly process is guided by digital visual intelligence and traceable, effectively ensuring the consistency and standardization of product quality. The production capacity reaches 15-20 times/MIN, which greatly improves production efficiency compared to manual assembly.

Pinggao 126 production line isolation switch assembly line intelligent transformation project

In response to the strategy of Pinggao Company and to enhance the intelligence and digitalization level of the assembly production line, measures such as the construction of automated conveyor lines, the installation of automatic tightening devices, and the comprehensive application of electronic inspection cards will be implemented starting from 2022. The transformation results are significant. After completing the construction of intelligent production management scenarios, the MES system was expanded and applied in combination with the catering mode, workstation system, and data collection requirements of lean production, resulting in clearer process flow paths and a 23.3% increase in production efficiency. Completed the construction of management scenarios, achieved the goal of automatic collection of manufacturing process quality data and factory test data, and shortened the production cycle by 13.2%. Complete the construction of intelligent assembly scenarios, equipped with automation, intelligent assembly and transportation devices, and achieve semi automated assembly of three station isolation switches for the new generation 126, lightweight 126, and fluorine free environmental protection products. The number of work in progress is reduced by 16.7%, and the first-time inspection pass rate of products is significantly improved.

Benefits and advantages brought by intelligent production line

Increase productivity

Intelligent production lines can significantly improve production efficiency. Through the application of automated equipment, the time and errors of manual operation have been reduced. The automatic assembly line for small solenoid valve coils has achieved fully automated operations, with a production capacity of 15-20 times/MIN. Compared to manual assembly, the efficiency has been significantly improved. After the intelligent transformation of the isolation switch assembly line of Pinggao's 126 production line, the production efficiency has increased by 23.3%, which can meet market demand faster.

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Improve product quality

The intelligent assembly production line can precisely control each assembly process, ensuring the consistency and stability of product quality. In precision assembly of small parts, precise automation equipment and intelligent control systems can reduce the impact of human factors on product quality. For example, the Jianfeng Z-type automatic torque electric screwdriver (DP-HL-003-Z) can apply the appropriate torque according to the specifications and requirements of different screws, ensuring that each screw can be uniformly and stably tightened, improving assembly quality. In the renovation project of Pinggao, the first inspection pass rate of products has significantly increased, indicating that the intelligence of the production line has played an important role in improving product quality.

reduce costs

Intelligent production lines can reduce reliance on manual labor and lower labor costs. At the same time, by improving production efficiency and product quality, the defect rate and rework rate have been reduced, and production costs have been lowered. Taking the automatic assembly line of small solenoid valve coils as an example, it significantly reduces the number of personnel required and lowers labor costs. In the renovation project of Pinggao, the production cycle was shortened by 13.2%, the number of work in progress was reduced by 16.7%, and the production cost was effectively reduced.

Future prospects of precision assembly of small parts and intelligent production lines

With the continuous advancement of technology, precision assembly of small parts and intelligent production lines will usher in broader development prospects. In the future, intelligent assembly production lines will become more intelligent, flexible, and green.

In terms of intelligence, technologies such as artificial intelligence and machine learning will be more widely applied in the production process. The intelligent control system will be able to adjust the production process in real-time based on production data, achieving adaptive production. For example, when an abnormality is detected in the assembly of a certain part, the system can automatically adjust the assembly parameters to ensure product quality.

In terms of flexibility, the production line will be able to quickly adapt to the assembly needs of different products. Through modular design and reconfigurable technology, the production line can be adjusted and switched in a short period of time to produce different types of small parts. This will meet the market's demand for product diversification and enhance the market competitiveness of enterprises.

In terms of greening, intelligent production lines will pay more attention to energy conservation and emission reduction. Adopting advanced energy-saving technologies and environmentally friendly materials to reduce energy consumption and environmental pollution in the production process. For example, optimizing the operating parameters of equipment to improve energy utilization efficiency; Use recyclable materials to reduce waste generation.

In short, precision assembly of small parts and intelligent production lines are inevitable trends in the development of manufacturing industry. Enterprises should actively promote the intelligent upgrading of production lines, enhance their competitiveness, and adapt to future market changes.

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