I'm a tech creator Imagine a car speeding out when the driver presses the accelerator. This silky process is inseparable from a key component – the automotive gearbox. It's like the "heart" of the car, silently transmitting power and ensuring that the vehicle runs smoothly. In the process of producing gearboxes, every step of the process requires extreme precision. From the selection of materials to precision machining to final assembly and inspection, every step of the process needs to be treated with the utmost care to ensure that each gearbox plays its due role in the car.
Today, in the face of digitalization, every gearbox manufacturer stands at a critical inflection point: choosing to continue with traditional production models or adopt forward-looking O&M solutions for a future of efficiency and innovation.
In different workshops of the gearbox factory, egMachine shopCNC machines and grinding machines are the heart of the production line, and any slight deviation can lead to a significant decrease in product accuracy. Another example is inHeat treatment workshopHigh temperatures and chemical processes have a significant impact on equipment, and maintenance ensures that the production process is not unexpectedly disturbed due to equipment failures. It is essential to carry out the best maintenance in the core workshop。By analyzing the machine's operating data, we are able to prevent production interruptions by analyzing any anomalies before a failure occurs.
And whereasRaw material handling (e.g. casting, forging workshop), assembly workshop and testing workshopThe coordination of the robotic arm and the automated assembly line ensures the continuity of productionReal-time monitoring systemAny potential assembly errors or delays can be detected instantly, ensuring a steady pace of production.
The implementation of this more demand-oriented and cost-effective strategy is a reflection of our deep understanding of the production details of the gearbox factory and our commitment to ensuring the stability of our customers' production with practical actions.
Here, we take the core equipment CNC machine tool in the machining workshop as an example to elaborate on the application and implementation of high-quality maintenance. As the most valuable equipment in the gearbox factory, its operation is directly related to the quality and productivity of gearbox production. In the event of a failure, it may affect the coordination of the entire production process and the quality of the gearbox.
CNC machine failures include mechanical failures, tool wear, electrical failures, servo motor failures, system failures, etc. Let's give an example here.
Mechanical failure
Although CNC machine tools are known for their stability and reliability, when mechanical failures occur, even if infrequent, can lead to high maintenance costs and lost production, which highlights the importance of high-quality maintenance in the management of core equipment in gearbox factories. In the figure below, we explain the common CNC machine mechanical failures. It can be seen that by installing sensors to detect vibration, temperature, and sound, it is possible to sensitively point out possible faults in advance.
Tool failure
Tool wear is an important subcategory of CNC machine failures, and we will expand on it in more detail here. The diagram below details the damage and impact of various tool failures and introduces targeted solutions for systematic monitoring.
systemFaults
The cooling system is responsible for keeping the machine operating within a safe temperature range and preventing overheating from damaging the machine's electronic and structural components. The lubrication system ensures the smooth operation of the moving parts of the machine tool, reduces wear and extends the service life of the machine tool. Any related failures can lead to a decrease in machine performance or even an outright shutdown that can lead to production interruptions.
In the solution, Fenxi Technology monitors key parameters such as coolant flow, temperature and lubricating oil pressure in real time to detect any signs of abnormality in time and prevent failures. This proactive maintenance strategy allows production managers to intervene before problems affect production, thereby reducing downtime and repair costs, and is key to achieving efficient, low-cost production.
The equipment operation and maintenance solutions we provide are designed to ensure the continuous operation of core equipment and core production process sections through advanced technology and systematic management, so as to prevent problems before they occur. Ensure that the equipment in the workshop can be fully monitored.
The following is a real solution of the requirements and hardware and software system components to share:
When it comes to temperature vibration sensors, three different models have been selected here. Including the Fx motor brain sensor, the star product of Fenxi Technology, through the perfect combination with SaaS applications, based on the exclusive expert experience library, it has achieved the amazing effect of the first failure in advance and the accuracy of up to 95%.
By simply attaching the sensor box to the surface of the device to be monitored, advanced algorithms such as built-in edge computing and deep learning frameworks for fault identification and model in SaaS systems will realize the continuous care of the target device in real time and accurately. We use AI algorithms combined with fault libraries to build and identify models when the motor may change its state. For experienced engineers in the factory, we also offer model configuration and threshold adjustments that can be done manually.
AgainstFor other workshops (such as surface treatment and foundry workshops), we recommend customers to choose FX temperature and vibration sensors with dynamic ring monitoring applets for real-time monitoring. According to the status of the monitored object and the workshop environment, two types of hardware are selected: RS485 and NB-IoT. The push and monitoring method of the applet is also a more relaxed and fresh experience for customer enterprises and employees: no need for **APP or login**, no additional SMS fee for alarm push, and it is directly sent to the person in charge of the equipment in the form of WeChat, so that the equipment monitoring can be reached with one click.
In the continuous iteration and market communication of the motor brain series products, the experience of working closely with many customers has made us deeply understand that the production in various fields is facing unique challenges and needs. Our solutions are based on the core idea of in-depth understanding of the specific pain points of each industry and providing precise and personalized solutions. We are now applying this concept to the field of automotive component manufacturing, especially in automotive gearbox factories, where precision and reliability are extremely demanding.
The complexity of auto parts production requires that every link must be accurate, and any small failure may lead to production stagnation, which in turn affects the operation of the entire chain. We fully understand that the pain point faced by gearbox factories is not only to keep the production line running continuously, but also to ensure that every component meets the highest standards of quality.
By implementing our state-of-the-art maintenance program, a proactive maintenance strategy has resulted in a significant reduction in operational costs and a reduction in unplanned downtime. From the perspective of auto parts manufacturers, choosing our first-class maintenance program is not only an upgrade of production efficiency and product quality, but also an investment in the future of the enterprise. Let's accelerate industrial intelligence together.