changan ford automobile福特汽車同色噴涂block painting introduction

1、同色比項(xiàng)目介紹Block Painting Introduction2The CQ2 Plant was set up and put into production in 2012 and the installed production capacity is about 340k per year(270d*21h/d*60jph),standard production capacity 225k per year(250d*15h/d*60jph). 2012年重慶二工廠建成并投產(chǎn)，年生產(chǎn)能力34萬臺(tái)（270d*21h/d*60jph），標(biāo)準(zhǔn)產(chǎn)能22.5萬（250d*15h/d*60

2、jph） 3 -Coat 1 bake (3C1B) high solid paint process for saving cost and reduce the VOC emission. 工藝采用3C1B高固體份緊湊性工藝,節(jié)約成本和降低VOC排放. Project Introduction項(xiàng)目介紹C 346 4 door, 5door, and C520, 3 primer , 12 basecoat color and 3 clear coat . 生產(chǎn) C 346 ,4 門和5門 和 520共 三種車型, 3 個(gè)中涂 顏色, 12個(gè)色漆 和 3 個(gè)清漆 涂料. Flow Chart

3、 車體流向圖 Two spray line 3 Buffer line and two sealer line , one sanding line , two spray booth line will bring the block NO. down.Block Paint down 同色比逐步減少把電泳儲(chǔ)備線先進(jìn)先出功能修改成按照顏色排序和出車的功能Modify the ED Buffer conveyor PLC and CCR program , From FIFO function change to color block function.Modify Method 電泳儲(chǔ)備線

4、改前 ED Buffer Modify BeforeED buffer line according FIFO (first in first out ) mode, body random in the buffer line 1 ,2,4,5 . random out from line 1,2,4,5. The paint block is reduced. 電泳儲(chǔ)備線是進(jìn)入儲(chǔ)備是隨機(jī)進(jìn)入各4道，出車規(guī)則是按照先進(jìn)先出的規(guī)則，顏色順序被打亂 RFID reader動(dòng)畫電泳儲(chǔ)備線改后 After Modify ED BufferED buffer line according same p

5、aint mode in and out, body according paint color into the buffer line , one line only 1 or 2 color can enter the 1 buffer line.車體進(jìn)入電泳儲(chǔ)備線 各道，是按照同色規(guī)則進(jìn)入，出車是按照1個(gè)眼色或2個(gè)顏色的出車順序出車面涂選色區(qū)儲(chǔ)備線改前 CSS Modify Before The Small color select station only 3 line , 5 body positions per line , so only can store 3 colors,

6、 if more than 3 colors ,the can not according the block paint function running . 只有15個(gè)車位3條道的小顏色選擇站, 超過3個(gè)顏色就不能調(diào)色.電泳打磨選色區(qū)改后CSS MODIFY After車體進(jìn)出儲(chǔ)備線按照同色進(jìn)同一道，出按照同色或間隔一個(gè)色出。Body in /out buffer according block paint orderED bufferOutletinlet23Body data read from RFID reader send to PLC when body to the inle

7、t roller bed PLC according FIFO rule send the destination signal to the buffer line 1Body data VINBody dataRFID Reader A ED bufferOutletInlet241Body dataBody data read from RFID reader send to PLC when body to the inlet roller bed PLC send body data to the CCR Server Server according color block rul

8、e send the destination signal to PLC PLC send the destination signal to the buffer line.Body data VINRFID Reader A FIFO Mode For the inlet/out by PLC control 車體進(jìn)出儲(chǔ)備采用FIFO模式，是輸送PLC控制Block Mode for the inlet /outlet by the CCR Server control 車體同色模式進(jìn)出儲(chǔ)備線采用中控服務(wù)器控制ED Buffer Detail Modify Method 電泳儲(chǔ)備改善點(diǎn)介紹

9、Modify the CCR Server and PLC Program from FIFO control mode changed to color block mode 通過修改中控室和輸送的控制程序， 把電泳儲(chǔ)備線的進(jìn)出車模式從先進(jìn)先出模式改成按照顏色進(jìn)出車的模式Add client PC on the ED buffer line and EMU station for make rule and monitor the body information and recovery the faults. 在電泳儲(chǔ)備和駝鳥毛擦站增加中控ECOEMOS 的客服機(jī)電腦，方便設(shè)定顏色選擇規(guī)

10、則和監(jiān)控設(shè)備運(yùn)行情況以及故障復(fù)位。3）No need full time worker 不需要專職人員Add EMU client computer for make rule and monitor Set Inlet Rule In The CCR ECOEMOS Web 在中控軟件ECOEMOS上設(shè)定車體入口規(guī)則 Inlet rules for the buffer入口規(guī)則設(shè)定界面Storage line NO.Set Color NO .TC 2TC 1 UBSPTEDED OVENED BufferSealer lineTC CSS BufferED sandingED Check

11、Add Web Monitoring Body Color From Paint In To Spraying booth增加監(jiān)控車體顏色界面（從噴涂入口到噴房）Form Body shopBody color information For easy make block rule 為設(shè)定 入口規(guī)則提供參考信息ED Buffer CSS Monitoring電泳儲(chǔ)備線的監(jiān)控畫面TC CSS Monitoring 面涂選色站監(jiān)控畫面 Page 16 of 12 Emergencies Control Mode ( HMI Set Mode)緊急控制模式IF the CCR systems ha

12、ve faults , can change to PLC control by HMI Set Inlet and outlet rules 如果CCR系統(tǒng)出現(xiàn)問題，會(huì)切換到PLC控制模式，該規(guī)則由HMI來設(shè)定HMI set inlet rule 在HMI上設(shè)定入口規(guī)則HMI Set outlet rule 在HMI 設(shè)定出口規(guī)則Quality Improvement 質(zhì)量改善Increase the block painting ratio , Reducing the painting color change times , reduce the painting contaminat

13、ed dirt defects . 同色噴涂提高,減少了換色次數(shù), 減少噴涂污染缺陷. 3Contaminated defect reduce 3/1000. Manpower 人工Block paint ratio 同色比 Remark Semi_Auto半自動(dòng)22.01 ED buffer and CSS AUTO 自動(dòng)00Manpower Reduction 人工減少 在2014 安排人員 在電泳儲(chǔ)備線和CSS 顏色選擇站半自動(dòng)排序車體. 在2015年通過項(xiàng)目全部改成自動(dòng)控制, 減少了2個(gè)操作者/班. Operator adjusting the body sequence in the

14、 ED buffer and CSS station, after the block painting project , all body sequence are auto control , no need the operator on the site .同色比增加, 減少了人工噴涂的換槍次數(shù),平均每次換槍時(shí)間5S ,減少工人的勞動(dòng)強(qiáng)度. Add blocking painting ratio, reduce the change spray gun times , about 5 s/ time09.04VOC 排放減少和成本節(jié)約 VOC Emission Reduced And

15、 Cost Save7.031.66.07投入節(jié)約對(duì)比 Investment / Save 1）Block paint from 2.01 increasing to 9.04 the solvent per unit reduce from 2.55l/unit to 0.95 L/unit, save solvent 1.6L/unit and paint 0.126L/unit 同色比從2.01提高到9.04 后,單車溶劑消耗可從2.55降低到.95 升/ 臺(tái)，可 節(jié)約清洗溶劑1.6升/ 臺(tái)，節(jié)約填色涂料0.126升/臺(tái)2) Save cost 19.27RMB/unit for solvent and paint , save solvent 3,750 ,274 RMB per year , fill