1. Home
  2. >
  3. Auto Technology
  4. >
  5. Technology Tutorials
  6. >
  7. More environmentally friendly and...

[YesAuto Factory Quest] We visited the Nanjing factory of SAIC Volkswagen a while ago, this time it is the Changsha factory. Isn't the same brand all the same set of standards? What's the point of this?

First, it is SAIC Volkswagen’s newest factory with the highest degree of automation; second, it is the most environmentally friendly of SAIC Volkswagen’s eight factories; third, it is the production site of Touran L. Does this interest you?

SAIC Volkswagen’s Changsha plant was completed and put into production in May 2015, with a total area of 1.68 million square meters and a planned annual production capacity of 300,000 vehicles. Currently, the models produced here are Touran L and Lavida.

The stamping workshop covers an area of about 40,000 square meters, and the workshop is equipped with 2 trial mold presses, an automatic uncoiling line and 2 high-speed automatic stamping lines. There are only 198 people in the entire workshop, divided into two shifts.

The blanking and uncoiling line can be regarded as the starting point for the birth of each car, and the coil will become the steel frame of the car in the future. These coils are galvanized steel sheets with high corrosion resistance, provided by manufacturers such as Baosteel and Pohang.

The equipment is provided by Schuler, Germany, with a maximum stroke rate of 75 times per minute. Here, the coil is cut into pieces of different shapes through the steps of uncoiling, cleaning, straightening, blanking, etc., for subsequent production.

The 8100-ton press line mainly presses four doors and two covers of these large parts. Like the Nanjing factory, the whole line consists of six presses, which can complete the production of six processes including drawing, punching, trimming and shaping.

The fastest stamping speed of the two stamping lines can reach 15 parts per minute. This efficiency is equivalent to the domestic mainstream joint venture brand factories of Changan Ford, GAC Fick and GAC Toyota that we have visited before.

The quality inspection line at the end of the press line is 28 meters long, which is one of the most interesting places in the factory we have visited so far. The factory claims that this will allow personnel to have relatively sufficient time for inspections.

The height of the roof of its production area is different from that of the end of the line, the heights are 19.1 meters and 9 meters respectively. This design takes into account that there is no need to install a crane at the end of the line, and saves costs by reducing the height.

Both production lines are equipped with integral soundproof covers, which can effectively absorb noise and reduce noise to below 85 decibels, and 85 decibels is the feeling of standing alone in a downtown area.

The stamped parts in the stamping workshop will be transported to the welding workshop next door for welding. SAIC Volkswagen Touran L uses 4 welding processes, namely spot welding, gas shielded welding, stud welding and laser welding.

The first is the underbody welding, which is mainly carried out through an automatic welding line, supplemented by manual repair welding. Manual repair welding can be welded to the places that are difficult to weld by the automatic mechanical arm, and strengthen welding in key parts.

Manual repair welding not only includes spot welding, but also gas shielded welding. After the welding is completed, in order to ensure the safety of the personnel, the staff must leave the grating monitoring area before they can transport the welded parts to the next process.

SAIC Volkswagen Touran L uses laser welding technology on the roof, threshold and sink. The laser welding process has a small deformation and has a good forming effect. Because the laser hurts the eyes, it needs to be monitored by a camera.

Because there is a part of mixed-line welding in the welding line, there will be identification cards on each floor assembly to identify different car bodies, and different welding parts and processes are used.

The parts after subassembly and welding (such as four doors and two covers, roof and side panels) will be assembled and welded together with the underbody. This step is carried out on the assembly line.

The AGV trolley realizes a certain degree of transportation automation along the prescribed guide path through the electromagnetic guide device. Stop automatically when encountering obstacles and buffer the shelf to prevent damage to parts.

In the last step, the quality inspector (MQ) will conduct quality inspections on the flatness and strength of the welded finished product, and will randomly inspect a part of it into the Audit station for detailed inspection.

The assembly workshop covers an area of more than 100,000 square meters, equivalent to the size of 15 standard football fields. It is divided into production assembly line area, off-line inspection area and material area. The production cycle is 60JPH.

The production process of the final assembly shop is no different from other factories, followed by the interior decoration line, the chassis line, the final assembly line and the inspection line. Compared with other joint venture brands, the equipment and details are slightly different.

If an abnormality is found during the operation, the worker can immediately press the button above the workstation. Among them, the red button represents emergency and must stop production processing; gray represents non-emergency, and processing can be suspended.

The assembly line station uses a white hanger to transport vehicles, which can identify different models and stations according to the preset height data, and automatically adjust the height according to the needs of the process to reduce employee fatigue.

We can find that the factory is very easy to deal with in detail. For example, the conveyor belt on the ground is relatively wide, while some are relatively narrow, which saves costs and is more environmentally friendly.

The glass adhesive vinyl is automatically sprayed by a KUKA six-axis robot, which ensures the consistency and stability of each piece of glass adhesive trajectory. The glued glass is then manually transported and installed.

There are 80 AGV cars here, which is currently the largest number of workshops among all Shanghai Volkswagen factories. It greatly improves work efficiency, and the reduction of logistics costs is also fully reflected here.

In order to reduce the fatigue of workers during work, the workshop is also equipped with movable chairs in some workstations so that workers can sit and work. This may seem casual but considerate.

After completing all the assembly, the quality inspector will use a professional inspection computer to conduct a preliminary inspection of the electrical system. All electrical equipment will complete a self-inspection procedure in this process to ensure that there is no malfunction.

After passing the electrical inspection line, the vehicle will enter the offline inspection area. Every vehicle assembled here will go through 13 inspection procedures, including four-wheel alignment, light adjustment, hub rotation and rain test.

The rain shower test is equipped with an advanced rain shower circulation system. The rain shower water flows into the recovery area to reach the circulation area, then passes through the filter pump to the clear water area, and finally re-cleans the car through the water pump, which is very environmentally friendly.

The Changsha factory pays great attention to environmental protection and has more advanced equipment, with an automation rate of 86%. Even if compared with mainstream joint venture brand factories, it can be in the forefront as a brand new factory.