After the implementation of automation transformation in the TBM tunneling machine production line, the efficiency of the core assembly process has been improved by 30% -50%, the offline cycle of a single product has been shortened by 20% -35%, and the defect rate has been reduced by 15% -25%. The actual effect depends on the degree of automation integration of the transformation and the basic conditions of the original production line.
1, The specific manifestation of improving the efficiency of the core process (1) is the assembly process of the cutterhead: using a 6-axis industrial robot instead of manual positioning and welding, the assembly time of a single cutterhead is compressed from 48 hours to 24-32 hours, and the efficiency is improved by 33% -50%. (2) Hydraulic/electrical system docking process: Automatic guided docking equipment replaces manual operation, reducing pipeline docking and wiring crimping time from 36 hours to 18-27 hours, and increasing efficiency by 25% -50%. (3) Whole machine debugging process: Integrating online detection and MES system, reducing manual repetitive debugging steps, shortening the total cycle from 12 days to 8-10 days, and improving efficiency by 20% -33%. 2, Improvement of Related Production Indicators (1) Defective Product Rate: The proportion of defects such as misconnected pipelines and loose connections caused by manual operation has decreased from 8% to 2% -6%, with a reduction of 15% -25%. (2) Safety and Cost: Reduce the number of core process workers by 40% -60%, while avoiding safety risks such as manual high-altitude welding and high-pressure pipeline docking. 3, Boundary constraint condition for effect (1) modification depth: Only local processes (such as welding) can be modified at a single point, resulting in an efficiency improvement of about 10% -20%; Only with the integration of full process robots and digital transformation can we achieve a 30% -50% improvement. (2) Existing production line: New lines will be synchronously implemented with automation transformation, with an improvement rate of up to 40% -50%; The renovation of old lines is limited by spatial layout and equipment foundation, resulting in an increase of approximately 20% -30%.
