EMAG helps Nanyan overcome problems and explore new energy opportunities

Every day, cars of different sizes and shapes are moving around, carrying the hard work of countless people. China has ranked first in the global auto market for nine consecutive years. Manual, automatic, unmanned... People's pursuit of driving experience has spawned iterations and updates of manufacturing technology.

The success of any new product is not the result of a single breakthrough, it is necessary to rely on the overall strength of the entire industry chain. In Shanghai--China's automobile "leading boss" SAIC Group's location, a well-perfected best-selling car continues to be underground; and in the Liuhe High-tech Development Zone of Taicang City, not far from it, China's well-known auto parts companies, The newly-built new energy transmission component manufacturing plant of Chongqing Nanyan Group is also fully equipped to produce various transmission pinion products such as EDU, EV and DCT at full speed. These high-quality components are in urgent need of SAIC. They were transported to the manufacturing base of SAIC, assembled with other components, and eventually sailed to thousands of households.

The close cooperation between SAIC and Nanyan is certainly an example of a car company and parts suppliers going hand in hand; but if you delve into it, you will find that there is another key figure in this "all-industry chain breakthrough". The world's machine tool giant - EMAG.

Top equipment overcomes many difficulties

As early as 2005, Nanyan became a supplier to SAIC, supplying products with manual transmission (MT) pinion; with the advent of the new energy era, the technology track was converted, automatic transmission (AT), dual clutch transmission (DCT) ), continuously variable transmission (CVT), etc. are increasingly becoming the mainstream of the market, but the breakthrough of these new products is not easy. "Automatic transmissions have not been made in China before, and MT technology cannot be applied to DCT. To break through, it is necessary to improve design and manufacturing capabilities. The design aspect is more mature, so the key lies in manufacturing, which depends on the overall technical level of our component companies. For improvement, it is necessary to have excellent processing equipment." He Jian, president of Taicang Nanyan New Energy Transmission Co., Ltd. said, "Further, electric vehicle transmission gears and gear shafts are different from traditional ones. The speed of conventional vehicles is 6000-8000rpm. The electric vehicle speed is generally more than 20,000 rpm, which is very high precision for the product. The process capability is the top priority of our competitiveness."

Without automating the transformation, it will not continue to grow and develop. However, the strict precision requirements have become the first difficulty in front of Nanyan. Wan Yanqun, Minister of Technology Department of Taicang Nanyan, told us that the key process of the manufacturing process is the finishing of the gear teeth. The accuracy error should be within 0.01, the roughness should be RA0.2-0.3, and the structure of the workpiece should be compared. Special, thinner thickness, inner hole taper and cylindricity are very difficult to control, so the equipment performance and process level are very tested. If the performance of the equipment is not up to standard and there is a slight difference, the processing will be scrapped and the loss will be caused.

How to do? The only way is to carefully select the top processing equipment. To this end, Nanyan has turned his attention to the world. After heavy screening, EMAG and several other machine tool manufacturers have entered the vision of Nanyan. In the end, through actual processing competition, EMAG defeated a number of powerful opponents and successfully won. This is an official alliance between the "old partners" who have already known each other.

After the 9th car grinding center of EMAG entered the Nanyan, the situation changed immediately. Its exceptionally strong performance fully met the stringent precision requirements. For the specific situation of the production site of Nanyan, the EMAG technical team tailored it. Customized process solutions. Therefore, the outstanding equipment and excellent process plan have formed a strong manufacturing capability: the compact structure and stable performance of the equipment ensure the high precision and high quality of the product, which has won the high recognition of SAIC; The workpiece clamping is consistent, thus continuously ensuring the best effect; the matching tool and grinding wheel scheme reduces wear and reduces cost... The processing problem is solved and the manufacturing strength is greatly enhanced, which makes Nan Yan He always admire: "The processing strength, technical grade and precision level of EMAG grinding center are the top level in the world. Looking at the world, there may be few equipment manufacturers that can reach this level."

After the accuracy is difficult to overcome, another problem comes along, which is to improve production efficiency. Nanyan Production Minister said that SAIC does not even have a holiday during the Spring Festival. In order to guarantee the supply of its products, Nanyan needs to adopt the production pace of "three shifts and two downs, 24 hours without downtime", and the production efficiency directly determines the enterprise. benefit. In the face of fierce market competition, continuous improvement of production efficiency is an inevitable pursuit. In order to solve the efficiency problem, EMAG has equipped the Nanyan with a dual-spindle machine tool, and its strong strength makes the efficiency increase quite remarkable.

The EMAG twin-spindle machine includes the loading and unloading workpiece transport system, the TrackMotion automation system and the modular basic structure of the machine tool, and combines them into an efficient production system to achieve maximum productivity in the smallest space; the machine's powerful torque and Abundant power ensures fast and precise cutting; 12 tools are placed on the cutter head, covering all machining processes such as outer circle, end face and lead angle; the twin-spindle machine is seamlessly connected with the grinding center to form a highly automated Smooth production line, reducing manual operation... The excellent combination of strong performance makes Nanyan's production efficiency as a whole greatly improved, and the production cost is rapidly reduced, fully satisfying the demand of "not stopping work and improving efficiency"--the production cycle of Nanyan It has reached more than 50 seconds and has become the industry's top level; the amount of work that can be completed by the original three equipments in the car grinding process can now be completed with only one EMAG machine; the entire site operator is reduced by 50%, and the production efficiency is Compared with the original, it has increased by 30%! The efficiency problem is perfect, which will undoubtedly make Nanyan have more competitive competitiveness in the booming and high-speed automobile manufacturing industry.

"Day and Night Companion" to help grow

In fact, in the cooperation with Nanyan, EMAG is not only simple to provide top-level equipment, but also provides a complete and complete "turnkey" solution, as well as full-hearted effort, grow together with customers, and create value together. In-depth service.

Minister Wan said that to win the trust and order of customers, process design capability is the key. Therefore, when SAIC began designing a new product project, Nanyan participated in the technical exchange with SAIC to ensure that the designed product was manufacturable. In this process, EMAG contributed a great deal of wisdom--cooperating with Nanyan to make process plans, adjust process layout, and enhance technical strength to win orders.

In actual production, EMAG provides a “turnkey” solution for Nanyan by improving efficiency and enterprise energy level – including processing equipment, process plan, tool plan, process parameters, production cycle and so on. For example, Minister Wan said: "We have a hole in the product that is long and difficult to process. The tool and the grinding wheel can neither be too short nor too long, and we must ensure that the roundness is up to standard. EMAG has developed a tool and a grinding wheel for us. The solution fully meets the processing needs. They helped us overcome the problem and quickly solidified the process. We only need to follow this process plan."

EMAG's technical team is also stationed at the production site of Nanyan for a long time, providing process and equipment training for Nanyan, on-site tracking service, and working closely with Nanyan's technical team to continuously optimize production line capacity and improve production. Efficiency and reduced production costs. Sun Jiaxi, the head of the EMAG Nanyan project, which is busy at the production site, said: "In addition to a large number of standardized trainings, we also specially trained on the needs of Nanyan, and we are on the spot, regardless of the night shift. Fighting high spirits is to serve Nanyan. In the cooperation with Nanyan, we can use our solution ability to promote the rapid growth of Nanyan, and ultimately serve the customers of Nanyan to help them transform and upgrade."

It is said that EMAG and Nanyan are a pair of "old partners" who have already known each other. He always said with emotion that in fact, they have been in contact with EMAG for nearly 10 years. In the past 7~8 years, there has been no real business cooperation between the two parties. Despite this, EMAG still provided technical and technical support for many projects in Nanyan, accompanied by the growth of Nanyan. "For a long time, we didn't buy equipment from EMAG, but they spent a lot of thoughts on docking our projects. Sincerely, in all equipment suppliers, I think EMAG is doing very well, otherwise We don't have 19 devices at a time. When we buy equipment, we value the value of the equipment. EMAG does it!

Just a few months ago, the Nanyan Taicang factory was just a newly completed factory building, which was slightly quiet; now, just like the increasingly hot weather, the production here is already in full swing. With its deep technical accumulation, vigorous innovation and comprehensive in-depth service, EMAG helps Nanyan quickly overcome the difficult problems and build a strong technological strength and manufacturing capability. The high-quality components that are off the assembly line of Nanyan Factory, It was also promptly and quickly supplied to customers such as SAIC to help them compete for the industry wave. It is in this "interlocking and relying on each other" that the overall breakthrough of the industrial chain, the rise of new things, and the industrial transformation and catch-up of a country can be quickly performed.

Nowadays, in the endless engine roar, more and more "new figures" are being poured into - new energy vehicles with low noise, low energy consumption and smart and light weight. After hundreds of years of development, the global automotive industry is welcoming a huge change. The replacement of fuel vehicles by new energy vehicles is considered to be the general trend. Get rid of the shackles of traditional fuel technology, China is making the "big to strong" and "curve overtaking" of the automotive industry through the development of new energy technologies. Those "voyagers" who are good at choice, cooperation and side by side are gaining momentum. Mr. He pointed to nearly one-third of the factory and said: "We plan to be in place within three years, with an annual output of 1 billion, and new energy components will be our next commanding height."

About Taicang Nanyan New Energy Transmission Co., Ltd.

The company was established in October 2016 and is one of the three wholly-owned subsidiaries of Chongqing Nanyan Industrial Group. The registered capital is 300 million yuan, the total investment is 850 million yuan, covers an area of ​​77.63 acres, and the total construction area is 38,000 square meters. The company's main business is to equip Shanghai Automotive Transmission Company with new energy transmission gear shafts such as EDU/EV/DCT, keeping up with SAIC's R&D pace, achieving simultaneous planning and simultaneous development, and is an important strategic cooperation supplier of SAIC. At the same time expand other high-end new energy vehicle market.

Figure 1: He Jian, president of Taicang Nanyan New Energy Transmission Co., Ltd. said that process capability is the top priority for its competitiveness.

Figure 2: Mr. Sun Jiaxi (right), General Manager of the EMAG Project, Wan Yanqun, Technical Director of Taicang Nanyan (left)

Figure 3: Strict accuracy requirements are the first difficulty for both sides to overcome. At the same time, the on-site operators reduced the 50%, and the production efficiency increased by 30%. The phased goal was achieved, which made Nanyan's competitiveness "surge" in a short period of time.

Figure 4: There are currently 19 EMAG machine tools in the factory that has been put into use in Taicang Nanyan, creating value for each day of production delivery. There are still one third of the factories in the planning, where EMAG and Taicang Nanyan will work together to explore the huge space of the new energy vehicle market.