Editor's Pick – Page 164
-
Article
冲压现状分析
大部分原始设备制造商多年来都是在厂内冲压车间生产汽车车体，但是现在出现新的契机，独立冲压部门正在悄然出现随着汽车制造商不断关注新技术、并不断追求规则引导的技术 — 尤其是排放量、连通性、自主性和电动车 — 在资源和能力方面的局限性，为Gestamp, Magna这样的公司提供了新的契机。汽车公司自己生产几乎所有Class-A表面外盒；有一些例外（比如Porsche Macan），但巨大多数可视车体都是在厂内冲压车间冲压而成，不论是钢材还是铝材。大部分工作实在相关汽车装配厂完成，但有些情况就涉及到复杂的冲压件内部供应链：比如，GM在欧洲各工厂之间运输冲压件 — 有些零部件是在英国制造的，运输到波兰，而有些是在波兰冲压制造，最后送到德国。GM甚至从Kaiserslautern（联邦德国）的组件厂派送冲压件到外饰座椅结构制造商或座椅装配厂，而自己的汽车厂充当一级、二级或三级供应商。规则之外虽然这个行业大多数独立公司生产不可见车体下部分、结构冲压件和装配，但是也有例外；其中一个就是美国公司Tower Automotive，公司在欧洲也有工厂，比如在比利时为Volvo供应，在德国东部也有工厂。公司在茨维考（德国东部城市）的工厂制造车体冲压件和外壳板材，尤其是为VW集团供应。特别的是，工厂为Porsche Macan提供80%的外板；工厂还制造Porsche Cayenne, Audi Q7和Volkswagen Touareg汽车的下部装配。促成这种结果的因素是Tower公司在茨维考的工厂过去曾制造声名狼藉的Trabant汽车。公司在2015年投资Ä11m（约合1,170万美元），实现冲压车间现代化，安装了AP&T的热冲压线。最近几年里，外部冲压件市场发生了很大变化，主要是通过公司合并，计划收购和淘汰并存。与此同步的是，热冲压成为主要工艺，使供应基地有机会改变投资，保证长期发展，而大多数汽车公司选择外包一些货全部流程。VW公司和Fiat公司都是安装自主热冲压线的公司，但是双方，尤其是VW公司使用外面的供应商，比如Gestamp和Tower公司，因为对使用该技术生产的零部件的需求迅速增长。因此，正如其他汽车领域一样，外部冲压部门正逐渐被大型国际公司所引导，最著名的是Magan, Gestamp和Kirchhoff公司；钢铁公司VoestAlpine建立了车体结构工厂，遍及全球，但是最近主要投资北美；这种综合方式很少被钢铁公司采用。ThyssenKrupp过去在结构冲压领域影响很深，但是不久前已经退出这个行业。从西班牙的小城镇到国际舞台Gestamp公司能从西班牙小公司转变成为全球领军公司，主要得益于最近刚刚兴起的热冲压技术，该技术已经成为核心工艺了。公司是第一批投资该技术的公司，最著名的是德国的Griwe工厂，而且在领域内的收购也很显著，首先是与瑞典SSAB Hardtech合并，之后是法国的Sofedit公司（是从ThyssenKrupp手中收购的）。公司还从ThyssenKrupp手中购得英国Tallent公司。 Gestamp has grown through both the acquisition of other companies and investment in new technologies, notably hot stampingGestamp公司还投资北美、西班牙的热冲压工厂，最近还在英国投资 — 在英国进行脱欧投票之前宣布，要在英国投资7,000万英镑（约合8,860万美元），确定后脱欧未来前景。新的投资是在伯明翰附近Cannock特意建造的工厂，将使用传统的热冲压系统和新的热冲压技术，使用一个传输伺服冲压线。公司还投资英国东北部Newton Aycliffe的Tallent工厂，在那里安装了两个新的冲压机，据说可以保证工厂未来30年的发展。冲压机是从西班牙供应商处购得，供应商离Gestamp西班牙总厂很近；这些冲压机已经老化淘汰，运送到英国用于再装配。他们不仅向英国的JLR，Nissan和Honda供应零部件，而且还想欧洲的Volov和Ford公司供应。Gestamp公司在2011年从ThyussenKrupp手中收购法国的Sofedit公司，此后投资3,300万英镑安装新的热冲压生产线，升级原有的生产线，增加激光切割设备，用于加工热冲压零部件。Gestamp公司不仅收购西班牙以外的公司，还收购国内的公司。2016年7月，公司收购西班牙同行冲压公司Estampaciones Sabadell公司60%的股份（2011年收购40%的股份）。Sabadell公司的一个亮点就是合约长期性 — 比如2014年，公司的一份合同里，为Mecedes Viano/Vito MPV/Van Programme提供构架，直到2027年。Gestamp目前一年的营业额为70亿Ä，来自全球100多个生产厂。公司报告称，2017年计划公开发行股票，这是在2016年日本Mistsui公司收购12.5%的股份之后提出的想法。Magna拓展冲压业务加拿大Magna公司也通过收购壮大；Cosma分公司获得冲压厂。最近还收购了英国的Stadco公司，后者也有收购历史，2011年收购英国的日本供应商Ogihara，并在Mayflower公司推出汽车业之后收购了该公司剩余股份。英国公司（长期以来为JLR, GM和Ford Saarlouis供应）现在已经并入Magna旗下Cosma分公司。Magna在英国Telford建设新工厂，从2018年开始为JLR供应结构铸件。Magna公司还进行大规模投资，建设自己的工厂，比如墨西哥Morelo建设工厂，这是Magna在该国的第31个工厂，于2015年开始营业。工厂位于墨西哥城以南100公里，为Nissan生产结构性焊接装备。此外，公司在中国重庆开设工厂，为Ford和VW公司供应。公司在中国的上海、长春和长沙也有冲压厂，在中国很有影响力。日本公司在欧洲和北美活跃日本的汽车公司已经将国内的供应商带到欧洲和北美的各个部门，包括冲压领域；但英国的Ogihara的业务却并没能持续，Unipres的情况有些不同 — 应该是更加乐观。Unipres在英国工厂的年营业额超过1,8亿英镑（大部分来自Nissan和Honda）。Unipres公司在近几年投资热冲压和传统冲压；2015年公司宣布增加两部冲压机（一台2,500吨压力Tri-Axis转移式冲压机，一台600吨冲压机，工厂冲压机总数量达到18台），主要视为西班牙的Renault供应，人们认为应该是Kadjar汽车，因为该车组件与Qashiqai基本一致，两款汽车平台相同。尽管公司位于英国北部，但是Unipres在西班牙中部的供应力也很具竞争力。此外，Unipres在中国与Dongfeng公司合作建立合资公司，铺设冲压生产线。公司在墨西哥投资6.7亿比索（约合3,300万美元），建立新厂，为Nissan在阿瓜斯卡连特斯工厂提供各种冲压装备，包括散热器悬挂梁架、中心后座构架和顶棚加固。跨国边境进入美国，Unipres公司投资了两个工厂；一个在田纳西Portland，和英国工厂一样，这里也安装了2,500吨转换式冲压机和一台600吨冲压机 — 这些冲压机用于制造Nissan ...
-
ArticleReality check for tech
In 2015, Samsung Electronics set up a team specifically to look at ways of penetrating the automotive industry. The South Korean tech giant was seeking to gain a firm foothold in an automotive electronics market that it predicted would grow to more than $100 billion in the next decade. Towards ...
-
ArticleOut now: ATS 2017
In the process of putting together this first ATS supplement, we heard from among the key players in the automotive tier supplier market about shifting customer preference, greater connectivity and the drive to innovate. All recurring themes, common to every OEM in each global region. As we discovered from speaking ...
-
Article
Seven key issues for tier suppliers
Taking examples from across the world of automotive tier supply, AMS looks at the seven key considerations from supply base consolidation, vertical integration and outsourcing to the changes that the move to electric, autonomous and connected vehicles might mean for the supplier industry1. Supply base consolidationWhile car companies make most ...
-
ArticleA kanban plan
eFlex vice-president George Jewell explores the software development collaboration tools that companies can use in manufacturingAfter working for many years at a vehicle manufacturer, I moved to a manufacturing software company. At first glance, you would assume they have very different processes, but in many ways they are similar. Both ...
-
ArticleGet the insight inside
With shorter lead times and constant cost pressures, OEMs are adopting CT scanning to analyse internal structures without the disassembling of countless prototypesToday’s automotive OEMs and suppliers face ever shortening lead times for introducing new products at a lower cost. Consequently, fewer prototype iterations are required and destructive testing is ...
-
ArticleThe smooth gear change
As transmission design grows more complex, the challenge for OEMs is to produce a greater range of gears in higher volume while ensuring qualityUp until a few years ago, five-speed transmissions reigned supreme in automotive design but in the last decade gear numbers have increased dramatically. With this change, 9- ...
-
ArticleEnsuring global productivity
With low heat input, high welding speed and short weld-to-weld times, laser welding is helping meet the demand for increased output and use of lightweight materialsAs a system integrator of high-end automatic welding equipment, the Dutch company AWL-Techniek has grown into a global partner for its customers with branches in ...
-
ArticleParts makers in the driver's seat
Using ABB robots, an IAC Group facility in Sweden has streamlined its production of interior plastic components for VolvoThe town of Skara in south-western Sweden is home to a manufacturing plant that has produced plastic goods since the mid-1930s. “In the beginning, the plant produced household goods, before shifting its ...
-
ArticleMetrology meets automation
Portable systems have made high-accuracy measurement possible across all plant areas – the next step in this evolution is the integration of metrology with automationIn years past, automotive manufacturers have been forced to choose between very different paradigms in the search to improve the quality, shorten design-to-launch times and better ...
-
ArticleA red e-volution
From NY to KL, cities all over the world are jumping on BYD’s electric bus It looks like any of the other thousands of red double-decker buses proceeding through the loud traffic on London’s streets, but if you listen closely you’ll soon realise that some buses are different. Instead of ...
-
ArticleFitting rewards
ArcelorMittal’s stronger hot-stamping grades are ideal for laser-welded blank applications, leading to further weight reductions and increased safetyThe automotive industry faces two major challenges today: emissions reduction and improvement of safety standards. Reducing vehicle weight by using lighter materials is an obvious way to cut emissions, but steel offers unbeatable ...
-
ArticleFrom success to excellence
Siemens’ TIA Portal helped Continental Regensburg simplify and interlink its evolving standard cell manufacturing processContinental AG is one of the world’s largest automotive parts suppliers. The group’s automotive division operates from around 200 locations worldwide and at its largest facility, in Regensburg, Germany, around 8,000 people are employed in production ...
-
ArticleJust-in-time to fit the perfect wheel
Series production of complete wheelsets in JIT manufacturing operations is one of the decisive process stages in final vehicles assemblyWith its new wheel-tyre assembly line, Schenck RoTec offers both OEMs and main tier one automotive suppliers and tyre wholesalers a flexible, highly scalable and efficient solution for just-in-time (JIT) production. ...
-
ArticleNew generation of robots
Dürr’s new seven-axis EcoRP E043i robot features a kinematic system, which the company claims enlarges the work zone and can be used instead of a linear displacement rail system. Dürr says this improves access and avoids collisions with the vehicle, particularly in interior painting.The six-axis EcoRP E/L133i robots can operate ...
-
ArticleConnected services for robot systems
Connected Services are a suite of resources designed to help UK manufacturers maximise robot uptime using data access and problem resolution says ABB Robotics. Delivered via the company’s single interface called MyRobot, Connected Services will make actionable data immediately available to plant engineers, maintenance staff and managing directors via smart ...
-
ArticleIndustrial Ethernet switches
Siemens says with its new Scalance XC-200 compact industrial ethernet switches users can set up electrical and optical line, star and ring structures in industrial networks. The layer 2 network components can be integrated into both Profinet and EtherNet/IPdiagnostics. For transferring large volumes of data, the company offers the Scalance ...
-
ArticleInjecting a dash of insulation
Automotive interiors specialist International Automotive Components (IAC) has further expanded its operations in EuropeIAC's newest production facility, at Prestice in the Czech Republic, will initially be producing the company’s injection moulded inner dash, acoustical insulation product for two major vehicle OEM customers – including trunk trim and dash insulation components ...
-
ArticlePloys against noise
Following a joint project with Henkel, BMW is piloting a new generation of sustainable, lighter, liquid-applied sound deadening materials for series productionWind whistle and engine sounds work against the quiet enjoyment that OEMs seek to provide for drivers and passengers. Noise-Vibration-Harshness (NVH) materials placed onto the vehicle BIW structures help ...
-
ArticleOperation and cooperation
The working relationship between design and manufacturing departments can optimise processes, reduce costs and make the most of the best ideasGenuine leather, synthetic leather, thermoplastic polyolefins and slush skins have become standard surface materials in cockpit production. These various surface concepts usually call for multiple-stage production processes, requiring specific tools. ...
