1.Project background

Zhongding Group is a domestic professional automobile body lock manufacturer, and its products are supplied to many independent and joint venture automobile companies. With the popularity of electronic lock products, product parts have become more precise and assembly accuracy requirements are higher. The original manual assembly mode has low efficiency, poor consistency, unstable sealing and life performance, and cannot meet the demand for order growth and quality upgrades.

2. Core pain points

1. Parts are small in size and require high assembly accuracy. Manual assembly is difficult, the defective rate is high, and it is difficult to increase production capacity;

2. Tests such as lock body sealing, on-off performance, and durability rely on manual sampling, which results in high risk of missed inspections and frequent after-sales complaints;

3. There are many product models, and manual model changes and adjustments are slow, making it difficult to accept multi-variety and small-batch orders;

4. There is no systematic record of assembly data, quality problems cannot be accurately traced, and there is no data support for quality optimization.

3. Overall solution

Guangke Industry has customized a linear fully automatic assembly line solution based on the characteristics of precision assembly of electronic locks. It adopts vibrating plate precision loading + visual positioning correction technology, combined with robot precision assembly and multi-station online inspection, to achieve unmanned production in the entire process from component loading to finished product unloading, ensuring assembly accuracy and product reliability, and supporting rapid changeover of multiple models.

4. Solution core configuration

1. Precision loading and visual positioning

Micro parts are loaded in an orderly manner using a vibrating plate, and the vision system is positioned and corrected to ensure accurate direction and position of the parts. Assembly accuracy is ensured from the source, and errors and omissions are eliminated.

2. Robot precision assembly unit

The core assembly process uses high-precision robot operations to complete the shell assembly, valve core assembly, motor press-fitting and other processes. The press-fitting force and stroke are monitored in real time, and the data is automatically uploaded and traced.

3. Multi-dimensional online detection system

Integrated on-off performance test, lock body sealing test, plug-in and pull-out force test, key processes are fully inspected online, and unqualified products are automatically diverted and eliminated to ensure the reliability of factory products.

4. Modular quick change design

The tooling and fixtures are standardized and modular. Changing product models only requires switching tooling and programs. The debugging cycle is short, and it is suitable for the co-line production of multiple models of electronic locks.

5. Whole-process data traceability

A traceability code is bound to a single product, and assembly parameters and inspection data are retained throughout the process. Quality problems can be accurately located in processes and material batches, helping to continuously optimize quality.

5. Project implementation results

1. Production efficiency increased by 40%: full-process automated operations, single-shift production capacity increased by 40%, front-line assembly personnel reduced by 60%, and labor costs dropped significantly;

2. The assembly quality has been significantly improved: the assembly defect rate has been reduced by 85%, seal detection has zero leaks, product consistency has been greatly improved, and the after-sales complaint rate has been significantly reduced;

3. Enhanced flexible adaptation capabilities: Product changeover time is shortened by 70%, orders for electronic locks for different models can be quickly responded to, and market acceptance capabilities are enhanced;

4. Digitization of quality management: The whole process data is traceable, quality optimization is supported by data, and product yields continue to improve steadily.

6. Customer value and evaluation

After the automated production line was put into operation, it helped Zhongding Group get rid of the dilemma of relying on manual labor for electronic lock assembly. It improved both production capacity and quality, forming a clear competitive advantage in the industry. Stable product quality has also helped customers successfully win designated projects for new models from many car companies, and the business scale has continued to expand.