This project provides a customized intelligent solution for the automatic assembly production line of brake discs. It is an intelligent system integrating robotics, automatic control, and information management technology. It addresses industry pain points such as traditional high-intensity, low-efficiency manual assembly, unstable assembly accuracy, and lack of data traceability. The production line achieves full-process automated operation from feeding to pre-treatment spraying, alignment pressing, bolt tightening, quality inspection, and finished product unloading, completely revolutionizing the traditional production model of manual lifting, manual oil spraying, and manual assembly. It effectively improves assembly consistency and production efficiency, reduces labor costs and safety risks, and fully meets the high-precision, high-reliability, and traceable mass production standards for railway transportation components.

Customer On-site Case

Core Features

• Unmanned Operation: Equipped with gantry robots and RGV automatic transport vehicles, automatically completing heavy workpiece lifting, material transfer, and lubrication spraying processes, completely replacing high-intensity manual work, reducing safety risks, and reducing dependence on skilled technicians.

• High-Precision Assembly: Integrated visual recognition and laser displacement sensors achieve precise workpiece positioning; equipped with multi-axis intelligent tightening equipment, closed-loop control of bolt torque and tightening angle, real-time upload of process parameters, completely avoiding errors caused by manual operations and ensuring assembly consistency.

• Full-Process Data Traceability: Integrated MES manufacturing execution system, automatically collecting pressing force, torque, pressing data and operation records generate unique codes, achieving permanent archiving of production data, meeting product full lifecycle quality control and industry audit requirements.

• Integrated Process: Integrates automatic feeding, pre-treatment spraying, precision pressing, bolt tightening, online inspection, and finished product unloading, with smooth process connection, controllable production rhythm, and significantly improved overall production line efficiency.

Cooperation Cases | Sujiatun Project On-site

Intelligent Operation Process

Taking wheel-mounted brake discs as an example, the standard automation process is as follows:

• Intelligent Feeding: Scan code to enter material information, robot grabs wheels and brake discs, and precisely transports them to the operation workstation.

• Spraying Pre-treatment: Robot automatically sprays molybdenum disulfide in a closed area, and synchronously detects coating thickness in real-time to ensure unified process standards.

• Pressing and Tightening: The system automatically aligns brake discs, anti-loosening keys, and wheels. After automatic sorting, bolts are tightened step by step by the tightening machine according to the strategy, synchronously monitoring torque and angle.

• Unloading and Inspection: Assembled wheel sets are automatically transported to the inspection area, where dynamic balancing equipment completes automatic inspection and correction, and then automatically transports to the finished product area for unloading after qualification.

Cooperation Cases | Taiyuan Project On-site

Project Value (Measured Data)

After intelligent upgrade of the production line, product quality and comprehensive benefits have significantly improved:

• Workforce Optimization: Single-shift operators reduced from 5-10 to 2-4, significantly reducing labor costs.

• Production Efficiency Improvement: Single-piece assembly time shortened by 50%, overall production efficiency improved by 65%.

• Operation Improvement: Per capita daily walking distance reduced by 80%, getting rid of heavy workpiece handling operations, significantly reducing labor intensity.