A car is primarily composed of four major parts: the engine, chassis, body, and electrical system. Each of these four parts is composed of countless tiny parts. In other words, a car is an electromechanical product composed of tens of thousands of small parts. To ensure efficient and high-quality automobile production, production monitoring is essential.
However, the traditional production monitoring methods are no longer sufficient for modern automobile production. To improve efficiency and quality, more and more automobile manufacturers are beginning to use visual configuration monitoring software to control and monitor the production process and improve production efficiency and product quality.
Hightopo 2.5D automobile manufacturing visual management software supports visual monitoring of the entire production process by collecting and analyzing production data. This monitoring method can intuitively reflect various data and information, such as the status and quality of stamping, body welding, paint spraying, assembly, and other processes, allowing for timely problem detection and resolution. The system can also automatically generate reports to facilitate data analysis of the production process, further improving production efficiency and quality.
Stamping Workshop
This module provides an overview of the stamping workshop. Its standard process includes the storage of raw materials (sheets and coils), the uncoiling line, the cleaning and oiling of large pieces, the uncoiling and shearing of small pieces, the stamping production line, the installation of molds, commissioning of the first piece to pass, mass production, rustproofing of qualified parts, and storage.
Hightopo software restored the entire stamping workshop according to the standard process. It allows operation and maintenance personnel to easily access the scene through cross-platform devices or mobile terminals. Users can use touchscreen devices to rotate, zoom, and translate with one, two, or three fingers. With the remote operation, you can have an overview of the entire stamping workshop, and control/monitor each process equipment.
The system links 2D and 2.5D UI elements with server data. When the user clicks on equipment on the page, a new page pops up, displaying the equipment’s detailed internal structure. This provides a more accurate view of the internal operation process. Raw materials are extracted from their storage area and transported to the stamping workshop via a robotic arm. After being stamped, some molds are delivered to the welding workshop by vehicles, while others are temporarily stored in the mold storage area for future use.
Hightopo allows for custom 2D interaction logic and can also be expanded to 3D and VR scenes. This means that users do not have to rebuild the interaction logic or be concerned about the differences in the mouse, touch screen, and VR interfaces. The system presents relevant data in a clear manner on both sides of the page and inside the scene, offering customers multi-dimensional technical assistance such as decision-making, early warning, and positioning.
To view the equipment ledger and operation details, simply click on the corresponding press machine. This will open a pop-up window displaying data from the industrial control data content of the user’s existing system. On the left-hand side, you will see a list of all operating or faulty equipment, including clamping machines, presses, conveyor belts, and washing machines. The search function can be used to locate the corresponding equipment quickly and easily. Clicking on a specific device will display detailed fault information and real-time operating parameters on the right-hand side of the window.
The real-time alarm information is displayed in a table format at the lower left corner of the page. This includes the name, time, and location of each device that is in alarm. The production situation can be combined with different production lines to carry out data visualization statistics according to the line body model, line body state, part number, part name, model, and production quantity of the production line.
The real-time display of the network status of Programmable Logic Controllers (PLCs) across various product lines will assist workshop staff in promptly identifying any issues with the production line’s normal functioning.
By producing the aforementioned content, the system can assist users in achieving production process discipline inspection. The content includes:
- Verify that the product drawings, standards, and design documents are complete and can fulfill production requirements, while also complying with relevant regulations on process management.
- Ensure that the process documents are complete and can satisfy production needs. These documents typically include work instructions, inspection instructions, and metal consumption quotas used on-site in the stamping workshop.
- Ensure the accuracy, completeness, and uniformity of technical documents.
- Confirm that materials, work-in-progress, and finished products meet process requirements, and assess the technical status of process equipment and tooling.
- Verify the accuracy and timeliness of quality inspections, as well as the management situation on the production site.
- Evaluate the performance of process management work and assess the implementation of work instructions by various personnel.
Welding workshop
Hightopo offers support for overlapping, rotating, and zooming 2D and 2.5D scenes. It also can simulate welding workshop operations and combines various welding processes to create realistic animations and scene constructions.
This scenario primarily involves using stamping welding, CO2-shielded welding, and laser welding in the automotive welding process. The process includes the following steps: floor assembly, left and right-side panel assembly, ceiling assembly, door cover installation, engine cover installation, trunk cover installation, robot resistance spot welding, stud welding, nut welding, glue application, surface adjustment (board repair), transportation to the parking area, and final assembly.
In the process of welding automobile parts, stamping welding is used to weld the basic body, frame, parking space, five doors, and one engine hood. For small parts or thick reinforcements that cannot be welded by stamping welding, CO2-shielded welding is used. Laser welding is mostly used in automobile manufacturing to weld large cover parts and appearance parts, such as the assembly of segmented doors, and the welding of top covers and side panels. The Hightopo system uses advanced visualization technology to simulate each step and achieve a digital twin simulation of the above processes, enabling users to monitor the process with a perfect visual experience without leaving their offices.
The real-time position of the current part in the workshop is displayed in the lower-left corner of the page, including various product models and output indicators to help operators understand changes comprehensively and in a timely manner. In case of detecting a problem or fault, the staff can also track the location in real time, enabling faster, more accurate, and scientific decision-making.
This system not only includes the simulation of the process flow, but also supports monitoring the current production line data, the real-time completion rate of the production line, the storage of parts, the storage location, and the total energy consumption of the workshop.
Paint workshop
The process flow of the automobile painting workshop involves several steps, including cleaning and dust removal, painting preparation, painting construction, drying and repairing. Initially, the workshop cleans and removes dust from the car, removing oil stains, moisture, and dust from the car surface. Next, it prepares the car for painting to ensure a smooth paint surface. Then, it carries out painting construction, using different painting methods (such as pistol painting or electric spray gun painting) based on the car model and specification. Finally, it dries and repairs to ensure the smoothness and gloss of the car surface coating.
This module will follow the steps of degreasing, surface conditioning, phosphating, pre-cleaning, draining before electrophoresis, drying, robot painting, PVC drying, sealant, grinding, retouching line, delivery line, and reserve area.
To achieve high-quality painting effects and good anti-corrosion performance, it is necessary to conduct surface treatment on the body before painting, conduct an overall inspection of the product, and repair and remedy repairable defects.
After that, the car body is sent to the spray gun position in the powder spray booth through the conveyor chain to prepare for the spraying operation.
The last step is the painting line process. Spray painting is a surface treatment that covers the products and semi-finished products that have passed the inspection. Spray paint can play the role of anti-rust and anti-corrosion.
Hightopo software can handle more than 100,000 levels of 2D, and 2.5D table tree component graphics, meeting the needs of massive IoT devices and data scenarios. In this system, it can fully reflect the complex production process of the paint shop.
Hightopo’s 2D animation technology can completely restore the entire car painting process. And clearly, accurately, and intuitively displaying each process to users.
By using Hightopo’s 2D chart components and data binding, the production data and energy consumption of the production line can be obtained and displayed in real time. The system can also make an overall display of the planned output and target output, as well as the operation of the robotic arm. Animated effects can make the entire page look more concise and beautiful, providing a high-quality user experience.
The statistics of the electrophoretic parts, intermediate time, drying room, and decoration room in the paint shop can be conveniently displayed. The system also supports combined VR/AR display, allowing users to immerse themselves in the virtual environment for experiences, especially for large-scale scenes such as factories, workshops, and production lines.
Summary
Hightopo software builds a complete digital simulation of the automobile production line process from 2D to 2.5D through data model + UI library + 2D topology, aiming to contribute to the construction of “digital twin + configuration monitoring + industrial Internet” and realize intelligent manufacturing.
Compared with traditional configuration software such as InTouch/IFix/WinCC, Hightopo’s web-based platform is more suitable for the general trend of transformation from C/S to B/S. Its multi-element-rich visual components and fast data binding methods can be used for the rapid creation and deployment of the system, completing real-time data monitoring based on web services and multi-user access on the server side. It can be applied to the power system, water supply system, petroleum, chemical industry, and other fields, providing various clear and beautiful visualization services in 2D, 2.5D, and 3D for various industrial scenes.
You can go to our official website to view more cases and effects:
https://www.hightopo.com/demos/en-index.html
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