1、同色比项目介绍2The CQ2 Plant was set up and put into production in 2012 and the installed production capacity is about 340k per year(270d*21h/d*60jph),standard production capacity 225k per year(250d*15h/d*60jph).2012年重庆二工厂建成并投产，年生产能力34万台（270d*21h/d*60jph），标准产能22.5万（250d*15h/d*60jph）3-Coat 1 bake(3C1B)high
2、solid paint process for saving cost and reduce the VOC emission.工艺采用3C1B高固体份紧凑性工艺,节约成本和降低VOC排放.Project Introduction项目介绍项目介绍C 346 4 door,5door,and C520,3 primer ,12 basecoat color and 3 clear coat.生产 C 346,4 门和5门 和 520共 三种车型,3 个中涂 颜色,12个色漆 和 3 个清漆 涂料.Flow Chart 车体流向图 Two spray line 3 Buffer line and
3、two sealer line,one sanding line ,two spray booth line will bring the block NO.down.Block Paint down 同色比逐步减少喷涂 SPRAY调色站 CSS密封胶Sealer电泳储备ED BufferBIW排产plan order6543210数数据据4.72883.08882.10561.63081.59722.0148各区域同色比箱型图 BOXPLOT OF BLOCK ORDER各区域同色比箱型图 BOXPLOT OF BLOCK ORDER把电泳储备线先进先出功能修改成按照颜色排序和出车的功能Mo
4、dify the ED Buffer conveyor PLC and CCR program,From FIFO function change to color block function.Modify Method 电泳储备线改前 ED Buffer Modify BeforeED buffer line according FIFO(first in first out)mode,body random in the buffer line 1,2,4,5.random out from line 1,2,4,5.The paint block is reduced.电泳储备线是进入
5、储备是随机进入各4道，出车规则是按照先进先出的规则，颜色顺序被打乱 RFID reader动画电泳储备线改后 After Modify ED BufferED buffer line according same paint mode in and out,body according paint color into the buffer line ,one line only 1 or 2 color can enter the 1 buffer line.车体进入电泳储备线 各道，是按照同色规则进入，出车是按照1个眼色或2个颜色的出车顺序出车面涂选色区储备线改前 CSS Modify B
6、efore The Small color select station only 3 line,5 body positions per line,so only can store 3 colors,if more than 3 colors ,the can not according the block paint function running.只有15个车位3条道的小颜色选择站,超过3个颜色就不能调色.电泳打磨选色区改后CSS MODIFY After车体进出储备线按照同色进同一道，出按照同色或间隔一个色出。Body in/out buffer according block p
7、aint orderED bufferOutletinlet23Body data read from RFID reader send to PLC when body to the inlet roller bed PLC according FIFO rule send the destination signal to the buffer line 1Body data VINBody dataRFID Reader A ED bufferOutletInlet241Body dataBody data read from RFID reader send to PLC when b
8、ody to the inlet roller bed PLC send body data to the CCR Server Server according color block rule send the destination signal to PLC PLC send the destination signal to the buffer line.Body data VINRFID Reader A FIFO Mode For the inlet/out by PLC control 车体进出储备采用FIFO模式，是输送PLC控制Block Mode for the inl
9、et/outlet by the CCR Server control 车体同色模式进出储备线采用中控服务器控制ED Buffer Detail Modify Method 电泳储备改善点介绍电泳储备改善点介绍1)Modify the CCR Server and PLC Program from FIFO control mode changed to color block mode 通过修改中控室和输送的控制程序，把电泳储备线的进出车模式从先进先出模式改成按照颜色进出车的模式2)Add client PC on the ED buffer line and EMU station for
10、 make rule and monitor the body information and recovery the faults.在电泳储备和驼鸟毛擦站增加中控ECOEMOS 的客服机电脑，方便设定颜色选择规则和监控设备运行情况以及故障复位。3）No need full time worker 不需要专职人员Add EMU client computer for make rule and monitor Set Inlet Rule In The CCR ECOEMOS Web 在中控软件ECOEMOS上设定车体入口规则 Inlet rules for the buffer入口规则设定
11、界面Storage line NO.Set Color NO.TC 2TC 1 UBSPTEDED OVENED BufferSealer lineTC CSS BufferED sandingED Check Add Web Monitoring Body Color From Paint In To Spraying booth增加监控车体颜色界面（从喷涂入口到喷房）Form Body shopBody color information For easy make block rule 为设定 入口规则提供参考信息ED Buffer CSS Monitoring电泳储备线的监控画面TC
12、CSS Monitoring 面涂选色站监控画面 Page 16 of 12 Emergencies Control Mode (HMI Set Mode)紧急控制模式IF the CCR systems have faults,can change to PLC control by HMI Set Inlet and outlet rules 如果CCR系统出现问题，会切换到PLC控制模式，该规则由HMI来设定HMI set inlet rule 在HMI上设定入口规则HMI Set outlet rule 在HMI 设定出口规则Quality Improvement 质量改善 Incre
13、ase the block painting ratio,Reducing the painting color change times ,reduce the painting contaminated dirt defects.同色喷涂提高,减少了换色次数,减少喷涂污染缺陷.3Contaminated defect reduce 3/1000.Manpower 人工Block paint ratio 同色比 Remark Semi_Auto半自动22.01 ED buffer and CSS AUTO 自动00Manpower Reduction 人工减少 在2014 安排人员 在电泳储
14、备线和CSS 颜色选择站半自动排序车体.在2015年通过项目全部改成自动控制,减少了2个操作者/班.Operator adjusting the body sequence in the ED buffer and CSS station,after the block painting project,all body sequence are auto control,no need the operator on the site.同色比增加,减少了人工喷涂的换枪次数,平均每次换枪时间5S,减少工人的劳动强度.Add blocking painting ratio,reduce the
15、change spray gun times,about 5 s/time09.04VOC 排放减少和成本节约排放减少和成本节约 VOC Emission Reduced And Cost Save7.031.66.07投入节约对比 Investment/Save 1）Block paint from 2.01 increasing to 9.04 the solvent per unit reduce from 2.55l/unit to 0.95 L/unit,save solvent 1.6L/unit and paint 0.126L/unit 同色比从2.01提高到9.04 后,单车
16、溶剂消耗可从2.55降低到.95 升/台，可 节约清洗溶剂1.6升/台，节约填色涂料0.126升/台2)Save cost 19.27RMB/unit for solvent and paint,save solvent 3,750,274 RMB per year,fill paint 2,995,069RMB per year,manpower 200,000RMB,total 6,945,000RMB.单车节约19.27元/台的清洗溶剂和填色涂料消耗，1年可节约清洗溶剂375万元(按照35万台的产量)，填色涂料299.5万，人工20万,合计694.5万。3)Project investment 1,200,000 RMB,Net Gain 5,745,000 RMB.改造成本120万,一年可节约：694.5-120=574.5万
