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简体中文 How Reciprocating Rod Conveying Balances Low Budgets with Basic Needs
Reciprocating rod conveying system with low price and simple structure as the core advantage, single line investment cost is lower than the roller bed sled more than 40%. Its 28-second conveying cycle determines the applicable scenario: when the production line beat is ≤20JPH (20 units per hour) and the number of workstations is less than 10, it can meet the basic capacity requirements. However, we need to be vigilant about two hidden costs - the additional positioning fixture investment caused by segmental arrangement, and the plant renovation cost caused by linear conveying limitation. For example, a commercial vehicle plant was forced to remove columns to increase the aisle width to accommodate the linear layout of reciprocating bars, and the civil construction cost exceeded the budget by 15%.
Why is the roller bed sled the default option for 50% car companies?
Roller skid's 16-second conveyor cycle time and flexible turning ability make it in the 25-45JPH medium-high beat production line to achieve the whole life cycle cost optimisation. Shenlong auto Wuhan plant case proves this advantage: through the sled system any turn characteristics, in 8000 square metres of plant to complete the 4 models of mixed line production, saving the original 12000 square metres of the plant expansion plan. But need to focus on controlling the cost of empty skid return, a new energy vehicle enterprises because of the skid return channel is not planned, resulting in workshop channel occupancy rate of 35%, logistics efficiency fell 22%.
The Value Paradox of On-the-Go Fixtures in Ultra-High-Period Production Lines
The ultimate conveying efficiency of 8 seconds for the follow-on fixture can support more than 50JPH production capacity, and by designing the conveyor mechanism and positioning fixture as one, the lifting and lowering device can be reduced to save 12% operation time. Dongfeng Honda's third plant adopted this solution, the annual production capacity of a single line exceeded 360,000 units. However, the cost of a single follower fixture is up to 3 times the cost of the roller skid, and needs to be matched with ± 0.1mm high-precision roller. More critical is its space occupancy rate is 25% higher than the traditional programme, when the workshop area is limited by the need for additional assessment of plant expansion costs.
Three-dimensional decision-making model for accurate cost matching
The first dimension to see the beat threshold: ≤ 20JPH choose reciprocating rod, 20-45JPH with roller skid, ≥ 50JPH consider the fixture. The second dimension counts the hidden cost: reciprocating rod needs to increase the linear layout transformation fee, the roller skid should reserve 15% area for skid return, and the accompanying jig needs to be equipped with high-precision roller bed. The third dimension controls the dynamic variables: Plantsimulation simulation is used to verify the cache requirements under different failure rates, and an enterprise has increased the start-up rate from 82.5% to 89.4% by adding 2 cache positions to avoid the loss of production stoppage due to the blind reduction of the cache.
Breakthrough Strategies When Cost and Beat Don't Go Together
In the scenario of 25JPH but strict budget, we recommend the hybrid solution of "Segmental Roller + Reciprocating Bar": the main line uses the roller to guarantee the efficiency, and the sub-assembly line uses the reciprocating bar to control the cost. In case of 50JPH demand but insufficient budget, the model of "follow-on fixture + shared cache" can be adopted. Duoyuan Intelligence designed a 6-station shared cache system for an automobile enterprise, which reduces the investment of equipment by 35%. For the project of limited space in the plant, the three-dimensional reflux design is preferred. Increase space utilisation by 40%.
Typical Paths to Repairing Poor Decision Making
When the misuse of reciprocating rods leads to substandard beats, it can be remedied by adding parallel stations, but the additional cost of fixtures needs to be accounted for simultaneously. Roller bed sled if the failure rate affects the start rate, should be added between MB2 and MB3 line cache lift, Chery case proved that the programme to improve the overall start rate of 6.9%. the accuracy of the follower fixture out of control, the need to calibrate the positioning point of the roller bed through the laser tracking instrument, a company calibrated to make the product qualification rate from 92% to 98%. all remedial programmes must be met: The cost of a single modification does not exceed the original investment of 20%, otherwise the model should be re-selected.
