Engine assembly line conveying method solution: step/chain/AGV comparison

​Fundamental issues: the nature and value of conveyor systems​

​1. Why do engine assembly lines need special conveyor systems?​
As a core component of automobile, the assembly of engine involves hundreds of precision parts, which have strict requirements on positioning accuracy (±0.1mm level), vibration prevention and anti-shift. Traditional manual handling is inefficient and prone to quality problems, while mechanised conveying systems are realised in three mainstream ways:

• ​step by step: Isometric layout of workstations, synchronised movement of all threads, suitable for standardised mass production
• ​chained: Uniform speed continuous conveying, support manual/semi-automatic assembly scenarios
• ​AGV: Autonomous movement based on navigation algorithms, breaking through fixed-orbit constraints

​2. What are the core differences between the different modes of delivery?​
The key differences are reflected inFlexibility, precision, costThree dimensions:

• ​step by stepSynchronisation of the entire line by lifting and panning or push-pull structures (e.g. cylinder pusher, hook chain), low cost but inflexible
• ​chainedSub-fixed bracket plate chain (single species) and activity trolley (multi-species mixed flow), to the ground drag chain drive bearing trolley, with accumulation and put function
• ​AGVFusion laser/SLAM/BeiDou navigation, ±10mm positioning accuracy, support for crankshaft auto-positioning

​Scenario Problem: Selection Logic and Landing Practice​

​1. How to choose the conveying method according to the production needs?​
Selection needs to matchProduct characteristics, capacity scale, degree of automationThree main elements:

• ​step by step: Small engines for cars (<30m line length), standardised production line with annual production capacity of 200,000 units or more
• ​Chain activity trolley: Multi-model engines for commercial vehicles, adapted to different cylinders by changing trolleys
• ​AGV: High-end passenger car/mixed line production, external assembly process with frequent attitude adjustments

Case: An engine factory in Shandong adopts AGV compatible with 10 diesel engine models, and realises automatic identification of models through magnetic navigation + RFID.

​2. What are the special programmes for the transport of heavy engines?​
Heavy-duty engines over 1.5 tonnes require enhanced load-bearing design:

• ​Friction Roller ConveyorTapered roller + double roller bar structure, single point load bearing up to 2 tonnes
• ​AGV Dual Differential Wheel Module: 20-tonne heavy-duty AGV with 5° climbing capacity + 30mm barrier-crossing design
• ​Chain Speed Chain: Horizontal ring layout + accumulation function, effectively reducing pallet wear and tear

​Solutions: Risk Avoidance and Technology Upgrade​

​1. What are the consequences of wrong selection?​

• ​Stepper for mixing lines: The distance between the work stations was fixed and could not be adjusted, and the whole line was shut down for modification when the model was changed.
• ​Chain mounting brackets for automated assembly: Lack of positioning function, tightening machine can not be synchronised with the traveller
• ​AGVs do not consider indoor-outdoor interface: Breakdown of navigation signals triggers downtime, affecting beats

Lesson: A factory chain conveyor line was forced to spend an additional 3 million on renovation because it did not reserve a positioning device

​2. How can conveyor systems be upgraded on existing lines?​
Older production lines can be retrofitted with modularity to increase flexibility:

• ​Step → Chain: Addition of movable trolley tracks, retaining the original drive system
• ​Chain → AGVDeployment of magnetic stripe navigation AGVs in parallel with the existing conveyor lines for gradual replacement.
• ​Hybrid dispatch system: AGV + friction roller synergy, AGVs are responsible for cross-shop transfer, rollers focus on mainline assembly

Practice: Aisino AGV system realises seamless transfer of engines from assembly workshop to painting workshop, saving manual transfer time 40%

​Technology evolution: future trends and directions for innovation​

​1. How do magnetic drive trays solve industry pain points?​
Traditional chain conveyor is prone to deflection in the turning section, while magnetic drive pallet technology breaks through the bottleneck:

• Permanent magnetic guides to control pallet spacing, cornering offset <1mm
• Energy consumption is reduced by 30% compared to chain type, and maintenance cost is reduced by 50%.
• Applied in Shanghai Volkswagen engine plant car assembly line

​2. How does 5G+AI reconfigure the delivery logic?​
The new generation of intelligent conveyor systems presents three major changes:

• ​Dynamic Path Planning: AGV scheduling algorithm based on real-time production data with 30% transport efficiency improvement
• ​digital twin control: Virtual commissioning verifies conveyor beats in advance and reduces the cost of trial and error 60%
• ​Self-aware safety systems: Millimetre wave radar + machine vision fusion for obstacle avoidance, accident rate down 90%

​industry consensus: Steppers still dominate economy lines, AGV penetration in flexible manufacturing scenarios to rise from 35% in 2025 to 60% in 2030