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Ministry of Industry announced the 2018 list of intelligent manufacturing pilot and demonstration projects, China Aviation Development Shanghai Commercial Aviation Engine Manufacturing Co., Ltd. (referred to as "business development to create") commercial aircraft engine intelligent assembly pilot and demonstration among them, which undoubtedly confirms the companies made manufacture exploration and practice of intelligent manufacturing. The face of the global technology and a new round of industrial revolution, manufacturing companies made a profound understanding of intelligent manufacturing company will be the implementation of innovation-driven development, achieve development mode transformation and upgrading of key initiatives to catch up with the world's advanced level of the aviation industry as soon as possible, and to propose the efforts to build China's first strategic planning commercial aircraft engine plant intelligence.
Domestic manufacturing companies made a high bypass ratio assembly and delivery center of commercial aircraft engines, aircraft engine products bear the manufacture, testing, testing, assembly and commissioning tasks, and final delivery to meet the design requirements and customer requirements. On a global scale, with fully independent development of civilian high bypass ratio turbofan engine capacity of only the United States (General Electric, Pratt & Whitney) and the UK (Rolls-Royce) two countries. Western countries expressly prohibit the export of related technologies.
As a research subject and the main manufacturers of large passenger aircraft engine manufacturing companies made a profound understanding of intelligent manufacturing company will be the implementation of innovation-driven development, achieve development mode transformation and upgrading of key initiatives to catch up with the world's advanced level of the aviation industry as soon as possible, and made efforts strategic planning to build China's first commercial aircraft engine plant intelligence. 2018 intelligent manufacturing and selected pilot projects of the Ministry of Industry, the company is exploring intelligent manufacturing, for the country to build a strong "Chinese Heart" boost "China Dream" is significant.
Business development Manufacturing uphold national will, independent research and development of commercial aircraft engines, as an innovation-driven enterprise, business development manufacturing planning through digital, networked, intelligent tools, and gradually build innovative self-developed system, to achieve the digital product definition, digital manufacturing and digital management, promotion of distributed collaborative design and collaborative manufacturing, and ultimately provide superior quality commercial aircraft engine product delivery and customer experience.
Intelligent Manufacturing Strategic Planning
Since the beginning of 2015, we set about building intelligent manufacturing planning and special projects one after another through the intelligent manufacturing countries and regions, pilot building to certain key processes for the implementation of commercial aviation engine carrier, according to the airworthiness requirements and aircraft engine development features to intelligent manufacturing, operations in parallel, collaboration and mutual assistance as a starting point, the application of advanced information technology, intelligent robotics, intelligent perception and decision technology, advanced manufacturing technology, high trusted network technology, the development of intelligent assembly robot, build a heterogeneous network DNC manufacturing environment, with a view to gradually improve the quality of management and control of commercial aero-engine pilot process, to build commercial aviation engine intelligent manufacturing the new model.
As business around the business of manufacturing hair Development Corporation assembly and delivery center, which undertakes the manufacture, testing, testing, assembly and commissioning of commercial aircraft engine products, and final delivery to meet the design requirements and customer demand for products the company positioning, proposed the implementation of the Manufacturing Business intelligent manufacturing objective of the strategy:
Manufacturing intelligence quotient hair factory overall goal is tooling around commercial aviation engine / transition piece / core parts processing, parts / unit body / machine assembly and components / core machine / machine test test three core business, product life cycle and high performance digital integrated management system as the basis for aero-engine products and their key components production decisions, process control intelligent, engaging with network interconnection, human-computer interaction, intelligent sensing and other features CPS construction business, eventually built to meet customer needs and achieve sustainable modernization of commercial aviation engine factory intelligent excellent delivery.
Companies made the development of intelligent manufacturing plant in principle the overall goal is to fully meet the four characteristics of intelligent manufacturing Made in China 2025 definition: intelligent plant as the carrier, the key manufacturing sector intelligence as the core, the core-end data flow, Netcom Internet as support. The overall objective of the implementation period corresponding to 2016 - 2025, three stages, each stage objectives:
The first phase (2016 Year - 2019): complete intelligent plant common infrastructure planning, infrastructure construction safety security conditions, standards, networking, manufacturing intelligence and other basic technology research, breaking a large part precise docking, high-pressure compressor rotor assembly straight self-locking nut is tightened, the concentricity of the evaluation of the engine represented by the intelligent key assembly technology, the basic realization of high bypass ratio engine core aviation intelligent assembly;
The second phase (2019 --2022): The ongoing construction of the plant to improve intelligence support facilities based on breakthroughs in key core components of the adaptive processing, intelligent setup, processing on-line monitoring and other intelligent processing technology, smart or intelligent workshop production line construction intelligent processing core components of the carrier, to further strengthen the high bypass ratio engine core assembly capacity, intelligent assembly machine to achieve breakthrough and intelligent experimental test;
The third stage (2023 --2025 years): basically completed Internet-based industry, the whole process of digitization, with a certain adaptive capacity to meet the high bypass ratio engine assembly of commercial aircraft engine plant requires intelligence, test, test tasks, 2025 an annual output of high-quality bulk X NTU off the engine capacity to deliver.
Based on the principle of overall planning step by step, and business development in manufacturing fully draw RAMI4.0, China "national standard construction Intelligent Manufacturing System Guide" and other intelligent manufacturing standard model at home and abroad, with its own business characteristics, business development proposed the overall architecture of intelligent manufacturing plant. The architecture for the enterprise from top to bottom layer, the Manufacturing cloud providers, business and foundation support layer CPS layer, all levels of planning are as follows:
Enterprise level: enterprise-wide business management layer (Enterprise Portal), responsible for business development throughout manufacturing facilities management business.
Manufacturing companies made the cloud: a private cloud provider made manufacture, refers to the entire plant resource sharing intelligent cloud platform, including business cloud cloud services and data services into two categories.
CPS service layer: information of the physical manufacturing at shop floor level fusion system (Cyber Physical System, CPS), respectively, to achieve commercially manufactured hair intelligent processing, intelligent assembly, intelligent service test testing
Base support layer: the business CPS, cloud manufacturing companies made some technical support and regulate business layer provides, including some common basic resources and infrastructure construction.
Companies made the manufacture of intelligent manufacturing construction work will steadily push forward based on the above milestones and overall architecture.
Intelligent Manufacturing Practice status and effect
Construction of the plant is the need for intelligent largest integrated, collaborative large complex system project to build and run smart plant requires strong management systems and the corresponding common infrastructure platform to support. Status practice made manufacturing intelligence quotient produced mainly in the general infrastructure and intelligent manufacturing pilot construction volume terms. In terms of general infrastructure, management and construction technology system, manufacturing companies made to build a multi-function remote system and collaborative work platform, processes, standards, specifications, instructions, checklists and its corresponding information carrier to achieve effective control of intelligent manufacturing construction work. In information technology, the company has established a comprehensive management system, project management, product data management system, currently under construction digital process management system, assembly execution system, test integrated management information system, distributed numerical control management system, equipment management system the future will also establish a production line simulation systems, supply chain management, production planning management system, materials management system, aimed at the device level, workshop level, enterprise-level and external supply chain hierarchy level support intelligent plant operation and maintenance of information systems .
2015, 2015 Intelligent Manufacturing special project company declared "commercial aircraft engine assembly intelligent assembly of new models" selected the Ministry of Industry, intelligent manufacturing pilot construction officially started. The commercial aviation engine projects the whole assembly of the low pressure turbine installation support embodiment according airworthiness requirements and characteristics of aero-engine, the development of intelligent assembly robot, DNC heterogeneous network structures manufacturing environment, build commercial aviation engines collaborative platform agile manufacturing platform the initial establishment of commercial aircraft engine assembly intelligent things. Currently Smart large parts of the automated docking technology in the project, DNC network interconnection technology, network information security, assembly systems and other key technology research and basic conditions for the construction work being carried out, information technology has been incorporated into the part involved in the actual construction of FIG. process and planning, follow-up support will be an important basis for the construction of intelligent factory.
The project's goal is to commercial aviation engine machine assembly in the low pressure turbine installation for the implementation of the object, by building management and control integration platform, design and manufacture of integrated cloud platform, intelligent platform assembly, agile operational support platform, industry information security systems, preliminary the formation of large commercial aircraft engine data and knowledge engineering, commercial aviation engine build intelligent assembly engineering environment, systems, standards, and smart install the whole assembly of aircraft engines in low-pressure turbine, low pressure turbine installation consistency solve problems, and improve assembly, stable sex, to shorten the product development cycle by 20%, productivity increased by 20%, operating costs by 30% once the assembly failure rate reduced by 10%, energy efficiency increased by 4% target, explore a new aero-engine intelligent manufacturing the new model to enhance the commercial aviation engine assembly level.
Typical case: Commercial aircraft engine assembly and assembly of smart new model
June 2015, the Manufacturing business declared "commercial aircraft engine assembly and assembly of smart new model" project by the Ministry of Industry approved the project, was officially launched. The project is led by the manufacturing business development, Shanghai Institute of Industrial Automation Instrumentation and Technology Co., Ltd. Shanghai Jun artificial intelligence as a reference research units work together.
The project's goal is to commercial aviation engine machine assembly in the low pressure turbine installation for the implementation of the object, by building management and control integration platform, design and manufacture of integrated cloud platform, intelligent platform assembly, agile operational support platform, industry information security systems, preliminary the formation of large commercial aircraft engine data and knowledge engineering, commercial aviation engine build intelligent assembly engineering environment, systems, standards, and smart install the whole assembly of aircraft engines in low-pressure turbine, low pressure turbine installation consistency solve problems, and improve assembly, stable sex, to shorten the product development cycle by 20%, productivity increased by 20%, operating costs by 30% once the assembly failure rate reduced by 10%, energy efficiency increased by 4% target, explore a new aero-engine intelligent manufacturing the new model to enhance the commercial aviation engine assembly level.
Smart schematic assembly platform
基于商发制造自身的业务，融入智能制造的元素，构建商用航空发动机装配协同平台、敏捷制造平台，建立商用航空发动机智能装配物联网，完成商用航空发动机专业数据库的初步建设，并开展数据挖掘，形成商用航空发动机专业大数据和知识工程，实现基于专业大数据和知识工程的产品设计、智能装配、本位检测，装配动态排产，资源的动态调控，以及制造过程的智能管控，打造商用航空发动机总装智能装配新模式，构建全新的商用航空发动机智能装配环境、流程、标准。提升商用航空发动机装配过程稳定性、一致性，提高管理水平，通过建立工业信息安全系统，保障整体运行的安全，打造商用航空发动机总装智能装配新模式，实现低压涡轮的智能安装。
商用航空发动机低压涡轮智能安装业务流程图
该项目以商用航空发动机大部件本体装配为实施载体，包括从产品设计/工艺设计/工装准备到装配过程全流程的管控，基于某型号的商用航空发动机低压涡轮对接装配过程：
1）构建低涡大部件智能装配平台。针对商用航空发动机整机装配中低压涡轮的安装过程，建立商用航空发动机装配过程综合受力、多维姿态对接测量、分析、反馈中多维度智能数据采集、分析、控制机制，建立集成传感器、激光对接系统的多维度自适应低压涡轮智能安装设备。
2）进行工业物联网建设，构建敏捷制造平台。实现装配设备，3D打印设备、数控加工设备、物料配送设备在内的异构敏捷制造，达到设备间数据的互联互通，进而实现生产资源的统一调度、动态管控。
3）研究低压涡轮安装产品设计和工艺设计方法，构建设计制造一体化云平台。开展基于工艺知识的商用航空发动机本体装配结构化工艺设计，通过装配过程仿真分析优化装配工艺，提升装配工艺的正确性、可行性和经济性。
4）建立基于RFID的物料智能配送系统，物料的智能配送并具有灵活的可追溯性，改变传统人工配送、单设备加工、人工装配的制造模式，减少生产各环节的浪费。
5）进行基于大数据与知识工程的智能决策分析与优化，建立管控一体化平台。
6）工业信息安全系统。依据ISO27001信息安全管理体系，建立商用航空发动机工业信息安全
商用航空发动机智能装配新模式总方案
从技术实现层面上看，商用航空发动机智能装配新模式以工业物联网、大数据技术、智能装备为基础，实现物流自动化、装配自适应调整、生产管控智能化，如图所示：
智能分析决策层：运用知识及工具进行优化决策，执行判断。
商用航空发动机装配大数据层：是航空发动机智能装配的大脑，完成信息集成，实现数据与物理对象融合计算，进行数据分类、清洗，按需进行信息分类，形成数据中心知识库。
数据物理交互层：是航空发动机智能装配的中枢神经，包括各种传感器及现场网络的接口和 通信控制，实现生产实施信息获取与数据物理交互。
智能设备物理层：是航空发动机智能装配的感官系统，包括生产系统涉及的设备、工装、人员和物流装置等，以及对物理对象进行感知和信息传输的RFID标识工具、传感器和工业物联网等。
航空发动机智能装配新模式建设
下一步智能升级计划
后续商发制造将依据《商发制造智能工厂建设规划方案》这一纲领性文件，同时考虑已开展的智能制造项目，按照“业务导向、顶层规划、项目驱动、整体推进”的建设思路和“统筹规划、协同推进；基础先行、分步实施；开放合作、创新发展”的原则将规划方案逐步落地，预期2025年建成产品全生命周期过程数字化，科研、生产、运营过程管控网络化等特征的航空发动机智能工厂，持续满足顾客需求并实现卓越交付。
智能制造一直是中国制造2025的主攻方向，航空发动机作为飞机制造业皇冠上的明珠，是智能制造最佳工程实践，也代表了一个国家制造业的水平和能力。相信商发制造在智能制造方面的先进实践对于打造“中国心”，实现“中国梦”具有深远的意义。