Pushing The Limits Of Smart Manufacturing
Process control solutions by Kistler enhance efficiency at the BorgWarner Tianjin plant for automotive powertrains
The BorgWarner Drivetrain Systems plant in Tianjin, China, relies on industrial process control solutions from Kistler for intelligent manufacturing of automotive components. Thanks to electromechanical joining systems, sensors and the maXYmos process monitoring system, BorgWarner achieved state-of-the-art product quality and gained valuable insights that enhanced the production efficiency.
Founded in 1928 and headquartered in Michigan (USA), BorgWarner is a leading manufacturer of automotive powertrain and engine components. 50,000 employees are working in almost 100 manufacturing and technical centers in 23 countries. With sales of almost RMB 15 billion in 2020, China is a key market for BorgWarner. Therefore, the BorgWarner Drivetrain Systems (DTS) Division has opened four plants and an R&D center in the country.
The Tianjin plant is the newest site and began manufacturing components for conventional powertrains in 2015. From initially only one production line, BorgWarner DTS scaled up to 31 production lines for 27 product types for automotive manufacturers and OEMs. Ranging from DQ500 to DL382 and DT450, the product mix for transmission systems meets the requirements of many diverse vehicles.
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Highly automated processes yield high quality components
BorgWarner's Tianjin plant has more production lines and a higher degree of automation than almost
any other automotive supplier in northern China. Even throughout the Covid-19 pandemic, the DTS plant focused on the global Industry 4.0 objectives and implemented China’s smart manufacturing vision.
“We aim to make our production line even more efficient and ensure high product quality at the same time,” explained Mr. Yu and Mr. Fan, maintenance engineers at the Tianjin plant. “We are developing production plans to manufacture different products and multiple batches of components simultaneously on the same workstation – with only small process adjustments or minimal simple modification.”
Reliable and precise control systems
Exponential growth of automated production capacities and the exploration of new ideas and methods have one thing in common: they both rely heavily on robust monitoring systems. Therefore, BorgWarner deployed electromechanical joining systems and measurement technology from Kistler in the Tianjin plant to monitor industrial processes of the automated assembly lines, including the key press-fitting stations for the DQ381 and CVT transmission system product lines.
“We chose measurement technology from Kistler because we needed to ensure our devices comply with the high global quality standards of BorgWarner. It is easy to use and enjoys a good reputation in the industry,” Mr. Fan notes. Several process control monitors were installed when the first independently integrated line went into production in 2016, providing accurate data and functioning well.
The service and maintenance team complimented the low maintenance requirements for Kistler solutions, adding: “They are stable in operation and perform well in terms of precision, flexibility, and user interaction.” Kistler’s measurement technology now allows operators to control press-fit speed and real-time visualization of all parameters in relation to the entire production line.
Seamless integration of process monitoring and joining systems
In addition, BorgWarner relies on electromechanical joining systems from Kistler to maximize the system-level advantages of its solenoid valve assembly: One of the most important benefits of the system is the combination of features of extremely durable piezoelectric force sensors and a monitoring system.
The Kistler sensors are especially suitable due to their high natural frequencies and loading capacity. Together with the maXYmos process monitoring system, BorgWarner is able to measure a broad range of forces and to visualize and analyse single processes in detail.
This customized measurement chain installed at BorgWarner's Tianjin plant can easily be integrated into various molding, testing and joining processes to ensure 100 percent end production quality. Faulty products are detected, separated, and processed at the earliest possible stage – this saves time and costs because unnecessary procedures are eliminated.
The joining system from Kistler includes internal monitoring with two types of sensors: One of them is the position of servo drive and another the force sensor to monitor assembly processes with maXYmos NC. “Its accuracy, controllability and universal compatibility make it a perfect fit for our assembly lines. Throughout the joining process, we can monitor the high-precision force-displacement process – the real-time data we gather from that are used to adjust the movement and force of the head,” explained Mr. Fan.
The smart and prompt response of mayXYmos is the key to seamless and accurate joining in a fully automated production line working at a fast pace with short intervals, ensuring high quality in mass production. Another benefit: In contrast to traditional hydraulic and pneumatic presses, the joining system solution is clean and dust-free, consumes less energy and generates little noise.
Flexibility for changing customer needs
Every product at BorgWarner has specific needs in terms of processes, tooling, costs and subsequent adaptation. Each of the highly automated and integrated production lines requires precise observation of the cycle times for all the systems involved. To achieve increased efficiency and productivity, the press-fit systems must be adaptable to the requirements for a varied range of products and work sequences.
Kistler’s sensor solution, including force sensors and the maXYmos system, is flexible and easy to integrate into existing environments – an important aspect for BorgWarner’s many production lines manufacturing a broad product portfolio. Thanks to their modular design, these solutions optimally meet BorgWarner’s varying needs due to changing process scenarios and integration requirements.
“Measurement technology from Kistler has made it much easier to optimize our production lines and explore ways of improving our manufacturing processes,” Mr. Yu comments. The Tianjin plant will continue to trial advanced equipment applications and use the knowledge to reduce costs, boost efficiency, and lay the foundations for potential product iterations in target markets.
For China's automotive industry, the future holds plenty of opportunities but also some uncertainties – especially in terms of the demands of mainstream markets for vehicles based on alternative power systems.
Current trends may be influenced by policy guidance, new automobile manufacturers, emerging internet companies, and the changing supply chain. With its high levels of industrial automation and process monitoring systems, the BorgWarner Group is prepared for the transformation of technology and the development of electrification.
Kistler Group
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info@kistler.com
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