Excavator Factory | Mega Manufacturing | Free Documentary

A new high-tech

excavator

is born in record time, the 23-ton sy to15 monster built in just 24 hours. The Lingam

mega

-

excavator

factory

. Robots and machines reign here. Its value is 375 million euros. The most modern technology prepares the work. highly trained specialists produce amazing results a new high tech excavator rolls off the line here every 10 minutes this is a

mega

manufacturing

one of the largest and most advanced excavator factories in the world built from scratch here in greater shanghai industries owned at a cost From With 500 million sunny euros, the Chinese market leader manufactures up to 40,000 new high-tech excavator seats every year in full production, the goal of dominating the world market helps them achieve it, the best-selling model in the range segment average, the Model S y21. 5 its price one hundred and ten thousand euros exceeds nine point five seven meters excavation force 138 kilonewtons the link dong site is almost one million square meters the

manufacturing

operation is divided into three buildings and it all starts here, at the back of the building , on a Monday morning at 10 o'clock a semi-trailer loaded with 75 tons of steel delivery value 32,000 euros Chief engineers Shubin inspects the goods his team will use the steel to build high-quality excavators capable of operating for more than 20,000 hours in the most extreme conditions Chief Engineer Xu is satisfied that production of the new vehicles cannot begin anyone.

This simple steel coating is where it all begins. A perfectly coordinated production chain begins with washing, cutting to size, forming, welding, coating and finally assembly. This basic raw material is transformed into cutting-edge technology. -art machine, I am proud 250 robots and cutting-edge machines will soon turn steel plates into high-tech excavators that were not with extreme precision down to the micrometer to guarantee this level of precision the rust must first be removed just 15 seconds later, everything smoothly and processing can begin the birth of the new excavator, the steel coating is transferred to a precision plasma cutting machine in just one operation, almost a hundred individual pieces emerged flashing to the world, all produced by a single supervisor badge, Lee Yoo.

Min Yong must rigidly adhere to the specified cutting pattern, but there is a problem: the steel plate is not perfectly straight. Supervisor Lee, you must now realign the plate exactly or the machine will cut past the edge, causing delays in the production line and losses. of several thousand euros the plating steel was slightly avoided the machine now has to compensate for this if the steel plate is cut at an angle the shapes will not be correct we have to reconfigure the machine there at the front and back so that the plate no longer it is crooked for the robot finally the plasma cutter no longer starts Corrections can be made now or all the parts will be imperfect and unusable an arc cuts the 80 millimeter thick steel plate using an electrically conductive gas the temperature at the site Cutting speed 30,000 degrees Celsius The great advantage of the plasma method The cutting speed is four times faster than with a conventional cutting torch, leading to greater productivity and overall precision 20 square meters of raw steel produces one hundred and eighty pieces individual pieces for the excavator that requires operation only seven minutes supervisor Lee Yu takes into account material waste not even 3% cuts more than 7,000 individual pieces in a single shift that will be collected for further processing in the time allotted to meet With the strict objectives set by the company management the task of producing a new excavator every 10 minutes the cut pieces continue their journey along a public road to building number 2, where the modern welding plant is located, the robots have taken over almost total control, here we are only humans responsible for starting the processes, then they hand them over to the pre-programmed experts, the humans begin to fasten the various cut parts of the undercarriage and the fixings.

This is just the preparatory work the actual welding operation is done by robots. Human precision here is of utmost importance. The machines on the welding line may be fast and accurate, but if parts are clamped incorrectly they can't do anything about it. This is the central element of the future excavator. The turning track. This is where the rotating superstructure and landing gear connect. within a 120-tooth ring gear and a 12-tooth sprocket that drives the assembly. The excavators can rotate on their own axis. The slewing ring is subjected to enormous forces. The connection must remain stable even under a load of four tons.

The workers alone They have ten minutes to join the components with millimeter precision the parts are temporarily fixed with ten centimeter welding points then the robots take control from now on human intervention is limited for control purposes only the state-of-the-art welding installation cost The 40 million euro investment has long since paid for itself. By itself, the work of robots is not only more precise than that of a mere mortal, but it is also twice as fast. The first step. The breakaway ring is placed in the center section of the chassis. The flame at the welding point at 1700 degrees Celsius.

Thirty-two robots have replaced. 24 human workers in this production step the processing is now flawless and absolutely precise Automation has increased the longevity of the huge excavators Read an important criterion for the Chinese to prevail in the competitive international market transportation from one station to another industrial accidents were common here in the past, when pieces weighing approximately 3 tons were still moved by workers using cranes and chains, this danger has now been completely eliminated, saving human lives. The landing gear consists of three elements: the center section on which the mud ring now sits and two side sections. This is where the track system will be mounted later.

The excavator is propelled by two sprockets on each side. The track plates sink up to 3 centimeters deep into the ground. The giant machines have to maintain their grip even on slopes of 70%. The final leg of the welding line joins the three human undercarriage elements, again only necessary for preparatory work throughout the

factory

as a whole. Increasing automation has led to a one-third reduction in manual labor. work and at the same time production has increased and with this the benefits of each movement made by the machines is recorded electronically, if the robot remains motionless even for a second, the company's control department immediately records the downtime. control center responsible for the mega excavator The factory is located almost one hundred kilometers northwest of Lin Ghana, at the Sony facility in Kunshan.

It is where real-time performance data is collected. Controllers also have access to cameras that monitor the line of robots. The images are sent to a 40 square meter screen. Pond Boy Gun and his team analyzed the data in order to further increase consolidated profits. The annual profit last year was about six hundred million euros if more orders are received. The Punt assistant manager increases production speed if individual machines are offline. Adjust the production schedule accordingly. They have over 30 welding machines in Lincoln and I have all the data for them. machines here everything is connected through the RTD network the civil one for example we can monitor a Panasonic welding machine has been on for 2.26 hours today and has been running for 1.78 hours its operational availability is ninety six points 81% a real operating ratio is 78 point 87 percent its power consumption is 17 point 30 kilowatt hours, as you can see, we have all the key data at our fingertips.

The position is ouya, the contour is the wrong formula, a masterpiece of internal data management back to the factory and linked to the distance by car, a good few hours of travel, data exchange between works takes only a few milliseconds , the welding of the excavator undercarriage is finished, it is now ready to be painted, absolute precision is required despite the temperatures of 40 degrees Celsius, the tolerances for the paint job are in the micrometer range The factory Lin Gong excavators, built from scratch in just 12 months, when operating at full capacity, Sunny could, in theory, produce 40,000 excavators here each year.

Transportation from one station to another. Perfect design. The welded parts are transported directly to the paint shop by an automatic overhead cable. Increasing speed and productivity is like renovating a room at home: First the surfaces are clean, then workers mask the areas that shouldn't be painted. The paint shop foreman, Kwangji Sheng, works eight hours a day and wears a protective suit, usually in sweltering conditions. But despite this, working here is his dream job. I really like working with paint. I like the smell. Coating the pieces with paint is a big job. I can take a product with a rough surface and improve it step by step until it's perfect. doing a sloppy job the vehicle will not be adequately protected against corrosion at the points that receive two thinner layers rusty excavators this would be a disaster for the image of the Chinese company reliability and performance are paramount workers only have eight minutes then the section lowers the line to receive its actual finish the primer has left some minor imperfections foreman Wong's people rectify them in just 40 seconds now comes the most difficult part they have only ten minutes to give the landing gear a black paint job perfect job precision in extreme conditions and 40 degrees of heat and with a respirator as he did that to pinch it.

The most important thing is that the spray nozzle always remains perpendicular to the surface and at a distance of 20 to 30 centimeters if the paint layer gets too close. it will be too thick if it is too far away the coat will be too thin painters must work very precisely to ensure the thickness of the coat is correct if two thinner coats are applied the slightest scratch will allow the primer to show through if it is too far thick the cost of the material will increase and reduce the important margin a few years ago this operation was automated for a short period but the management decided to retire the robots again, in this case they were too inaccurate and as a consequence they were replaced by humans the massive parts hang due to two chains swinging slightly back and forth, the robots were unable to compensate for this with sufficient precision.

I use this meter to verify work. I press it firmly against the surface and check the scale to see how much paint has adhered and at what point the paint has adhered. The layer here is 125 micrometers thick according to the specifications, it should be between 80 and 140, which means this product is acceptable. Welman, on your nose, your posture passes until the moment you know that the parts are already painted, the excavator will soon be taken to Life on one of the most modern production lines in the world works non-stop, the pressure of time is the final assembly of the high-tech monsters, but how do the freshly painted parts get to the assembly building without getting wet?

The Chinese solved this problem by building a tunnel. 120 meters long and 10 meters deep connects building 2 with building 3 this is where the final assembly line is located here a new excavator is produced every 10 minutes at the end of the tunnel one of the most modern temporary storage facilities in the world and is also the start of the final assembly line the 10 meter high warehouse ensures a constant supply of components are spaced for 20 pieces on each side a detailed schedule indicates which part is needed when the fully automated crane transports the items from its storage place to the production line, which makes Lin Gong mega factory unique, the final assembly line allows the Chinese to not only manufacture a large number of excavators, but also different models on the same production line. assembly, depending on demand.

Chief Engineer Shoe Bin has a complete overview of this. the screen is updated every few minutes everything is recorded each serial number and the sequence of models this shows us how many parts are delivered that day and how many excavators we have to produce here the number varies from day to day showing the number The third day of the week this year, the fourth, we can control every detail of the manufacturing process and we have the production rate under control at all times. The four-ton undercarriage must be delivered first, which used to be necessary for theassembly workers. and it took five minutes and unfortunately industrial accidents were not uncommon today this task is performed by a robot in just 50 seconds the workers can now install the guide wheels for the rail system more than 3000 screws pass through the hands of each worker each day to manufacture up to 50 new excavators, final assembly robots and human specialists working in perfectly coordinated synergy.

The megafactory houses 375 million euros of heavy robotic machinery. The tracks will later pass over these rollers. They must be able to maintain their grip on 70% slopes. on site an assembly error at this station that put the life of the excavator operator at risk the time has come to assemble the tracks wound around two large guide wheels and nine small rollers 49 interlocking track links on each side will hold more After the 23 one-tonne machine runs at a speed of up to six kilometers per hour on the production line - a team works in parallel on the superstructure, here too the production schedule must be strictly adhered to in order to meet the immense production figures. daily production of several dozen Cab shells in black and yellow await installation.

Workers first install the inner equipment of the calves. One hour of manual work for the seat control equipment and electronics. This is the important operator interface directly behind the driver's seat. A component that sets new standards in the sector. global market a highly intelligent black box the high-tech device records all key performance data of the superstructure during operation engine parameters fuel consumption hydraulic system oil pressure if their values ​​deviate too much from the set points it is activated an alarm that is transmitted in real time to the control center thousands of kilometers away from kun-sun in the northwest of Shanghai all vehicle data is collected in Kunsan from everywhere around the world 24 hours a day Pond Regan is proud of this technology at peak times up to half a million sunny vehicles are online its team detects technical problems immediately, usually before the driver operating the excavator does, regardless of which continent you are on, we have a complete Here we have an overview and can take action ourselves.

This is a great advantage if the parameters of an excavator are unusual, a red alarm is triggered, for example, if there is a problem with the taste of the oil, our colleagues contact the customer by phone or via the Internet. and inform them of the situation, as a result we can provide better customer service than our competitors, a big advantage in the battle for greater market share, but the Chinese want to impress customers with their innovations and service in lingam el development. The department continually tests new features. The excavator of the future. As will be? This red test model is also a two-one-five system, but it is equipped with the latest generation of high-tech special equipment.

The key new feature: the excavator can be controlled remotely. The driver can control about a thousand different movement sequences using a joystick, including a great advantage from a long distance. Excavators like this can be used in very stressful or even life-threatening environments. The driver's seat of the special edition model s y21 5e. remains completely empty and sunny, similar machines were provided to help in the cleanup work in Fukushima thanks to remote-controlled excavators, in the future no driver will have to expose themselves to radioactivity or other dangers and in extreme situations like this, the Chinese can control the machines even from very far away a cabin an excavator operator and a virtual reality helmet not much more is needed to control the tuner 23 during the tests, since here the excavator of the future is only a few meters away, but in case of emergency the operator can control an excavator elsewhere in the world from his Lingam cabin and if necessary on a completely different continent, the only prerequisite is 5g network coverage in the deployment area, then It is possible to control the vehicle in real time from anywhere in the world to production line two, the clock is ticking. 2 1 5 should be completed in 4 hours workers install the seat directly in front of the black box key components are installed in the superstructure every 10 minutes the hydraulic pump feeds the arms and blade with an oil pressure of 300 bar this allows excavator to lift weights of one and a half tons the cabin air conditioning system fully soundproofed panoramic vision operator safety is a key consideration for sunny days and for customers a five-liter Japanese Isuzu engine power 128 kilowatts finally the superstructure is finished The most complicated and the most dangerous stage of final assembly is before two production lines join under the carriages and the superstructures arrive at 10-minute intervals.

The final preparations have the first production line. Workers fill the rotating ring with grease this is the junction between the landing gear and the superstructure where the wheels meet the engine and the camp is where the excavator rotates the critical 360 degrees in just five seconds with the least possible resistance the enormous superstructure will soon be mounted on the speed of rotation a special adhesive provides an initial grip directly after the two sections made contact but when exposed to air and only act for a short time once applied every second counts for the workers the time has come for the so-called marriage can begin a crane system transports the rotating superstructure that now weighs 12 tons to 20 meters long in the air the difficulty of the superstructure swinging back and forth about 20 centimeters shift worker Seung Jin Jung is responsible for this critical step, He and his two colleagues must maneuver the swinging cabin up to turning speed with millimeter precision and do it as quickly as possible.

Because the adhesive is constantly losing its effect, we have been specially trained for this job, given precise instructions and what needs to be done, we have to work quickly but carefully, it can only be done if you have good reactions, your eyes and your brain. and the hands must act together experience is also extremely important the critical moment has arrived the enormous superstructure is still swaying alarmingly and suddenly everything is going very quickly done the workers secure with bolts the connection maintained until now by the adhesive the next big moment Assembly is approaching quickly, there are only a few final operations left to carry out the oil and fuel, they are added to the tanks and finally the excavator can move under its own power for the first time, but the entire front section is still missing A lifting system with massive arms and flexible hydraulics is missing. systems and the lunchtime digging bucket, even for shift workers who have just maneuvered the superstructure to the undercarriage the company management strictly controls the work and rest periods using a facial recognition system a recognition system facial records when we arrive at work and when we leave the modern clock cannot be fooled it stores your photo along with the exact time you are heading to the canteen in an orderly manner it is not a requirement but it is certainly a wish everyone here feels more comfortable With a certain order, 1600 people work here and one of the largest and most modern excavator factories in the world.

Lunch is served in several shifts. Workers can choose between three different meals. The price is one euro. Rice and soup are

free

on average. worker at Lyngen earns 1,500 euros per month the back of the building 2 Here begins the critical phase of installing the excavator arms. A hundred excavator arms are stored here. One thousand tons of steel, enough for two days. Freshly painted arms should not come into contact with rain during final assembly. In the event that they are not protected by a tunnel but by a bridge that connects building two with building three at a height of eight meters, the workers now begin to assemble the complex articulated arm, especially important are these thin hoses with a diameter of only 2 centimeters, the hydraulic oil then flows through them under extreme pressure, the hoses must be able to withstand it but still be elastic and flexible.

Chief Engineer Shubin checks that they are installed correctly. He knows how important these hoses are. Extreme pressure additives flow through them to withstand the immense pressure. The hoses are reinforced with four to five overlapping layers of wire on the inside, these are surrounded by two layers of plastic on the outside, allowing the hoses to stretch to accommodate movements while still being able to withstand the extreme oil pressure. Correct installation of the hydraulic system is absolutely critical. When in operation, the bucket can be up to ten meters from the excavator's center of gravity, but even there it must be able to lift and turn one and a half tons.

At the heart of the hydraulic system is the pump with a capacity of 200 liters. of oil per minute generates a working pressure within the hoses of more than 300 bar feeds all hydraulic components boom cylinder arm cylinder bucket cylinder this is necessary for the bucket to reach its maximum digging force of 138 kilonewtons the final push on the assembly Line workers attach the prepared arms to the excavators after less than 23 hours of work. This new 1/5 system is almost finished. Sunny has nearly doubled its annual profits in the excavator segment, the construction machinery giant displays most of its vehicles in China, but is now increasingly looking to grow its business abroad, a slightly less expensive strategy than its European and American counterparts to attract new customers and a little more expensive than the Koreans, whom they want to get out of the market with higher quality and greater reliability. the final touches now only remains to attach the bucket to the excavator it is already finished a new to15 system is underway it is worth 110 thousand euros like all vehicles the next stop is quality control even in its maximum range of nine point five seven meters the hydraulic system must still operate at full power the test center is located a few meters ahead, at the end of the building 320 meters high approximately one thousand square meters extreme stress tests strict inspectors the newly assembled excavators now have to demonstrate what they are capable of meet the requirement when in use, over a thousand different motion sequences, the most important 200 will now be tested before the test drive, then fill the hydraulic system with oil, the stress test starts while still running on the first test of the excavator. drives early runs through the most important basic functions killing two birds with one stone in the process the oil is distributed evenly and he gets his first impressions at the same time with authority we have just filled the new machine with hydraulic oil The most important thing right now I want to filter the hydraulic fluid in each system and oil tank to ensure oil purity.

The next station here is the tracking tested, the tracking systems are perfectly installed and can the 23 ton monster. drive in a straight line you check the deviation by driving forward and backward down there is the reference line we check if the deviation is within our tolerance range when the excavator is driven at a distance of 20 meters our standard is very strict the allowed deviation 20 centimeters here there are only eight everything great the hydraulic systems test the bucket rises to a height of almost 10 meters and lowers again five times in a minute the flexible hoses withstand the oil pressure now it's up to the rotating crown five rotations in just 25 seconds in both directions technicians perfectly join the superstructure and landing gear the excavator passes the test the functional test of a new model takes 30 minutes to properly test the procession of new excavators four test operators are required in service at the same time, test drive early, live his childhood dream every day, drive an excavator in extreme conditions and get paid to do it too.

Luda, it really is fascinating work. I am involved with excavators in my spare time; I like the extreme. Challenges in the cab I even won an award on a TV show as an excavator operator. All tests passed. One in six new excavators per hour is ready for sale. The chief engineer. Heshoe container continues the final test, and does so with some pride. In just 24 hours of work, a few pieces of sheet steel have been transformed into a new high-tech excavator. I have worked in the excavator industry for many years and am very proud of the advancements over the last few years.

It is impressive to see the performance and quality of excavators in China continually improving. Another system15 has been born on the market. Manufactured in one of the largest excavator factories in the world. The capacity of the state-of-the-art plant is enormous. By operating a three-shift system, the Chinese could flood the market. up to 40,000 excavators each year