Dongfeng Limited Blade Tools Factory Automotive Parts Development Team

Not long ago, the EFI engine gear and the 13-ton wheel and side bridge gear developed by the Dongfeng Blades Tool Factory in 2006 were separately qualified for Dongfeng Cummins and the exclusive supplier qualification for Dongfeng Dana Axle Co., Ltd., breaking similar products. In the first quarter, the new sales revenue of the blade measuring plant reached 7.47 million yuan, and 38 kinds of new parts were exported in batches. It is understood that strengthening the development of new products has become an important “tactic” for cutting edge tools to break through in the market competition. The blade measuring plant automotive parts development team is the breakthrough of the leading forces, in 2006 they developed a total of 107 kinds of new gear.

Responsible for the responsibility

The auto parts development team of the blade measuring factory has 2 senior technical experts and 11 young people with a bachelor's degree and an average age of just 30. It is such a young team that undertakes important tasks such as pre-development and processing technology development of auto parts for more than 90% of the blade measuring factory, and bears major responsibility for providing new product support for the company to open up the market.

“The pressure last year was particularly great. Everyone worked hard. In the whole year, a total of 107 new gear products were developed.” Vice Minister Zhou Yongping, responsible for the development of auto parts, of the blade measuring plant's technical department, said that since the 2005 commercial vehicle market, After the declining demand, the production and operation of the blade measuring factory also suffered a huge impact. The product was sluggish and the factory was underemployed. The employees began to complain that the technicians did not develop marketable products. The leaders also hoped that new products could quickly open up the market. This allows R&D personnel to truly feel the heavy responsibility on their shoulders.

Inspired by the responsibility, the blade parts factory auto parts development team has emerged a lot of "hard-witted Saburo." In 2006, due to the large number of new products and the small number of new trial products, the workshops were generally placed in the daytime for mechanical processing and heat treatment at night. The heat treatment engineer Cheng Tao, in order to prevent the deformation of the trial heat treatment products, often worked after the day shift and waited until the evening. Nine o'clock instruction, check the operation of the tooling furnace after returning home, there is a trial of a camshaft gear to be sent the next day, the workshop can not be cold processing until dark, he had to guard the phone and other messages at home It was already 1:00 in the morning when he received a phone call. He hadn’t been able to get it from the airport after he arrived at the scene. He had no choice but to take a taxi home and slept.

In order to ensure the progress of new product development, the blade measuring factory also fully introduced the project responsibility system in the development of auto parts. “Now, as long as projects are started, we will not have regular holidays.” Shu Zhongmao, head of the Gear Product Development Team, with a deep apology for the team, said: In 2006 National Day, QSKV project gears are at At the trial production stage, two types of samples from Dongfeng Cummins require emergency delivery within one week. To ensure the project progress and the timely delivery of prototypes, more than a dozen developers had to take the initiative and some went to trial production site tracking services. The use of gaps to prepare PPAP documents, the National Day holiday almost all soaked in the scene. In March 2007, the young engineer Xiao Zhenbin's lover was just born with children, but it could be completed smoothly for the new KV gears. Xiao Zhenbin only rushed back to the factory to work in the hospital for two days...

“It takes a long period of time from development to profit formation for new products. Although we developed a lot of new products last year, and the developers are very hard, now the profit contribution of new products has not been fully reflected. Everyone is afraid to relax. "Zhou Yongping said.

To overcome difficulties in innovation

They said that “new born calves are not afraid of tigers”. Every time a problem is encountered in development, the young auto parts development team at the blade measuring factory has never shrunk. They firmly believe that “the method is always more problematic than the problem”, and everyone uses their brains to think of new ideas. . As a result, in the process of solving one problem after another, they have become a team that is good at innovation.

In the development of the QSKV project, 3089121 and 3089087 idler gears were formed by press-fitting of two gears, and there was a strict angle relationship between the two gears. This was a product that the blade measuring factory had never encountered before and it was difficult to develop. Big, but only 60 days from design to delivery. A developer had seen the situation of crankshaft and gear heating and press-fitting, and put forward the innovative idea of ​​heating and press-fitting. However, there is no dedicated thermocouple heating device at the blade measuring plant. As soon as everyone came together, they came up with a way to heat the press with unused ovens. At this time, the problem of angle control made them once again get into thinking. Some people suggested designing special tooling, but it would not take long to do so. It would cost more than 20,000 yuan to make a special tooling. The ensuing problems did not discourage the young auto parts development team. They observed and analyzed existing processing equipment, tested and improved over and over, and finally came up with trapezoidal slots using the press table plus two The positioning block and gear sample positioning method successfully solved the angle control problem. So far, the plant has successfully produced thousands of products using the above process.

The export market is an important development direction for the blade measuring factory to seek sales breakthroughs. When developing export automotive parts, the blade parts factory auto parts development team relied on innovation to solve many technical problems. During the development of the 3950135 camshaft gear hobbing process, they found that the floating plate end flange has a strict positional relationship with the processed teeth. The method of positioning the hobbing position while maintaining the hobbing has no experience in the country. Difficult groping once plunged them into confusion, but they firmly believed that “we can do what foreigners can do”. Under the control of this belief, they began a new round of discussion, but also I do not know who suddenly proposed: "CNC hobbing machine in the processing process is not automatically accurate string knife it?" A word to remind everyone, in your words In my discussion, the new method of “positioning the flange, calculating the phase angle of the tooth profile, performing the sample tool setting, and determining the initial position of the hob and the workpiece” was quickly revealed.

There is also the use of split guide sleeve to solve the development of super machining range gear technology, grinding tool substitution ... ... one after another case with innovative thinking, innovation has become a cutting tool factory auto parts development team to overcome the difficult tool.