Foton Motor Co., Ltd.

- India
Projects assembly shop
TCF line

2. Complete supply list

No. Conveyor line name Equipment Type Quantity Unit Remark

Cab interior assembly
1 Slat chain 2 piece
line
Dashboard sub-
2 Friction trolley line 1 Set
assembly line
Door sub-assembly 4 inch power and With hanging
3 1 Set
storage line free chain steel structure
Single chain trolley
4 Frame pre-assembly line 2 Set
+ double slat chain
The chassis line +final Single chain trolley
5 2 Set
assembly line + double slat chain
Frame turning-over With hanging
6 2 Set
machine steel structure
The battery box sub- Double roller
7 2 Set
assembly line conveyor line
Engine - gearbox
8 slat chain 2 Set
assembly line
Front axle sub-assembly
9 6 Set
stand
Rear axle sub-assembly
10 4 Set
stand
11 Double rear axle leaf 4 Set
spring balance shaft sub-

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 assembly station

Factory basic parameters:

7.1 Plant Overview
All plants are new.
Chassis assembly part of the plant length 144 m, total width of 56 m. Portal frame plant, lower chord
10m, side columns and column are 8m.
Assembly shop and plant length 400m, the total width of 100m. Steel truss plant, lower chord 10m, side
column 6m, column 24m, truss 4 6m.
7.2 Process Parameters
1) year working time: 251 days, single shift work system, each shift 8 h, 5 days per week.
2) annual output: 50,000 / year (each assembly line),
3) takt time: 4 minutes / vehicle (2 Lines); 3 minutes / units (single line)
7.3 Utilities dynamic parameters
1) Power supply voltage: AC 440V 10% 50HZ 1HZ (Three-phase five-wire system)
2) Compressed air: 0 .6 Mpa
3) Use of the environment: the maximum temperature of 60 C; minimum temperature 0 C; humidity
50-98%
7.4 Product parameters
The B platform H4-
A platform H4 ETX-H3-aging
European version of
upgrading product products
the product
Project
EXT-H3 model
Concept car Concept car Concept car Concept car (maximum parameter
models)

BJ1317VNPJJ
Model BJ4183-A1 BJ4183-A2 BJ4183-A3 BJ4183-B BJ4253SMFJB-S3

8x4
Drive form 4x2 4x2 6x2 4x2 6x4

12000x2495x33025
Foot Dimensions (mm) 6145x2494x3500 6145x2494x3500 6915x2494x3500 5810x249 4x3453 6915x2495x3460/3760

Inch Wheelbase (mm) 3600 3600 3300 +1350 3600 1700 +4800 +1350 3300 +1350

Tread (front / rear)

2005/1800 2005/1800 2005/1800 2020/1800 1930/1847 2005/1800
mm
Participate
Front / rear
1440/1105 1440/1105 1440/825 1440/770
overhang (mm)

The Saddles front

Number 550 550 340 550
distance (mm)

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 Curb weight (kg) 8050 8050 9990 7 610 12050 9880
Quality
Full load weight
19000 19000 32000 18000 31000 32000
Amount (kg)

Participate
GVW (kg) 50000 50000 60000 40000

Number

8. The sub-line equipment Main technical parameters and technical requirements:

8.1 cab interior trimming line (two):
8.1 .1 Main technical specifications and the corresponding parameters:
Structure: ground slat chain;
Slat width: 4000mm;
Head and tail center distance: 152000mm
Number of stations (each line): 35 +2 (loading and unloading)
Station distance: 4000mm
Line running speed: 0.5m / min ~ 2 m / min (frequency control)
Cab Weight: 650Kg without interior trimming, 1000Kg with interior trimming;
1 .2 structural characteristics
Automatically returns to single slat conveyor pallet with fixtures.
Using two single flanging chains to drive conveyor slat. Add two roller in the middle to ensure
rigidity of the chain slat.
Each unit modular assembly into one shipment.
8.1.3 Structural characteristics and technical parameters of each unit
8.1 .3.1 drive station
Structural features:
The motor selection directly connected deceleration inverter motor, in order to adapt to the 0.5
2.0m/min frequency control requirements.
SEW gear motor.
The tension of the drive chain (sleeve roller chain) through the the bolt top wire tension.
Base and embedded plate welding.
8 .2.3.2 head frame
Structural features:

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 The modular assembly of the entire drive shaft means connected with welding structural frame
bolts. The adjustment is completed with square steel head frame skeleton welding.
Drive frames are made of welded steel, the main direction of the force and bracing, can provide
sufficient strength and rigidity.
To feet with adjustable height device, easy installation. Adjustment is completed with the
embedded plate welding.
1 .3.3 tailstock
Structural features:
Tension with casting Slider Block spherical ball bearing tensioning shaft, the drag tension screw,
nut, which is a mature structure, a large number of plate conveyor.
Drive frames are made of welded steel, the main direction of the force and bracing, can provide
sufficient strength and rigidity.
To feet with adjustable height device, easy installation. Adjustment is completed with the
embedded plate welding.
8.1 .3.4 intermediate piece frame
Structural features
Beams undergo a rigorous strength and stiffness of the sheet frame beams with steel structure;
On the right track rail (GB11264-89) with a pressure plate fixed on the chip rack. Lower rails
with angle steel with an on-chip frame welded wheel contact surface material for 16Mn.
8.1 .3.5 chain
Structural features
Two single flange chain.
Selection of domestic famous product.
Conveyor Chain Care roll the installation of ball bearings, lower operating resistance, avoid
crawling.
Care roll the outer side of both oil filling and oil cup, to facilitate the filling dry oil maintenance.
It features automatic chain lubrication oil lubrication system, lubrication device famous domestic
brands.
8.1 .3.6 conveying plate
Structural features
Two 6mm thick tread plate bent into a U-shaped buckle welding, to ensure sufficient rigidity to
support the weight of the entire powertrain.

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 Countersunk head screw and lock nut structure connected to the conveyor chain.
8.1 .3. 7 maintenance pit
Along the length of the line body at intervals between 15 meters staggered set up a maintenance
pit, pit equipped with emergency stop station and 36V security lighting;
Line edge located on both sides 350mm wide cover, easy to observe the conveyor chain running
state;
Pit cover screwing, tread plate cover;
8.1 .3.8
Plate chain was designed with the body support bracket backward program;
With a work around in the cab on the interior line riding, convenient online assembly of the cab.
The step units screwing in the transportation board, with the transport board perpendicular to return.
Install air horn station design platform around the platform to achieve air connectivity .

8.2 Dashboard conveyor line

For dashboard sub-assembly, consisting of driving device, roll assembly, ground rails, inlet guide
device and dashboard assembly trolley.
8 2.1 Main technical specifications and the corresponding parameters:
Station distance: 30 00mm
Effective Station number: 10
Assembly trolley number: 16
Line width: about 00mm
Trolley size: 20 00mm (L) 00mm (W) x 00 (H) (to be determined after drawing countersign)
Process line conveying speed: 1 .0 m / min to 2 .0 m / min
Dashboard Weight: 70 Kg

8.3 door sub-assembly conveyor line

8.3 1 general description and parameters
1) The door sub-assembly conveyor line using 4 inch wide push rod power and free conveyor line
about 370m, conveyor speed 12 m / min, push rod head distance 2048mm; the process speed 0.5-2m / min,
push rod head distance 1433.6 mm. Conveyor line for door storage, transportation and sub-assembly.
Disassemble door on cab storage line, use lifting device for door assembly. Across the line there a total of
about 80 sets of hangers. Each hanger carries two doors of the same cab.

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 In order to facilitate the hanger and vehicle set maintenance, repair area is reserved under hanger zone.
Hangers to be repaired will enter this repair area and return to main line after repair. Hangers and vehicle set
to be changed are unloaded by lifting device.
2) Technical parameters
No.
Item Eye
Unit
Parameters
1
Use

Storage, sub-assembly and transport of the door

2
Door size
mm
1200 250 1200
3
Conveyor Model

4 "wide putter power and free Overhead conveyor

4
Production program
60000
5
Takt
min
3
6
Line length (bearer)
m
About 370
7
The number of hanger
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 A
Approximately 8 0
8
vehicle set type

3
9
power and free length
mm
2050
10
Chain Model

X-458
11
Chain pitch
mm
102.4
12
push rod head distance (fast chain)
mm
1433.6
13
push rod head distance (slow chain)
mm
2048
14
The number of driving unit
A
2
15
Speed adjusting mode

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The fast chain constant speed, slow chain frequency control
16
Running speed
m / min
The fast chain 12 slow chain 0.5 to 2 .0
17
The number of assembly station
m
12 (station distance 2867.2mm)
18
Door lifts (2)
Structure
Vertical belt lift

Vertical lifting stroke

About 6000 mm (designed to determine)

Running speed
5 -24 m / min Frequency Control

Locate
Automatic positioning

8.4 Frame pre-assembly line

8.4 .1 The main technical specifications and technical parameters accordingly:
Station distance: 1000 mm
Effective Station number: 10
trolley height from ground: approximately 440 (countersigned drawings to finalize the)
Line speed: 1 ~ 3 (frequency control)
Line head and tail center distance: about 125200mm
Workpiece weight: 5000 Kg

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 Chain pitch 2 0 0mm.

8.5 chassis line + final assembly line

8.5 .1 The main technical specifications and technical parameters accordingly:
Use: Used heavy truck final assembly
Effective operation station number: 25 + 6 station
Station spacing: 12000mm
Trolley support surface height: 350mm;
Front section head and tail center distance: approximately 30 9 05 0 mm
Rear section head and tail center distance: about 72 000 mm
Line speed: 1 m / min ~ 3 m / min (frequency control)
Workpiece weight: 10000 Kg

8.8 battery box sub-assembly line

8.8 .1 corresponding technical specifications and technical parameters:
Line total length: about 10600mm
Operating height: 700mm (final number subject drawings countersigned)
Effective station number: 5
Station distance: 2000mm
Quality of workpiece: 100kg
8.8.2 Number of pallets: 7

8.9 Engine - gearbox assembly line

8.9 .1 The main technical specifications and technical parameters accordingly:
Structure: ground slat chain;
Plate chain width: 2000mm;
Head and tail center distance: about 32000mm
Effective Station number: 12
Station distance: 2500mm
Crankshaft center height: 800mm
Line running speed: 0.2m / min ~ 0.8 m / min (frequency control)
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 Workpiece weight: 2000 Kg

8.10 Electronic control system

8.10.1 Control layer
The core of the control of each device are selected Siemens PLC, the PLC should be set to Ethernet
Ethernet interface module, to the scene of the data transmitted to the upper control layer.
When PLC programming, equipment all production control information, device status and fault
information should be stored in the PLC consecutive data registers, and the meaning of the data be stated for
future monitoring layer directly.
Final acceptance former factory system integration, Party B should be free of charge to assist Fukuda
development and debugging work.
8.10.2 device layer
Each device Siemens PLC and ELCO fieldbus module through the PLC I / O modules are connected
directly with the field components, or form of network PROFIBUS-DP fieldbus module with on-site sensing
and actuator such as.
The standards adopted by the design and manufacture of electronic control devices
- Design criteria based on national standards and relevant international standards;
- Manufacturing standards based on national standards and international standards;
8.10.3 General technical requirements Description
1. Voltage rating and protective measures
The main power
- 440 V 10% 3-phase 50 HZ 2 Hz
- Master switch must have over-current and under-voltage protection function
Auxiliary voltage

Control loop AC 22 0V 50Hz or DC 24V

Control equipment power circuit AC 220V single phase 50Hz
The control cabinet fluorescent lamps AC 220V single phase 50Hz
The outlet of the control cabinet AC 220V
Dedicated control circuit DC 5V to 30 V
AC induction motor AC 440V 3 phase 50Hz
Control voltage AC 220 V 50Hz or DC 24V
PLC input voltage AC 220 V
Indicator, solenoid valve and limit switch DC 24V

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voltage

heavy truck assembly line equipment color requirements

No. Markers Color Color label Remark

1 The lift moving parts moving parts Yellow RAL 1018

2 Stop, only retreat Fire red RAL 3000

Lift column machine operation and
3 Light gray RAL 7035
stationary parts
4 Electrical cabinet Light gray RAL 7035

5 Steel structure White RAL 9010

6 The fixing member Light gray RAL 7035

Conveyor line (trundle bed part and the
7 Light gray RAL 7035
conveyor line framework)
8 Hoist frame Light gray RAL 7035

9 Scissor lift platform Yellow RAL 1018

Machine chasing platform (upper
10 Light gray RAL 7035
surface)
Machine chasing platform (lower
11 White RAL 9010
surface)
12 Platform handrails Yellow RAL 1018
Yellow and RAL 1018
13 Bumper
black RAL 9005
14 Control box Light gray RAL 7035

15 Equipment protective railings Yellow RAL 1018

Color label
16 Plate chain conveyor plate Orange provided by the
owner

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