A Certain Shell Digital Machining Cell

• Core Requirements: The client's requirement focuses on the multi-position precision machining of XX shell-type parts made of superalloy materials for aero-engines.
• Existing Pain Points: The existing machining mode suffers from low automation levels, cumbersome and poorly connected processes, and significant fluctuations in machining precision, making it difficult to meet the stringent tolerance requirements for such parts. Additionally, issues such as non-standardized tool management and inefficient quality inspection processes exist, preventing the realization of full-process automated closed-loop production. Consequently, production efficiency and product consistency are hard to improve. Therefore, the client urgently requires an integrated digital machining solution to systematically resolve current production bottlenecks and achieve an intelligent and standardized upgrade in the machining of shell-type parts.

• Core Machining Equipment: 1 turn-milling compound machine and 2 four-axis milling centers, specifically adapted to the characteristics of superalloy materials, enabling integrated precision machining of multiple positions on the shell to balance machining efficiency and accuracy.
• Automated Logistics: A 6-axis articulated robot (equipped with a 7th axis linear rail), custom material warehouse, loading/unloading stations, and a self-developed automatic changeover system construct a full-process automated closed loop for parts from loading, transfer, and reclamping to unloading, minimizing manual intervention.
• Precision Assurance and Quality Control: High-precision zero-point positioning systems, tool setters, vision systems, and identification systems effectively avoid human errors and ensure stability in machining accuracy. Complemented by cleaning stations, marking equipment, and constant temperature CMMs, post-machining treatment, identification, and full-process precision inspection are realized, ensuring quality traceability.
• Integration and Assurance: In-line tool magazines, custom fixtures, safety protection systems, and PCS Production Manufacturing Management Software, combined with a turnkey package, achieve seamless integration of equipment, software, and tooling, completing project implementation through a one-stop turnkey service.

• Efficiency Leap: Full-process automation replaces manual labor, enabling 24-hour uninterrupted production. Compared to the original manual + single-machine mode, the production cycle time is shortened by 42%, and daily output is increased by 56%. This significantly reduces delivery lead times, ensuring worry-free batch delivery of precision parts for clients with stable production capacity.
• Controllable Quality: Relying on the core technology combination of "zero-point positioning + visual identification + full closed-loop compensation," machining dimensional tolerances are precisely controlled within ±0.003mm, and the product consistency qualification rate reaches 99.97%. This thoroughly resolves common industry challenges such as deformation and unstable precision in superalloy material machining.
• Cost Reduction and Efficiency Increase: Through intelligent scheduling by the PCS system and in-line tool magazine management, tool consumption is reduced by 35%, and Overall Equipment Effectiveness (OEE) is increased to over 85%. Simultaneously, manual intervention is reduced, per capita productivity is tripled, and direct labor and rework costs are cut by approximately 28%.
• Worry-Free Implementation: Full-process turnkey service covers all aspects from solution design, equipment configuration, and integration debugging to later-stage operation and maintenance. This reduces the client's project implementation and operation management costs while accelerating their digital and intelligent manufacturing transformation.