Manufacturing Capabilities
There are 2 casting sites and 1 mechanical processing site in NorStark China.
No. | Site | Capacity（’000 pcs） | Total Capacity（’000 pcs） |
01 | Casting site 1 | 80 | 380 |
02 | Casting site 2 | 300 | |
03 | Mechanical Processing site | 400 | 400 |
Norstark China factory
01.Casting site
No.of Operators：
Casting site 2
112operators
Main Products：
Casting axle housing
Capacity：
380,000pcs/year
Casting site 1 Main Production Equipment
The casting site 1 has an annual capacity achieves 80,000 pcs of medium & heavy truck axle housing.
Site | Main Equipment | Qty |
01Casting site 1 | Vacuum Process Molding Line | 2 |
Medium Frequency Induction Furnace | 4 | |
Laminated Sand Core Making Machine | 10 | |
Sand Recycling Line | 1 | |
Cart Resistance Furnace | 1 | |
Shot Blasting Machine | 2 |
Vacuum Process Molding Line
Medium Frequency Induction Furnace
Laminated Sand Core Making Machine
Sand Recycling Line
Shot Blasting Machine
Cart Resistance Furnace
Casting site 2 Main Production Equipment (Under Construction)
Casting site 2 has an annual capacity of 300,000 pcs. The new site will use smart AI technology to optimize production process, equipment management & energy utilization.
Line | Main Equipment | Qty |
Core Making Line | Auto Core Making Line | 16 |
Core Dip Coating Robot | 2 | |
Auto-Transfer vertical Warehouse for Core | 2 | |
Molding Line | Vacuum Process Molding Line | 2 |
Surface Spraying Robot | 4 | |
Auto Pouring Machine | 2 |
Core Making
Use AI visual system to process 100% sand inspection, use automatic logistic system to transport cores, robot will automatically control dip coating procedure.
Auto Core Making Line
Core Dip Coating Robot
Auto-Transfer Vertical Warehouse for Core
Molding
Transmit batch number via position coordinate, and combine batch number with process location information of products to secure manufacturing information tra ceability.
Vacuum Process Molding Line
Surface Spraying Robot
Auto Pouring Machine
Line | Main Equipment | Qty |
Smelting Line | Automatic Feeding System | 4 |
Medium Frequency Induction Furnace | 4 | |
Feeding Spheroidization System | 2 | |
Cleaning Line | Material Feeding Arm | 2 |
Slot Blasting Machine | 4 | |
Auto Grinding Robots | 8 |
Smelting
Automatic feed according to the receipt, and sync with spectral information, reducing the receipt error due to operator skills, to secure accurate control of chemical composition.
Automatic Feeding System
Medium Frequency Induction Furnace
Feeding Spheroidization System
Cleaning
Use AI visual technology to identify the datum, automatically adjust compensation, to avoid accidental damage to the body, the flash margin can be controlled within 0-0.5mm.
Material Feeding Arm
Slot Blasting Machine
Auto Grinding Robots
Casting site 2 AI Visual Equipment (Under Construction)
Smart AI Visual Application
AI Visual Diameters Measuring
100% fully inspection for cores or raw cast
100% fully inspection for cores or raw cast. Measurement accuracy can achieve ±0.15mm. Combine product inspection information & batch number. Scan batch number. Each product are traceable.
AI Visual Core Setting Inspection
Core Setting Inspection
Robot arm proceeds visual scanning & positioning before grasping the core, launch second scanning after grasping, for adjusting location precision compensation. Process scanning and positioning to cavity before core setting, then finish the core setting action.
AI Visual Cold Iron Guiding
Cold Iron position inspecion
Locate Cold Iron Through Projection. Recognize any missed cold iron or precision via AI visual function after placement. Alarm will be initiated if process not conform to the requirements. Working line resume running after alarm released.
AI Visual Real-time Temperature Measurement
Real-time temperature measurement during pouring.
Real-time collection of pouring temperature and efficiency of each box, compared with the process standard, send out warning and stop operation when non-conforming. Connect pouring information and MES system to make product process parameter traceability
AI Visual Surface Defect Detection
100% fully inspection for raw cast appearance
100% fully inspection for raw cast appearance. Recognize surface or inner defects of casting via AI algorithm, automatically isolate defective products to prevent any non-conforming product pass.
AI Visual Forbidden Zone Monitoring
Forbidden Zone Personnel Monitoring
When the equipment is abnormal or in normal maintenance condition, the monitoring system will identify the personnel entering and leaving the forbidden area. The equipment can not be started if any personnel is within the zone.
02.Mechanical Processing site
No.of Operators：
Mechanical processing workshop 1:
126operators
Mechanical processing workshop 2
92operators
Main Products：
Casting axle housing
Capacity：
400,000pcs/year
Mechanical Processing workshop 1
Mechanical Processing workshop 2
Mechanical Processing Workshop 1 - Main Production Equipment
There are 6 mechanical processing lines (annual capacity 150,000 pcs) and 1 spray line (annual capacity 216,000 pcs) in workshop 1. It meets requirements of flexible mechanical process of many types of axle housings. The lines equipped with high precision 4-axis rotary table, Maposs automatic measuring instrument, Renishaw infrared probe and automatic hydraulic pressure tooling. The max axle housing length of mechanical processing is 2300mm, the axle housing rotary diameter 850mm, the bearing position can achieve grade 6 accuracy and roughness achieves Ra0.4.
site | Main Equipment | Qty |
Mechanical Processing Workshop 1 | Double-sided horizontal CNC boring and milling machines | 4 |
Two-heads CNC lathes | 11 | |
Horizontal drilling and milling machining centers | 3 | |
Vertical machining centers | 26 | |
CNC angular approach cylindrical grinding machines | 4 |
Double-sided horizontal CNC boring and milling machines
Two-heads CNC lathes
Horizontal drilling and milling machining centers
Vertical machining centers
CNC angular approach cylindrical grinding machines
Spray Line
Mechanical Processing Workshop 2 - Main Production Equipment
There are 3 mechanical processing lines (annual capacity 250,000 pcs) and 1 electrophoresis coating line (annual capacity 300,000 pcs) of workshop 2. It meets air suspension integrated axle housing mechanical processing work. The lines are equipped with Maposs automatic measuring instrument, Renishaw infrared probe, gantry manipulator, articulated robot, AGV cart, MES system. The max axle housing length of mechanical processing is 2300mm, the axle housing rotary diameter is 1500mm, the bearing position can achieve grade 6 accuracy, and the roughness achieve Ra0.4.
site | Main Equipment | Qty |
Mechanical Processing Workshop 2 | Double-sided horizontal CNC boring and milling machines | 6 |
Two-heads CNC lathes | 6 | |
CNC Angular Approach Cylindrical Grinding Machines | 6 | |
4-axis Horizontal Machining Centers | 57 | |
High Pressure Cleaning Machine | 3 | |
High Pressure Cleaning Machine | 3 |
Two-heads CNC lathes
4-axis horizontal machining centers
CNC angular approach cylindrical grinding machines
High Pressure Cleaning Machine
Robot grinding center
Electrophoresis coating line
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