Inside the LiuGong 65 automated excavator factory in China

Peter Haddock visits Luzhoz in China to discover how autonomous robots and smart tools are helping to build its growing technology enabled diesel and electric excavator range.

Joined by Harry Mellor, Peter walks through the factory, which is part of its huge ‘Intelligent Industrial Park’ that can support the manufacture of up to 20,000 excavators from 15 to 200 tonnes.

Harry: “We have invested around £374 million in building this excavator manufacturing plant, at the same time as our new Energy and Innovation Centre next door.

“By creating a smart, robotics-driven production environment, we have already achieved 65% automation.

“This means we can increase the speed at which we build machines whilst driving quality through enhanced traceability. It’s also much easier and quicker to introduce upgrades as products evolve.”

In the hydraulic assembly area, staff were assembling Kawasaki valve sets using Continental hoses.

Harry: “Our intelligent tool data collection station ensures every part that is torqued is registered into the system. So we know exactly what has been done on each machine. This gives us complete data tracking and quality control.”

On the main assembly line, which is split into key zones, automation moves from controlled processes to full autonomy.

Harry: “We use Automated Guided Vehicles AGVs that move around key components using overhead transport systems, lifts and underground tunnels.

“By designing our own stacker system, as a machine is being assembled, it automatically finds the right-sized boom and stick, bringing them down to the line at exactly the right time.”

At the heavy end of the range, there is less automation due to the size of the machines.

Harry: “We now build from 95 tonne up to 200 tonne machines here. It takes around 142 hours per machine, with a capacity of up to 500 units per year.”

Before some digger dancing in the testing area, it was time for a lights and camera moment in the PDI hall.

Harry: “We have designed a system that takes around 80 photos to assess build quality, paint and inspection before a machine leaves the factory.”

Peter added: “I talk a lot about technology and automation in my videos, so it was great to see how it’s driving the quality of the machine manufacturing process in this factory of the future.”