3 2 1
Parallel Line 并线
•••
Hybrid Line: 混线 Parallel-Serial 并串线
BIW Process Hierarchy 白车身装配工艺层次
Serial assembly
串线装配
2
•
1
•
Roof
顶盖
3
•
4•
Underbody
底部
•
2
•1
Aperture Complet • 3•
车辆开发工艺
Time
时间
Virtual Engineering 虚拟工程
• CAD • Robust Design/DFSS/鲁棒设计与六西格玛设计 • Virtual Dynamics and NVH虚拟动力和NVH分析 • Virtual Safety/Crash Simulation虚拟安全性/碰撞模拟分析 • Virtual Durability Simulation虚拟疲劳模拟分析 • Dimensional Managements尺寸管理 • Virtual Assembly/Virtual Body Shop虚拟装配/虚拟车间
T物hr流ou分g析hput
3D Plant 3D车间 Casting 铸造分析
GA 总装
Engine& TM
Dimensional Management 尺寸管理 In Body Development Process车身开发工艺
Dimensional management and control enables designed products insensitive to process variation. It represents the up-front planning for tolerance and the measurement of key features, coupled to the design of manufacturing process to meet the target specifications. 尺寸管理和控制能够让设计产品对工艺变更影响不大。根据它为公差和
2
Virtual Engineering
Product Design/Analysis
产品设计/分析
3D CAD Master
CAE
Digital Mockup(Ass./Proto.)
Stamping 冲压
Manufacturing Engineering Center
Press
Body 车身
Paint 冲压涂装分析
公差分解
Door Ring ± 0.35 mm
Quarter ± 0.35 mm
门框 后背门
Tolerance Planning Approach 公差逼近方法
设计目的 宽松范围
制造目的
缩小的δ
10
Part Responsibility for the Designer
零件设计者职责
设计“门”
设计“盖板”
零件的公差虽很重要，但在整个制造中只起次要影响， 白车身制造工艺和装配顺序对最终产品的质量起主要影响。
11
Interdisciplinary Task: Tolerance Planning
Objectives of Tolerance Planning 公差计划目标
The Objective of Tolerance Planning is to develop a Tolerance Concept for the complete car for every development phase which is documented, evaluated and confirmed by the customers.
客户不满意 未计划的资源消耗 暴涨消耗 对下个产品造成危害
反馈设计
5
DFSS Framework/ DFSS框架
获得正确的产品 确定一个高利润的产品
深入了解客户需要 选择最好的解决方案
确保生产的正确性 优化设计 预留设计余量
IDDOV= Identify, Define, Develop, Optimize and Verify
关键面测量拟定计划，结合加工工艺的设计达到计划指标。
3
Tools for Dimensional Management尺寸管理工具
• Robust Design/DFSS鲁棒设计/DFSS • Tolerance Planning/Variation Simulation公差计划/偏差模拟 • Measurement Planning测量计划 • Datum Optimizations基准优化 • Digital Assembly/Digital Functional Build数字装配/数字功能体系 • Process Monitoring and Statistical Process Control工艺监控和统计工
公差计划的目的就是为整车的每个开发阶段展开 公差概念的设计，同时被客户所证实、评价肯定。
Application Fields:应用范围Body-I Nhomakorabea-White
白车身
Interior/Exterior
外饰/内饰
Chassis
底盘
Powertrain
动力系统
12
Benefits of Tolerance Planning
minimum process variation, and result in a robust final
BIW build
选择的装配线布局应使工艺变量最小，白车身结构最稳定
a
b
c
d
Serial Line 串线
n
••• •••
Hybrid Line: 混线 Serial-Parallel 串并线
装配模型：运动规律
Surface mating 匹配面
Roller 滚珠
Hub
毂
Alignment
同轴线
Ring 外环
Shaft 轴
对齐 Alignment
匹配面 Surface Mating
密封
Enclosure
6
Assembly Characteristics 装配特征
• Sheet metal assemblies
4
车厢 Trunk
Deck 地板
Underbody with Dash 地板
Motor Rail 机舱横梁
Parallel assembly
并线装配
Aperture Inner
Quarter Outer Aperture
Aperture Outer
9
Assembly Tolerancing Example 装配公差实例
1
Why Virtual Engineering
Virtual Engineering Driven VDP
Resulted In Significantly Reduced Engineering Changes
虚拟工程竖向数据处理减小了工程变更
变更的造价
Cost of
未虚拟装配的变化曲线
changes
产品设计
产品开发及工程
产品验证
Total Product Product Concept
Planning
Development
Product Design
Product Development & Engineering
Trial Production
Robust Design/DFSS
鲁棒设计/六西格玛设计
关联 ，定义 ，过程 ，最优化 和 核实。
Assembly Characteristics 装配特征
• Rigid body assemblies
- Geometric closure; 几何封闭 - Non-interference. 不干涉 - Assembly modeling: kinematics laws
Body Side Joint Architectures 测围结合特征
Under Body Joint Architectures 地板结合特征
典型截面
8
Basic Line Configurations 主线配置
Selected assembly line configurations should achieve
白车身
BIW ± 1.0 mm
公差合成
Tolerance Synthesis
Roof ± 0.5 mm
Side Frame(L) ± 0.5 mm
Side Frame(R) ± 0.5 mm
UnderBody ± 0.5 mm
顶盖 左侧围 右侧围 地板
Tolerance (Stack-up) Analysis
Joint architectures should achieve maximally stress free vehicle body assembly build
结合处结构要承受车身装配结构的最大压力
Lap joint
搭接
z y
x
Butt joint 对接
Lap-Butt joint搭-对接
7
艺管理
尺寸有效管理
Enablers For Dimensional Management
3D Visualization & Simulations (CAD/CAE/Digital Assembly)
3D虚拟仿真
In-Line Body Inspection System