车身工艺介绍
sub assembly
Closure Parts Closure Parts
门盖分总成
Deck Lid
Rear Door RH
Front Door RH Fender RH To Next Process Front Door LH Hood Fender LH
Rear Door LH
Vehicle Manufacturing Engineering
M/C SUB ASM
Vehicle Manufacturing Engineering
Body Assembly Process
Under body sub assembly UB(地板) UR(地板补焊)
Under body
Under Body ASM Rear Floor Front Floor Motor Compartment
Framing (Modui)
Roof
Shelf
Rear End Body Side RH
To Next Process Framing (Marriage)
Under Body ASM Body Side LH
Vehicle Manufacturing Engineering
Body Assembly Process
Vehicle Manufacturing Engineering
车间B+U的输入
• 管路排设要求
车间的能源主要包括水、气、电;所有这些主管路的排设均在车间地面高度7米 以上;7米以下的部分由M+E供应商负责
• 焊接冷却水的要求
输入压力:0.4 MPa 输出压力:0.25 MPa 输入温度:< 24° 焊接水为闭环系统;每15米,车间提供1个焊接冷却水接口
Vehicle Manufacturing Engineering
典型生产工艺
Welding Clinch
Sealing
Hemming
Torque
• 压机(die hemming)
零件
- 前盖, 门, 后盖, 后举门等.
Inner Panel Adhesive (折边胶) Pre-punch Mastic Sealer
To Next Process
Skid (搬送用)
Vehicle Manufacturing Engineering
Body Assembly Process
Body side sub assembly (Modular Build )
BS (侧围) BSI (侧围内板) BSO (侧围外板)
Outer
framing ( Layer Build )
FO(外板总拼)
Outer framing
Body Side outer RH
Rear end
Body Side outer LH To Next Process
Vehicle Manufacturing Engineering
Body Assembly Process
Parts Loading Pre-hemming
典型生产工艺
Welding Clinch
Sealing
Hemming
Torque
• die hemming
Closure Parts
- Hood, Doors, Deck Lid, Tailgate etc.
Lower Die
Main-hemming
Pin Locator
Fix Locator
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定位工装
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定位工装
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开放式总拼Open Gate
Gate:用来安装定 位元件
Body Assembly Process
前围 分总成
侧围内板 分总成
侧围外板 分总成
四门两盖 分总成
底板分总成
内总拼
外总拼
B-LINE
Vehicle Manufacturing Engineering
Body Assembly Process
Motor compartment MC(发动机舱)
•
气体保护焊 (MAG Welding)
保护气体 焊枪 焊机
自动送丝系统
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典型生产工艺
Welding
Clinch Sealing Hemming Torque
•
激光焊 (Laser Welding)
Laserbeam
Pressure Roller Device
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输送方式
SHUTTLE输送线
EMS小车
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雪橇输送系统
车身 概况
车身 焊装 过程
车身 主要 设备
典型 加工 工艺
车身 新技 术
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• 气源的要求
•输入压力:0.6 MPa
•气源为开环系统;每15米,车间提供1个气源接口
Vehicle Manufacturing Engineering
车间B+U的输入
• 电源的要求
• 车间使用的电压分380V和220V • 电源的分配采用母线+插接箱的结构;
• 母线分为焊接母线和清洁母线;焊接母线的作用是为焊接设备提供电源供应;清 洁母线的作用是为照明和控制元器件提供电源供应;1台焊机需要1个插接箱;1 个控制箱需要1个插接箱
D06\16 BSI
SGM308 U/B
Hood
D06 D16 BSO SGM 308 BSO
D06\D16 U/B Material Storage
Phase I only
Material Storage Phase I only
Deck lid
Material Storage
T/G
Material Storage
Center station: 用来定位地板
Gate support: 用来移动Gate
Transfer System:用 来纵向移动Gate
Vehicle Manufacturing Engineering
Y approach device: 用来横向移动gate, 并将Gate锁定
开放式总拼Open Gate
典型加工工艺
Welding
Hemming
Sealer
Torque
Clinch
Vehicle Manufacturing Engineering
典型生产工艺
Welding Clinch Sealing Hemming Torque
电源
• 电阻焊 (spot weld) 电阻焊是车身车间的主要焊接工
焊接控制箱 C型焊枪
悬挂平衡系统
艺,我们选用了带自馈系统的梅
达焊接控制器,保证我们的焊接 质量,目前所有车型焊点合格率 在99.3%以上。
焊接电缆 焊接变 压器
冷却水系统
气路系统
X型焊枪
手工焊枪
Vehicle Manufacturing Engineering
典型生产工艺
Welding Clinch Sealing Hemming Torque
Pressure Pad Sealer Gun Main Punch
Sealing Inner Loading
Bending:45° Hemming Machine
Outer Panel
Lower Die
Parts Loading Guide Vehicle Manufacturing Engineering
Roof
Side panel outer
95°
4
Vehicle Manufacturing Engineering
典型生产工艺
Welding
Clinch
Sealing
Hemming
Torque
•
铆接(Clinch)
– Clinch是采用自铆接的方式,来实现板材和板材之间的连接。
– 与点焊相比,clinch的费用可以节省30%~60% – 与点焊相比,clinch的强度只有焊点的50%~70%;但是其抗疲劳强度远远高于焊点。因此, clinch工艺比较多的应用在对强度要求不高的门盖区域。 – 铝材,多采用clinch的工艺
Body Assembly Process
Body in White (Fitting) FITTING(调整线 调整门盖安装 的间隙等)Door RH Front Door RH Fender RH to Paint Shop Hood Rear Door LH
Roof
and brace loading ( Layer Build )
Roof
RSP或RL(补焊线)
Roof
brace
To Next Process (Respot)
brace
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Body Assembly Process
Closure
电阻点焊 (spot weld) 的概念
加压 : 180 ~ 300 Kg・n
Weld Gun
加 压
通 电 1 Spot Weld Time Manual = 2.0 ~ 4.0 Sec. Robot = 1.5 ~ 3.0 Sec.