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上海交通大学硕士学位论文轿车车顶无饰条工艺方案实施过程研究姓名:魏大卫申请学位级别:硕士专业:工业工程指导教师:张洁;卢兵兵20090604IIIFMEAFMEAFMEA,ABSTRACTIIIPASSEGNERCARSROOFDITCHMOLDINGFREEPROPOSALIMPLEMENTATIONPROCESSSTUDYABSTRACTIntheearlierautodesignstage,itwasrequiringalongperiodandastep-by-stepcourse.Normally,newprocessdesignwasnotconcurrenttothenewproductdevelopment,andlaunchedintheexistingproducts,andthenthevehiclepropertieswasbuiltafterthedesigncompletelyfinished.Thismethodreducedthehighlaunchfailurerisk,butitalsodelayedthenewprocessimplementationspeedonthenewproduct.Nowadayswiththeintroductionofdigitaldesignandconcurrentengineering,thespeedofnewproductsdevelopmentareacceleratingcontinuously.andwhichhavemuchhigherrequirementsonqualityandtimingofproductandprocessdevelopment.Thesourceofthisarticleiscomingfromtheprocessofnewproductdevelopment.Acompletenewmoldingfreeproposalisdecidedtobeusedinanewvehiclemodel.Thereisabigimpactonproductandprocessdevelopmentandthefollowingmassvolumeproduction.Howtoimplementthisproposalandcontroltheriskeffectivelyisthepurposeofthisarticle.Forautodesignprocess,concurrentengineeringisalreadyinwidelyuse.Someautomotivecompanieshavealreadystartedtohaveprocessdesignparalleledwithproductdesign,sothatnewprocesscouldbelaunchedonthenewproduct.Therearealotofdifferetpointscomparingwithtraditionalprojects,forexample,processneedtoberearrangedanddeveloped,materialneedtobenewdeveloped,facilityneedtodevelopedandprojecttimingisfixedwithproductmilestoneandsoon.Allthesearecompletelydifferentfromtraditionalwayandcausealotofchallenges.Aparallelprojecttimetableshouldbepreparedtobalancetheprocessdevelopmentandproductdevelopment.TheFMEAtoolshouldbeutilizedtomakesuretheprojectimplementationqualityduringtheearlierimplementationprocessandfuturemanufacturingprocess.MoldingfreeprojectisbasedonprincipleofconcurrentABSTRACTIVengineeringandusingqualitymanagementmethodtoimplementonacompletelynewvehicle.Thisisagoodstartforprocessandproductparalleldesign.Bystudyingofproductdevelopmentprocessandeffectiveuseofconcurrentengineering,moldingfreeproductdesignandprocessdesignareimplementedforwardparallelly.Thequalityandtimingtargetsareachieved.Aeffectiveproposalofconcurrentengineeringimplementedforpaintprocessisbuiltandcouldbeabenchmarkforfuturesimilarprojectsimplementation.KEYWORDS:ConcurrentEngineering,ProcessDesign,FMEA,Molding20092009200911.121[1][2]1.21.2.121),11Figure1Moldingtype2)223Figure2--LaserbrazingFigure3Moldingfreeditchstructure331.2.21988IDAInstituteofDefenseAnalyzeCEConcurrentEngineering[3]()(1)50%(2)40%60%(3)30%50%[4]60%30%-50%70%-80%20%[5]4CAE[6]1.2.3FMEAFMEA,FailureModeandEffectsAnalysisFMEAFMEA[7-8]FMEA60FMEA60570FMEA90FMEAFMEA9-10FMEAFMEA(DFMEA)FMEA(EFMEA)FMEAPFMEAFMEAFMEAFMEAFMEAFMEA1.31.3.1FMEA1.3.212FMEA61.4FMEAFMEA(FMEA)FMEAFMEAFMEAFMEAFMEAFMEA474Figure4ArticleStructure1.5FMEAFMEAFMEA82.12.2()[11],,,,,[12]9,,,,,,,,[13](1)50%(2)40%60%(3)30%50%2.3,,,,,,,,,,,[14],”,,,,,,,10,,,[15],,[16],,,,,[17],,,,,,,,,,,,11/,,2.42.4.1125Figure5–Moldingfreeprocessofroofditchlaserweldingplussealer[18]2.4.211311540204001RoofPanelPVCsealingSidepanelLaserweldRoofPanelPVCsealingSidepanelLaserweldRoofPanelPVCsealingSidepanelLaserweld142.52.5.1[10],66Figure6–ConcurrentEngineeringOverview2.5.21512222.5.31633172.5.4418442.5.451952.6620FMEA21FMEA3.1[19][19]FailureModesandEffectsAnalysisFMEAFMEA[20]FMEAFMEA3.2FMEAFailureModesandEffectsAnalysisFMEAFMEA22601974[21]3.2.1FMEAabcFMEAFMEAFMEAFMEAFMEAFMEAFMEAFMEAFMEAFMEAFMEAFMEA233.2.2FMEAFMEAFMEAFMEAFMEADesignFMEADFMEAFMEAProcessFMEAPFMEAFMEAFMEA,[22]FMEAFMEAFMEA//FMEA/FMEAFMEA()FMEA24FMEAFMEAFMEA3.2.3FMEAFMEA,1FMEA2345FMEAFMEAFMEA6FMEAFMEAFMEA257FMEA3.2.4FMEA1234FMEA26RiskPriorityNumberRPN56123.3FMEA3.3.1FMEAFMEA27FMEAFMEAFMEAFMEA7FMEA28FMEA29FMEA30FMEA31FMEA323.3.2FMEA3.3.2.1FMEA,1)2),3)FMEA334)3.3.2.2(FarageCageeffect)77Figure7PaintabilitystudyoverviewFMEA34:350µA:60KV450001/min/:25cm:Eco–Bell():190ml/min/:180l/min/3.3.2.38981Figure8Sealerfailurepicture1FMEA3592Figure9Sealerfailurepicture210PanelIDDow64395BASFPURPrimerprimerBakeBasecoatFlashOvenClearcoatTopcoatBake1CELPO10mmwidex2mmthickbeadApplyCKPSSeecolorsbelowBake25'x130oC(25'x265oF)ApplyBCSeecolorsbelowBake5'x80oCCCBake25'x130oC(25'x265oF)2CELPO10mmwidex2mmthickbeadNoneBake25'x130oC(25'x265oF)ApplyBCSeecolorsbelowBake5'x80oCCCBake25'x130oC(25'x265oF)10Figure10Materialmatchtest3.3.3FMEA11FMEA3612111Figure11Sealinglinelayout1122Figure12Sealinglinelayout2882727A1.2.4050%FMEA3782727B1.2.1.4727C1.2.1.2.3.4050%B1313Figure13Processlayoutproposal3.3.4FMEA3.3.4.1FMEA38141514Figure14Sealerapplicationtest15Figure15Sealerapplicationtestbasedwithdifferentnozzles3.3.4.2FMEA1616Figure16LaserweldingdefectoverviewFMEA399911mmØ2mmØ21mmØ3mmØ2mm3mmØ49031mm40mmMIG49044DWeldWatcher490540mmMIG4DWeldWatcher490490640mm40mmMIG4DWeldWatcher480740mm4DWeldWatcher490840mmMIG4DWeldWatcher490910mmMIG4DWeldWatcher4901010mm4DWeldWatcher490114DWeldWatcher490171817Figure17sealerapplicationdefectFMEA4018Figure18sealingdefectrepairchart3.3.5FMEAFMEA3.4FMEA3.4.1FMEAFMEAFMEAOKOKFMEA411)/2)/3,,.4/
本文标题:硕士论文-轿车车顶无饰条工艺方案实施过程研究
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