车身工艺介绍

VehicleManufacturingEngineeringVehicleManufacturingEngineering将介绍...车身概况车身焊装过程车身典型加工工艺车身新技术车身工装设备VehicleManufacturingEngineering车间立柱１bay=15mX15m物流通道生产区域物料存储区车身车间概述LayoutVehicleManufacturingEngineeringD06\D16U/BSGM308U/BD06D16BSOD06\16BSISGM308BSOHoodDecklidT/GFRTDoorLHU/BRespotInnerFramingCommonRespotLineFRTDoorRHRRDoorLHRRDoorRHOuterFramingClosureInstallLineMaterialStorageMaterialStorageMaterialStoragePhaseIonlyMaterialStoragePhaseIonlyRoofRoofBlockLayout车身车间概述VehicleManufacturingEngineering•气源的要求•输入压力：0.6MPa•气源为开环系统；每15米，车间提供1个气源接口•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：0.4MPa输出压力：0.25MPa输入温度：24°焊接水为闭环系统；每15米，车间提供1个焊接冷却水接口车间B+U的输入VehicleManufacturingEngineering•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•地面的要求•车间的地面承重通常都是3吨/平房米•在压机区域的地面承重是5吨/平房米•CMM室和VISION工位地面特殊要求车间B+U的输入VehicleManufacturingEngineering车身概况车身焊装过程典型加工工艺车身新技术车身主要设备VehicleManufacturingEngineeringBodyAssemblyProcess前围分总成侧围内板分总成底板分总成内总拼外总拼B-LINE侧围外板分总成四门两盖分总成VehicleManufacturingEngineeringBodyAssemblyProcessMotorcompartmentMC(发动机舱)M/CSUBASMVehicleManufacturingEngineeringUnderbodysubassemblyUB(地板)UR(地板补焊)Skid(搬送用)MotorCompartmentRearFloorFrontFloorToNextProcessUnderBodyASMBodyAssemblyProcessUnderbodyVehicleManufacturingEngineeringBodysidesubassembly(ModularBuild)BS(侧围)BSI(侧围内板)BSO(侧围外板)BodySideRHBodySideLHToNextProcessBodySide(左)BodySide(右)BodyAssemblyProcessVehicleManufacturingEngineeringFraming(ModularBuild)总拼BodySideRHBodySideLHUnderBodyASMFraming(Marriage)RoofRearEndShelfToNextProcessFraming(Modui)BodyAssemblyProcessVehicleManufacturingEngineeringBodySideinnerRHBodySideinnerLHRoofbarShelfLayerBuild－InnerframingFI(内板总拼)ToNextProcessBodyAssemblyProcessVehicleManufacturingEngineeringBodySideouterRHBodySideouterLHRearendOuterframing(LayerBuild)FO(外板总拼)ToNextProcessBodyAssemblyProcessOuterframingVehicleManufacturingEngineeringBodyAssemblyProcessRoofRoofRoofandbraceloading(LayerBuild)RSP或RL(补焊线)bracebraceToNextProcess(Respot)VehicleManufacturingEngineeringDeckLidHoodFenderRHFenderLHFrontDoorLHFrontDoorRHRearDoorRHRearDoorLHToNextProcessClosurePartsClosurePartsBodyAssemblyProcessClosuresubassembly门盖分总成VehicleManufacturingEngineeringMainBodyDeckLidRearDoorLHRearDoorRHFrontDoorLHFrontDoorRHFenderLHFenderRHHoodtoPaintShopBodyAssemblyProcessFittinglineBodyinWhite(Fitting)FITTING(调整线调整门盖安装的间隙等)VehicleManufacturingEngineering车身概况车身焊装过程典型加工工艺车身新技术车身主要设备VehicleManufacturingEngineering工装定位概念SteelMaterialASteelMaterialBFixLocatorClampLocatorPinLocator工装VehicleManufacturingEngineering定位工装VehicleManufacturingEngineering定位工装VehicleManufacturingEngineeringGate：用来安装定位元件Gatesupport:用来移动GateCenterstation:用来定位地板Yapproachdevice:用来横向移动gate,并将Gate锁定TransferSystem:用来纵向移动Gate开放式总拼OpenGateVehicleManufacturingEngineering开放式总拼OpenGateVehicleManufacturingEngineering输送方式EMS小车雪橇输送系统SHUTTLE输送线VehicleManufacturingEngineering车身概况车身焊装过程典型加工工艺车身新技术车身主要设备VehicleManufacturingEngineering典型加工工艺WeldingSealerClinchTorqueHemmingVehicleManufacturingEngineering•电阻焊(spotweld)电阻焊是车身车间的主要焊接工艺，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。典型生产工艺电源悬挂平衡系统焊接控制箱手工焊枪焊接变压器焊接电缆气路系统冷却水系统WeldingClinchSealingHemmingTorqueX型焊枪C型焊枪VehicleManufacturingEngineeringWeldGun加压通电加压:180～300Kg・n电压:380V电流:9,000～14,000A1SpotWeldTimeManual=2.0～4.0Sec.Robot=1.5～3.0Sec.电阻点焊(spotweld)的概念典型生产工艺WeldingClinchSealingHemmingTorqueVehicleManufacturingEngineering•螺柱焊(screwweld)螺柱输送管螺柱枪螺柱焊电源控制器螺柱料箱STUDBODYPANELMETALWeldingClinchSealingHemmingTorqueVehicleManufacturingEngineering•气体保护焊（MAGWelding)焊机保护气体自动送丝系统焊枪典型生产工艺WeldingClinchSealingHemmingTorqueVehicleManufacturingEngineering•激光焊（LaserWelding）Laserbeam4PressureRollerDeviceSidepanelouterRoof95°典型生产工艺WeldingClinchSealingHemmingTorqueVehicleManufacturingEngineering•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WeldingClinchSealingHemmingTorque典型生产工艺VehicleManufacturingEngineering•压机（diehemming）OuterPanel零件-前盖,门,后盖,后举门等.Adhesive（折边胶）MasticSealerPre-punchPartsLoadingBending:45°PartsLoadingGuideLowerDieSealerGunPre-hemmingSealingInnerLoadingInnerPanelHemmingMachinePressurePadMainPunchWeldingClinchSealingHemmingTorque典型生产工艺VehicleManufacturingEngineering•diehemmingClosureParts-Hood,Doors,DeckLid,Tailgateetc.LowerDieMain-hemmingWeldingClinchSealingHemmingTorque典型生产工艺VehicleManufacturingEngineering•diehemmingClosureParts-Hood,Doors,DeckLid,Tailgateetc.WeldingClinchSealingHemmingTorque典型生产工艺VehicleManufacturingEngineering•RollerHemmingProcess0.StartingPosition2.StepPreHemming45°RollerRoller45°3.StepFinalHemming90°Roller90°PanelBodySideInnerPanelBodySideOuterHemmingFlangeAdh.1.StepPositioningofHemmingBedHemmingBed－门,车顶,翼子板,前后盖,C-pillar,wheelhouse,etc.零件WeldingClinchSealingHemmingTorque典型生产工艺VehicleManufacturingEngineering•RollerHemmingProcess2or3stepsstandardrollerNumberofhemmingstepswith30or45degreesperstep.Dependingonthegeneralcondit