Introduction : In the automobile factory, the welding production line is rigid with respect to the coating line and the assembly line. The versatility of the multi-variety models is poor. Every new type of vehicle is updated, and a large number of special equipment and production processes need to be updated. The welding process design can be called the "soul" of the welding production line, involving the expertise...
In the automobile factory, the welding production line is rigid with respect to the coating line and the assembly line, and the versatility of the multi-variety models is poor. Each newer type of vehicle is required to update a large number of special equipment and production processes in the workshop. The welding process design can be called the “soul†of the welding production line, involving more professional knowledge, such as mechanization, electronic control, non-standard equipment, construction, structure, waterway, HVAC, power, electrical, computer, environmental protection and communication. Etc., macroscopically determine the process level, logistics, investment and reserve development of the workshop, specifically determining the type and quantity of process equipment, fixture form, logistics station equipment form, mechanized transportation mode and control mode. Therefore, the welding process design plays an important role in the development of the welding production line and is the key to producing a cost-effective welding production line.
1. Prerequisites for body welding process design
1.1 Product Information
a. Mathematical model of the product (referred to as digital model). In the automobile manufacturing industry, three-dimensional software such as UG, Catia, and ProE can be used to open digital models and obtain data or perform deep work. In the process design process, all the digital modules are assembled together to form a complete vehicle digital model, and the structural size and positional relationship of the components can be obtained from the digital model. From the digital model, various views (including the axonometric drawings) of the entire vehicle, sub-assembly, and stamping parts can be generated, and the sectional view can be output.
b. Complete product drawings.
c. Sample car, sample (including vehicle body assembly, major assemblies, sub-assemblies and stampings).
d. Product parts list (including the name and number of each part, the name, number, quantity of the stamping parts, the specifications and quantity of the standard parts).
When designing the process, the owner must provide at least one of the above a, b, and c. The d item can be analyzed from the first three items. Under normal conditions, the item d has been determined as early as the end of the car design. If only item b is provided, then a lot of body disassembly and analysis work needs to be added.
1.2 Factory design parameters
The parameters of the factory design include the following:
a. Production program is the annual output;
b. The annual base is the production shift, the utilization rate of the production line, etc.;
c. The degree of automation of the production line (robot + automatic welding tongs / total body welding points x 100% = automation rate);
d. The technical level requirements of the production line (such as the principle of selection of main equipment, the transportation mode of the production line, the level of electrical control, etc.);
e. Selection principles of various materials and purchased parts (such as profiles, control components, pneumatic components, motors, reducers);
f. Various public power medium supply methods, capabilities, quality and other parameters, the environmental conditions of the location where the plant is built, such as temperature, humidity, etc.;
g. When the production line is arranged in the original factory, the civil and public related materials of the original house, such as the elevation of the column top of the plant, the carrying capacity of the truss, and the richness of the power and power medium, etc., should be collected.
2, process analysis
2.1 Process line analysis
According to the product information provided by the owner, the product process line analysis (if the owner only provides the sample car and the sample, it needs to go through the sample car analysis → sample car disassembly → sample car measurement → sample car reassembly process), complete the welding process route diagram Or explosion map design.
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