During the debugging of the trihedral turntable flexible switching system for BIW assembly, issues such as Z-axis clamping cylinder jamming, trolley position loss, and body dimensional deviation were identified. This paper proposes a systematic optimization approach. By introducing a Y-axis pre-positioning station and reducing motor torque, internal stresses within the frame are eliminated, thereby resolving cylinder jamming. The adoption of dynamic tolerance concepts and differential servo motor parameter settings for different vehicle models effectively prevents position loss. Additionally, optimizing the different vehicle sequencing strategy by implementing small-batch continuous production of identical models significantly reduces the switching frequency of the assembly system. Following implementation, the average daily downtime decreased from 36.7 min to 1.6 min. The research demonstrates that a combined approach of mechanical optimization and production sequence adjustment is an effective solution for mitigating downtime in complex flexible assembly systems.

Body in White(BIW)  /  Assembly  /  Flexible Switching  /  Framer  /  Dynamic tolerance