Based on the 25% offset collision condition defined by the China Insurance Research Institute, this paper studies the structural design scheme of the A-pillar of a new energy vehicle. The effect on the crash safety of the basic structure, CBS rubber block reinforced structure, and hot blow forming tube reinforced structure are evaluated and compared. The manufacturing process of CBS rubber block and tube hot blow forming are introduced, and the hot blow forming process is simulated and analyzed. The tooling capital investment and unit cost of the two reinforced structures are further analyzed. The study shows that in the case of achieving an excellent level of small offset collision safety, the 1 500 MPa tube hot blow forming scheme has more advantages than the CBS rubber block scheme in terms of unit cost and light weight.

In order to analyze the influence of gravity deformation on the size pass rate of sheet stampings, Hypermesh and Abaqus were used to construct the nonlinear co-simulation model of gravity deformation of the sunroof cover plate and the tunnel welding assembly. The results show that different placement positions have different abilities to overcome gravity deformation, and the convex placement can improve the ability of parts to overcome gravity deformation. The simulation results verify the feasibility of nonlinear analysis method of gravity deformation to guide the measurement scheme design of sheet stampings of BIW.

In order to solve the cracking problem of automobile wing during road test, this paper analyzes the residual stresses of the Fender produced during the stamping and assembly processes, and studies the influence of residual stress on fatigue failure. The process notch near the fender mounting point is optimized based on the Miner theory to reduce the stress concentration during the assembly process, which effectively improves the fatigue life of the Fender. The problem of fatigue cracking of the Fender is solved without the fatigue simulation based on the road spectrum. This paper provides ideas and theoretical basis for rapid analysis and solution of engineering problems.

Welding tests are carried out on flat copper wires for stator of new energy vehicles’ drive motors by using two processes, ring spot laser welding and TIG welding. Moreover, the welding process and the performance of the joints are investigated and analyzed. The results show that the optimal process of flat copper wire laser welding is 2 500 W for the center core power, 1 500 W for the ring core power, 290 mm/s for the welding speed, and +5 mm for the defocusing amount, and the obtained joints are well formed without weld defects such as pores, etc.; the optimal process parameters of TIG welding are 140 A for the welding current, 150 mm/s for the welding speed, and a small amount of shrinkage holes exists in the obtained joints. The maximum shear strength of the joint obtained by the ring spot laser welding process is 132 MPa, and the maximum hardness of the joint appears in the center of the weld, which is about 140 HV0.2; while the maximum shear strength obtained by TIG welding is 110 MPa, and the maximum hardness of the joint appears in the center of the weld, which is about 128 HV0.2. The welded joints obtained by ring spot laser welding are better than the TIG welded joints in the organization, morphology, and mechanical properties, and they are more suitable for the welding of flat copper wire.

This study focuses on the adhesive-rivet composite connection of automotive body dissimilar metal sheets. A finite element model of adhesive riveting and self-piercing riveting composite connection established using Simufact Forming software. The upper plate made of 1mm DC04 steel plate, and the lower plate made of 2 mm 5052 aluminum alloy plate. The adhesive-rivet composite connection process using epoxy resin structural adhesive simulated using finite element analysis. By analyzing the specific parameters of the internal locking value, nail head height, and remaining thickness of the adhesive-rivet composite joint by changing the height of the rivet, the depth of the concave mold, the height of the convex platform, and the pressing speed, it found that the optimal forming process achieved when the rivet height 5 mm, the diameter of the concave mold 10 mm, the depth of the concave mold 1.9 mm, the height of the convex platform 0.9 mm, and the pressing speed 45 mm/s. And the simulation results are verified through riveting equipment, and the trend of riveting force change in both results the same as the shear tensile failure mode. The error of joint characterization parameters within 10%, which further verified the high reliability of Simufact Forming software.

To improve numerical control plasma cutting appearance quality of longitudinal beam, the Lean Six Sigma DMAIC model is used as the research framework to analyze the factors leading to unqualified appearance quality of longitudinal beam numerical control plasma cutting. A test model is established, and data analysis and result prediction are carried out through Minitab software to identify the key factors leading to the abnormal appearance quality of longitudinal beam numerical control plasma cutting. The processing parameter setting scheme of longitudinal beam numerical control plasma cutting is determined. Trial production on the production site indicates that the optimization scheme can effectively reduce the unqualified rate of longitudinal beam numerical control plasma cutting appearance, and improve the production quality of longitudinal beam of heavy truck frame.

In order to improve the quality and efficiency of the DTS inspection for the automobile class-A-surface and assembly data, a DTS rapid inspection application is developed by using the Component Application Architecture (CAA) technology of CATIA, This application can quickly identify measurement objects, cancel the creation of auxiliary elements, automatically obtain the positions to be inspected, automatically measure gaps and flushes, and judge the qualification status so as to achieve intelligent inspection. The results show that the inspection efficiency is improved by more than 50% through verification.

To achieve lightweight and energy saving and emission reduction of heavy trucks, load bearing condition (displacement change, bending, pictures of Scanning Electron Microscope (SEM) and surface appearance) of Expanded Polypropylene (EPP) with different foaming ratios (10 times, 9 times and 8 times) is analyzed and studied based on the basic design criterion of EPP products. Through UG NX 11.0 simulation analysis software, the structural strength of different thicknesses (30 mm, 40 mm, 50 mm) is analyzed by finite element method, and combined with material properties and appearance surface effects, the optimal foaming ratio and thickness of EPP heavy truck sleeper are defined.

The problem of blowing white powder from the air conditioning box of the test car is analyzed by means of energy spectrum and metallographic analysis, and it is confirmed that white powder is an oxide of aluminum formed after corrosion of the evaporator. Through infrared and corrosion resistance test analysis, the results show that the serious corrosion is caused by the evaporator in a humid environment in which galvanic corrosion occurred under the catalysis of Cu. The solutions such as replacing materials and using passivation and hydrophilic chemicals with higher corrosion resistance are proposed so as to effectively solve the problem of blowing white powder in air conditioning boxes because of the evaporator’s corrosion.

In order to meet the demand of automated guided vehicle (AGV) as transport carrier in final assembly workshop, the AGV design scheme is optimized to enhance the function of AGV transport system. Based on the operation of a passenger car assembly workshop, the AGV conveying line is designed, and combined with the workshop conveying design scheme, AGV characteristics, the operational logic of the line and the line business process, the AGV conveying system simulation model is constructed by using Siemens Plant Simulation software soas to analyze the number of AGVs at different beats. In order to meet the production cycle time, the design of experiment (DOE) method is carried out through the design of test manager, and the charging time walking speed of the automatic workstation is optimized to cache the battery capacity of the AGV between the lines. After optimization, the conveying efficiency of AGV line is increased by 24%, and the utilization rate of AGV is increased by 26%。

In order to improve the flexibility of the welding production line for car body in white, this paper proposes a T-shaped automotive flexible switching system. Firstly, this article studies the composition of the T-type flexible switching system and the working process of each component, and proposes that this switching system can switch 2N+1 vehicle models. Secondly, the power and transmission parts of the switching system are studied, and the motor parameters, guidance and positioning schemes are determined. Moreower,the module division and interface design of the switching system is proposed, and a module division diagram is obtained. Finally, the working process of the switching system is simulated in the Tecnomatix environment. The results show that the design of the T-type flexible switching system is reasonable and can achieve switching between 2N+1 vehicle models.

Based on the thread slip-tooth occurred when the front suspension assembly upper support seat is assembled with the body in the assembly process, this paper analyzes the excessive contact gap between the front suspension support seat and the body, poor positioning angle of the front suspension assembly upper support seat, and the related supporting tools,. Correspondingly’ it is a so proposes an optimization scheme to improve the front suspension tray support tooling and the new front suspension upper support positioning tooling, which ultimately reduces the defect rate.