In order to improve the path planning efficiency of Automated Guided Vehicles (AGVs), the research is based on the Ant Colony Algorithm and Dijkstra’s Algorithm, taking the path length as the optimization objective, to conduct path planning for a single AGV. Firstly, the actual environment is simplified to MAKLINK environment by MAKLINK graph theory. Then, the shortest path of the starting point is obtained by Dijkstra algorithm. Finally, the path is optimized by ant colony algorithm to obtain the final selected path, which improves the transportation efficiency of AGV and reduces the energy consumption.

In order to improve safety performance of new energy vehicles (NEVs), this paper studies safety regulation insulation testing in NEV factories, especially the application of synchronous mobile technology therein. By analyzing the situation and existing problems of the current detection process, the paper proposes solutions based on synchronous mobile technology. From the theoretical basis of synchronous mobile technology to specific applications, this paper elaborates on multiple dimensions such as process planning, equipment design, and safety guarantee. Practice has proved that this solution has achieved an online follow-up detection mode with high cycle rate, high flexibility and high safety, it thereby is an efficient, accurate and reliable insulation detection solution, ensuring the safety and compliance of new energy vehicles.

In order to optimize the off-line running, performance of line modification and transfer efficiency of Semi-knocked Down(SKD) vehicle bodies, this paper introduces the off-line, transshipment and assembly scheme of a domestic SKD vehicle for export. Taking a certain model as an example, the paper discusses the scheme and implementation method of how to use the fork transplanting machine and Radio Frequency Identification(RFID) identification with Manufacturing Execution System(MES) system to transfer the body of SKD export vehicle from domestic OEM production line to another Knocked Down(KD) workshop for assembly, and proposes corresponding solutions for the beat issue and empty skid reflux.

Resistance Spot Welding (RSW) is widely applied in automotive body manufacturing for its advantages such as high efficiency, high-quality, high automation and good flexibility. This paper commences by reviewing domestic and foreign research on RSW, including parameter optimization, electrode optimization, and new materials application, summarizes the current research status of RSW, it then delves into recent advancements in novel hybrid RSW technologies, such as ultrasonic hybrid resistance welding and laser hybrid resistance welding. Lastly, based on the current research status, the paper identifies existing issues and proposes future directions for development.

To improve the rationality of automotive spray design, spraying simulation technology is introduced to dynamically analyze the commissioning process of spraying robots on the basis of traditional spraying technology, and the paint film thickness effect is evaluated visually for the spraying path and spraying parameters. The results show that the matching rate between simulation calculation of painting film thickness and painting workshop reaches 84%, the homogeneity of painting film thickness is improved by 15%. In addition, the wastage of paint is reduced, paint cost is reduced by 5%, and varnish cost is reduced by 11%.

Aiming at the concave deformation of a certain vehicle front door panel,this paper conducts a concavity resistance analysis and optimization on the front door outer panel through a joint numerical simulation. Firstly, Hypermesh is utilized to construct the CAE calculation files. Secondly, the uniform distribution method is applied to fix the loading points in the key areas of the front door panels. Thirdly, the successive loading method is utilized to load and unload the front door panels. Finally, the ABAQUS solver is called for calculation to obtain the “Force-Displacement” curve,the front door displacement contour plot, and residual deformation contour plot. The results show that the anti-denting performance of the key area of the original state of the front door outer panel is insufficient, requiring optimization and improvement. The optimization results indicate that the maximum displacement at point P₂ is reduced by 33.72 %, and the residual deformation is reduced by 86.66 %; the maximum displacement at point P₃ is reduced by 28.33 %, and the residual deformation is reduced by 96.58 %.

In order to achieve the connectors docking of automatic charging robots for elevtric vehicles under Low-precision conditions, a connector flexible docking mechanism with 4 degrees of freedom has been designed. Through tolerance analysis, the flexible mechanism can satisfy the requirement of operation range when the positioning deviation is 10 mm and angle deviation is 5°. Force analysis determines the adjustement of design parameters to reduce insertion and extraction force. Simulation analysis and actual experiment prove that the insertion and extraction force is under 140 N which satisfies the requirement specified by standard.

To improve the service life of automotive brake pedals, this paper investigates the impact of different factors affecting the fatigue failure of automotive pedal components, applies the Fault Tree Analysis (FTA) method to solve the structural importance of components through the minimal cutset. The frndings indicates that material and load are the primary causes affecting the life of brake pedal components, with stress concentration being a seeondary cause. Taking a heavy truck brake pedal Finite Element(FE) model as an example, the finite element software Hypermesh and fatigue software nCode are used for predication and analysis, and the stiffness test experiment of the pedal is carried out to verify the rationality of the model.

To in vestigate the consistency of results from outdoor exposure and xenon lamp aging tests on exterior plastics, 8 kinds of materials are selected to compare their appearance, clolr difference, gloss and tensile strength, and correlation coefficient is used to analyze the correlation between the two tests. The research results show that results of xenon lamp aging and outdoor exposure vary for ditferent materials, among which 6 materials have more severe results after Hainan exposure than Dunhuang exposure. For PMMA+ASA, PC and PMMA, SAE J2527 cannot accurately simulate exposure results in Hainan region. Furthermore the changes of tensile strength after xenon arc exposure 4 000 kJ are the same as 2 years outdoor exposure.

In order to address cracking failure of door arrester of a vehicle in door slamming durability test, polarized microscope and mold flow analysis are used to analyze defects in parts and develop process optimization measures. The results show that extending the shot blasting time of steel core can effectively remove surface burrs and reduce microdefect and stress concentration around sharp boundary after injection molding. Extending boiling time can improve water absorption of plastic cladding, thereby enhancing the notch impact strength and failure stress. Adding exhaust insert in the tooling can improve parting line and reduce air pockets inside the plastic cladding. Adjust injection hole of check link arm to transfer the uneven flow of material to low stress zone, reducing failure risk. Finally, the reliability of optimized parts is verified via door slamming durability test, which solves plastic cladding cracking failure.