This article provides an overview of the current research status and development trends of key technologies for brake discs. It primarily focuses on aspects such as temperature field control, fatigue life prediction, lightweight design, and brake noise control. Research indicates that by optimizing structures such as ventilation holes, heat dissipation rib layout, and surface grooves, combined with geometric parameter control, convective heat transfer efficiency can be significantly enhanced, temperature gradients effectively reduced, thermal stress peaks lowered, thermal deformation suppressed, the risk of thermal cracks reduced, and fatigue life improved. The introduction of optimization algorithms has facilitated the collaborative design of heat dissipation performance and structural strength. Through topological optimization, material distribution and shape optimization can be restructured, leading to significant weight reduction. Optimizing the vibration source or improving the thermodynamic characteristics can effectively suppress brake noise. In the future, the optimization of brake discs needs to consider the effects of dynamic thermal-mechanical coupling, cyclic mechanical vibration, and extreme operating conditions during actual braking processes.

To address the issues of low accuracy and poor robustness in hole detection within 3D scanned point clouds of automotive components, this paper proposes a hole detection method that integrates α-Shapes with geometric-topological dual constraints. First, an improved voxel filter is used to preprocess the point cloud for noise reduction; Subsequently, a multi-scale triangular mesh is constructed via α-Shapes, and potential hole regions are extracted by combining boundary analysis; Finally, curvature features and normal vector consistency constraints are introduced to screen for real holes.Experimental results show that on a dataset containing 30 groups of automotive component point clouds, the proposed method achieves a hole detection accuracy of 97.3%. Its recognition rate and efficiency are both improved compared with the traditional Delaunay algorithm, and it can effectively adapt to scenarios with complex surfaces and multi-scale holes.

To reveal the influence of lubricant parameters on the efficiency of parallel-axis electric drive axle systems and optimize the lubrication matching design, a theoretical model of power loss and efficiency is established using a commercial vehicle parallel-axis electric drive axle as the subject. Theoretical analysis and bench tests are conducted around oil viscosity, operating oil temperature, and lubricant filling volume. The results indicate that using 75W-80 low-viscosity lubricant can improve system efficiency by approximately 0.84%, maintaining oil temperature at (90±5) ℃ enhances efficiency by about 0.99%, and filling 80% of the designed oil volume boosts efficiency by roughly 1.40%.

This article focuses on the fatigue performance of thin aluminum plate SPR riveted joint. Through a series of physical tests on the fatigue performance of thin aluminum plate SPR joint, the fatigue life relationship under tensile and shear loads are obtained. Based on the Rupp theory and combined with simulation method, the stress range and fatigue life relationship under tension and shear loads are obtained. Nine parameters of Rupp constitutive model are optimized using Excel & Hyperstudy, and a normalized S-N curve for the fatigue life of thin aluminum plate SPR joint is constructed. The fatigue life prediction method for thin aluminum plate SPR joint is established, supporting the forward design of thin aluminum plate SPR joint structure.

In the automotive painting pretreatment process, one-step phosphating method is suitable for bodies with an aluminum content of ≤40%, while two-step phosphating (phosphating + passivation) can handle high-aluminum or all-aluminum bodies. This paper compares their process characteristics, consumable consumption, and body appearance quality. Case analysis reveals that when the aluminum content is low (below 30% in this case), the two-step method consumes approximately 20% more materials per vehicle than the one-step method. Furthermore, the two-step process is prone to causing streaks and pit defects on the surface of aluminum outer panels after electrophoretic painting. These streak defects can be mitigated by optimizing phosphating parameters and spray processes, while pitting defects can be reduced by adjusting the aluminum sheet's Electro Discharge Texture(EDT) process. The research demonstrates that for production lines with low aluminum content, the one-step phosphating method holds significant advantages in both economy and final quality.

To investigate the film-forming performance of nickel-free phosphating on various substrates and its compatibility with coatings, this paper examines the characteristics of nickel-free phosphating films on cold-rolled steel sheets, hot-rolled steel sheets, and aluminum alloys, and evaluates their compatibility with electrophoretic paint and powder coatings. The results show that the performance of the nickel-free phosphating film on the tested substrates is comparable to that of ternary phosphating films, and it demonstrates good compatibility with both electrophoretic paint and powder coatings. Therefore, it can be applied to the pre-paint phosphating treatment of automotive components such as vehicle bodies and powder-coated frames.

To address the issue of large fluctuations in subjective odor evaluation within vehicles and the high difficulty in tracing the source and making rectifications, research on the objective evaluation of vehicle cabin odors is conducted. Gas Chromatography-Mass Spectrometry (GC-MS), high-performance liquid chromatography, and Gas Chromatography-Ion Mobility Spectrometry (GC-IMS) are employed to test the entire vehicle and its interior components such as seats, door panels, and instrument panels. Key odor-contributing substances are screened out through odor activity values. The results indicate that aldehydes, ketones, and acid esters are the core odor-contributing components, and the door panels have the highest odor similarity to the entire vehicle. A corresponding relationship between subjective odor perception and objective substance content is established. GC-MS and GC-IMS are able to achieve precise odor source tracing and verification of rectification effects, providing technical support for the control of in-vehicle air quality.

Currently, internal components of automotive lamps are primarily secured by methods such as snap-fit or mechanical fastening. However, snap-fit assemblies carry risks of material embrittlement and fracture, while mechanical fastening structures require reserved space for screw holes, leading to inefficient space utilization. These issues constrain the improvement of weight reduction and reliability in automotive lamps. To address these challenges, this paper proposes an adhesive bonding solution for lamp components based on ultraviolet (UV) -curable adhesive. Tests were conducted on the tensile strength, moisture resistance, high-temperature resistance, and thermal cycling performance of different adhesive materials, as well as the reinforcing effect of plasma treatment on the bonding interface. The test results indicate that UV adhesive can achieve a bonding strength of approximately 10 MPa when bonding plastic parts, demonstrating certain engineering feasibility. This provides a new technical pathway for upgrading automotive lamp manufacturing processes.

This paper addresses the issues of low offline program availability, long commissioning periods, and frequent equipment collisions in the commissioning phase of body integration projects. It proposes a systematic digital solution that integrates 3D large-space laser scanning, Delmia-based robot simulation, and EKS virtual commissioning with Scout verification. It achieved over 50% first-time utilization of robot offline programs and raised commissioning efficiency by approximately 30%. Statistical analysis further predicted the consistency between simulation model and actual conditions across the entire workshop and identified the influence of equipment type on deviations. The research provides an effective methodological reference for equipment installation and commissioning period reduction in body integration projects.

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.