This article mainly introduces the application innovation of Automatic Guided Vehicle (AGV) systems in the application scenarios of material transportation, storage, and sorting between production lines, in process planning layouts, intelligent system design, upward and downward circulation, consolidated sorting processes, and the technique of keeping materials moving continuously. Additionally, it covers multi-path planning with intelligent adjacent scheduling and digital network connectivity innovations. These advancements not only reduce the production area but also provide a more convenient and cost-effective response to the rapidly growing need for flexible, modular production lines in the automotive industry, driven by the increasing demand for personalized customized vehicles.

This article mainly introduces a fast verification of the effectiveness of the optimization scheme for durability cracking of body sheet metal using a simple bench test combined with Miner principle, and then verifies it through vehicle durability testing to form a close-loop optimization method. First, reproduce the problem of body sheet metal cracking in vehicle enhanced durability testing using CAE analysis method. Then, confirm the cause of body sheet metal durability cracking and make optimization scheme. Next, through CAE simulation analysis, design a simple bench test. Through this simple bench test, it is necessary to accurately reproduce the durability cracking problem of body sheet metal, then quickly verify the effectiveness of the optimization scheme. Finally, after verification through vehicle durability testing, the body sheet metal with added optimization scheme did not show any durability cracking problem, which proves the accuracy and effectiveness of this method.

By analyzing the current situation of rear suspension assembly of heavy engineering vehicle, a set of automatic tightening system for rear suspension assembly is designed and manufactured according to input of process design. The tightening system adopts high-precision flexible displacement sub assembly station, high-precision servo rotation interactive platform, digital information production technology, which can realize robot automatic tightening assembly through 3D visual identification camera and positioning technology. This system solves the knotty problem of rear suspension assembly, and it is stable, reliable and practical.

In order to ensure the dimensional accuracy of the outer belt weather-strip, reduce the extrusion production defects and ensure the stability of the outer belt weather-strip installation on the door, the shape of the metal insert and the forming accuracy are particularly important. In this paper, the roll forming process of a kind of asymmetric metal insert section is studied, the cross-section structure is simulated and analyzed by CAE method, and the metal insert structure is optimized and the structure of the existing roll-forming tooling is optimized without affecting the performance, thus solving the defects of material crossing and grinding in the production of a kind of asymmetric section products. Based on this, multiple sets of roll-forming tooling are developed, which effectively improves the production quality of auto parts.

In order to reduce rubber cost of high-speed oil seals for automobiles, performance requirements for rubber materials used in high-speed oil seals are determined according to the application locations and operation conditions. The acrylic rubber formula is analyzed and designed from the aspects of raw rubber selection, reinforcement system, vulcanization system, aging system, wear resistance system, and processing system. Finally, the acrylic rubber formula for high-speed oil seals in automobiles is developed. The test shows that the developed acrylic rubber fully meets the performance requirements of rubber materials for high-speed oil seals, and can replace the expensive fluororubber material for large-scale application in automotive high-speed oil seals.

In order to improve the flexibility level of the integrated body casting production line, through the study of the flexibility and full automation of the material rack, gripper, fixture, logistics and assembly unit, the forward products is designed for the purpose of manufacturing needs, which takes into account the needs of the manufacturing process, and satisfies the requirement of reliable performance, strong practicability, and flexible and rapid switching of multiple platforms and models so as to meet the production requirements of high quality, high efficiency, low cost and multi-model.

To address the limitations of the electric drive system in terms of performance, this paper proposes a performance detection method based on key parameters, which introduces machine learning algorithm based on Gradient Boosted Decision Tree (GBDT) to construct and verify the performance quality detection model, including quality sample data collection, feature engineering analysis, model construction, model fusion and model self-training mechanism, etc., to determine product performance inspection quality based on key production and processing parameters of electric drive system. Combined with production practice, the paper proposes the idea of application scenario construction and its deepening direction. The results show that electric drive system quality inspection can be realized based on key parameters.

Due to the significant difference in the position of the body pivot holes between the new model produced in an assembly workshop and the original one, the existing spreader can’t meet the production needs. Therefore, a solution is proposed to achieve co-production of 2 platform vehicle models by replacing the lifting fulcrum and rear support arm. This solution greatly reduces the modification workload of spreader and the impact on related equipment, shortens the spreader modification cycle, and reduces the cost in integrating new vehicle models. Based on the ANSYS simulation platform, the stiffness and strength analysis of the modified spreader under static and dynamic working conditions are carried out. Online no-load operation testing and vehicle assembly testing are carried out on the spreader samples. The results show that the modified spreader can meet the co-production needs of this dual platform models.

In order to determine the assembly scheme of permanent magnet synchronous motor assembly for new energy vehicle, this paper compares the front magnetized rotor with rear magnetized rotor. The study shows that the magnetic flux of the front magnetization scheme is higher than that of the rear magnetization scheme, and its peak value external characteristics, comparison in the controlled variable motor test is less than 2%, which meets the requirements of power performance indicators, and the efficiency indicators of the two schemes are the same.Moreover, the rear magnetization scheme does not affect product performance, it is the best choice for the rotor assembly magnetization process for good assembly process, high yield, and low equipment maintenance cost.

In order to speed up the process of introducing aluminum engine hood, numerical simulation and Global Manufacturing Simulation (GMS) are used to verify the accessibility, interference, production cycle of the welding robot, and numerical simulation is used to confirm that the welding deformation can satisfy the process requirements, realize parallel engineering with production line, tooling and fixture, and accelerate the introduction of tooling and fixtures. Finally, the introduction cycle of models can be shortened by 3 months, cost reduction of 200,000 RMB, with improved welding quality.