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%。

Taking the cast iron rear axle housing of commercial vehicle as the research object, the bench test fatigue life data analysis and processing of several axle shell types are carried out. And the number of loading cycles at failure is obtained. Using the finite element fatigue analysis method based on time history load, the fatigue equivalent stress of the cast axle housing under the corresponding load cycle is obtained. Then the S-N curve of the cast axle housing is fitted by combining the fatigue equivalent stress and number of failure cycles. The results show that, the current analysing cast axle housing has a problem of low defect control level. The manufacturing process level needs to be improved. Moreover, the importance of formulating defect level classification during design is proposed. The application of the finite element fatigue analysis combined with the test data can effectively predict the fatigue life of the newly designed structure on the premise of stable process level. The finite element analysis results and manufacturing process can be combined effectively to expand the practicability of the bench test data.

In order to trial produce qualified carbon fiber engine hood products and solve technical issues in the manufacturing process, CAE technology method is adopted to optimize and simulate the product structure, determine the manufacturing technology scheme, optimize the product layering technology data, autoclave molding parameters and mold tooling development method, and obtain the development technical specifications and process trial production experience of carbon fiber composite material products. The development and manufacturing process of carbon fiber composite engine hood are complex, and technical specifications and trial production experience have a significant impact on product quality.

Because of high integration, lightweight, good rigidity and the other advantages, the application of integrated high-pressure casting aluminum alloy structural parts in the passenger car body is gradually increasing,and the size of high-pressure casting aluminum alloy structural parts is also developing towards large scale. At the same time, the development of large-scale high-pressure casting aluminum alloy structural parts is bringing greater challenges to the connection technology. The Paper describes the typical application parts of high-pressure casting aluminum alloy for passenger car body, analyzes the difficulties and the connection technology corresponding strategies for applying large-sized high-pressure casting aluminum alloy structural parts. The development trend of high-pressure casting aluminum alloy structural parts and the new requirements for connection technology are also prospected.

The radiator bracket of a vehicle fractured and failed during a vehicle road test. To find the causes of fracture failure, macroscopic inspection, fracture morphology analysis are performed, and numerical simulation method is adopted to perform simulation analysis, and it is found that the irrational structure design leaded to excessive stress in some areas exceeding the yield limit. Then, according to the simulation results, optimization measures are proposed for stress concentration area. After structural optimization, the optimized bracket structure is obtained. The optimized structural strength simulation shows that the maximum regional stress level of the bracket structure is 375 MPa under the maximum load, which is lower than the yield strength of the material (450 MPa), meeting the strength performance requirements.

At present, the automotive market is reshaped with the coexistence of pure electric and hybrid models, and the automotive factories are facing higher quality requirements and faster manufacturing response for flexible manufacturing, equipment sharing, personalized customization. By combining work practice and benchmarking global benchmark automakers, this paper provides key manufacturing factors for adapting multi-energy vehicle assembly processes for efficient co-production through the application of strategic approaehes to advanced teehnology sector including lean production mode, digital simulation, user experience, and carbon neutrality, which can be used as reference for the construction of future highly efficient hybrid assembly factories.

In this research, a new flexible automation technology is adopted to achieve full process automatic production of light truck longitudinal beam. According to the electrophoretic process requirements of longitudinal beam parts, combined with the product characteristics of longitudinal beam cross-section, by using the automatic transportation system to connect the punching machine, cutting machine, forming press and automatic hanging rack, this paperaims to achieve the automation and intelligent production of light truck longitudinal beam at the entire process from sheet metal to forming and hanging. This method has been successfully applied to the actual production in a commercial vehicle in China. After trial production verification, automation level, production efficiency, and cost operation control have been significantly improved compared with traditional production methods.

A new Al-5C intermediate alloy is prepared by in-situ reaction sintering method. Optical Microscope (OM), X-Ray Diffraction (XRD) and Scanning Electron Microscope (SEM) are used to study the effect of the preparation process on the microstructure of Al-5C intermediate alloy and the grain refinement of Mg-Al alloy. The results show that the in-situ reaction sintering method improves the wettability of Al and C, and the reaction degree of Al-C is related to milling time, sintering temperature, sintering time and pressing method. Prolongation of milling time, increase of sintering temperature or appropriate extension of sintering time can promote the Al-C reaction, resulting in the formation of fine Al₄C₃ particles. Al-5C intermediate alloy can effectively refine the microstructure of Mg-3Al alloy, and the best grain refinement effect is obtained when the addition amount (mass fraction) is 2%.

In order to address the issue of microbes slimegenerated by bacteria and microbial breeding sticking on the car bodies and affect E-coat quality, taking bacteria and microbial breeding in pretreatment phosphorization and E-coat process of a painting shop and management as example, this article explores the management of bacteria and microbes from 2 aspects including precautions during production and maintenance during shutdown. Precaution during production refers to improving water rinsing station turnover rate and improving filtration efficiency to prevent microbe slime from contaminating car bodies, whereas maintenance during shutdown refers to dismantling and deep cleaning, combined with bactericide, hot water rinsing and special rinsing tool to form an effective management strategy.

In order to improve the lightweight degree of the whole vehicle, according to the equal strength principle and iterative optimization method, a lightweight new energy tractor frame is designed by using 6082-T6 aluminum alloy extrusion and referring to the structure of steel frame. Through finite element modeling and simulation, simply supported beam simulation calculation, multi-channel bench simulation analysis and physical bench test, the static strength, bending stiffness, torsional fatigue strength performance are verified. The minimum safety factor of static strength of the final frame scheme is 1.11, the bending stiffness is 1.06×10¹³ N/mm, and the torsional fatigue test has not failed for 400 000 times. The results show that the newly designed frame of new energy tractor can meet the performance requirements and reduce weight by 40% on the basis of steel frame.