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.

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.

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 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.

To accumulate experience in the design and manufacturing of lightweight vehicle body connection technologies and enhance the quality of vehicle body mechanical connection processes, this paper summarizes and analyzes lightweight vehicle body mechanical connection technologies such as self-piercing riveting, rivetless connection, hot-melt self-tapping riveting, bolt connection, pull riveting and pressing riveting, and elaborates in detail the process principles, process characteristics, quality control methods and innovative process schemes of each process.

To increase the paint transfer efficiency, reduce production costs, minimize environmental pollution, and enhance production efficiency, this paper first introduces traditional automotive painting technology and the necessity of increasing the pain transfer efficiency, then elaborates the technical direction of paint atomization, and provides a detailed overview of several high paint transfer efficiency technologies, including electrostatic atomization, ultrasonic atomization, microporous atomization. It also elaborates fundamental principle, technical features and current development and application progress of these high print transfer technologies. After that, this paper compares the index and range of application of the above technical approaches as well.

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.

In order to solve the issue of cracking in the polyvinyl chloride (PVC) fine sealing strips in the folded edge areas of passenger car doors, hoods, and trunk lids, and in conjunction with production manufacturing cases of PVC fine sealing strip cracking in the corresponding areas, the paper analyzes the cause of PVC cracking and proposes measures with metallographic analysis method. For the cracking caused by insufficient glue volume of folding edge glue, and sufficient inner and outer board bonding, measures are taken to increase the amount of glue, while ensuring the uniformity of the glue coating. For the cracking caused by external forces, measures are taken to optimize the PVC finishing process to avoid stress concentration. For the cracking caused by over-drying, measures are taken to control the drying time of the PVC. Through the above measures, the cracking are eliminated and solved.

In order to ensure the products applied Arplas welding process to meet users’ requirements, it is necessary to have a perfect and effective process quality standard, and a set of reasonable and effective control methods on the process and equipment to achieve the relevant process standards and quality standards. In this paper, the application of Arplas welding process at the D-pillar position of a vehicle model is taken as an example. Through the accumulation of practical application experience and process control optimization practice, the quality standard and inspection method of Arplas welding process are determined. At the same time, a set of process and equipment control methods are summarized through experience to meet the product quality standards applied in Arplas process.