In order to address the issue of low automation and digitalization of the automotive body wax filling process, this paper discussed feasibility of total process automation from production, inspection to repair in automobile wax filling, and proposed an automatic solution of automobile wax filling. In the production process, the body wax filling was realized through technological transformation by the application of low cost automation. In the inspection process, visual identification technology was used instead of manual inspection to capture and identify the wax mist on the vehicle body and reduce the body defect outflow rate. In the repair process, through the analysis of the wax defects, the auto body bottom plate purge device was designed to eliminate the wax overflow on the premise of meeting the performance requirements of the vehicle. In addition, the paper also proposed the data interconnectivity scheme. The results show that the production efficiency and cost have been greatly improved through the application of automation.

This paper analyzed the working principle and structure of PEMFC with emphasis on the key components of bipolar plate, proton exchange membrane, electrocatalyst and membrane electrode. The high production cost is the main factors hindering the commercial popularization of PEMFC. In the future with the technological advance of PEMFC, production cost will decline dramatically, PEMFC is expected to be widely applied in the automotive industry.

In order to improve working efficiency, operation accuracy and safety, and reduce the error rate, based on the automatic spindle equipment, after the engine is connected to the gearbox, the servo motor of the spindle equipment automatically rotates the engine pulley to drive the crankshaft flywheel group to rotate. The high precision rotation of the servo motor ensures that the flywheel and the coupler are connected and fastened after the flywheel and the coupler are connected and fastened, and the coupler is rotated and fastened by automatic equipment to replace the traditional manual operation, which saves manual cost of connecting flywheel with coupler, and can precisely implement the spindle operation. The engine flywheel disc is fixed by the automatic clamping mechanism on the device, which solves the problem of affecting the operation efficiency of the disc shaft due to shaking in the process of lifting the engine disc shaft, and improves the success rate of coupler tightening.

Carbon Fiber Reinforced Polymer (CFRP) is a material with excellent mechanical properties. The application of bonding CFRP parts with body has not been realized in mass automobile production in China. The article described the performance test on CFRP parts bonding with aluminum material and the optimization of process flow. The bonding process flow and process parameters of each process of CFRP on ES6 were ultimately determined based on the test of the curing strength of adhesive under different conditions and the influence of external factors on the adhesive bonding strength, Thus, for the first time, CFRP was applied to the body structure of new energy vehicle on a large scale (production capacity 20 job/hour) in China.

In order to eliminate abnormal sound of the knuckle cone ball stud of a passenger car on proving ground test, this paper proposed a new method based on virtual simulation. Firstly, the ball stud contact area variation tendency was simulated and the contact area critical preload was identified according to limit value of the road load data; then the residual preload under alternate working condition was simulated, and the residual preload was controlled larger than critical preload to avoid large contact area separation which will cause abnormal sound; finally, the tightening process was determined through joint test. The results show that this method can redefine the tightening torque, and the abnormal sound problem was eliminated successfully.

Based on the Gissmo damage failure model, the failure parameters of 6082 automotive aluminum alloy profile were obtained by numerical parameter inverse method. The reasonability of the Gissmo damage failure model of 6082 aluminum alloy was verified by the quasi-static three-point bending test of the aluminum alloy impact beam. Firstly, the hardening curve of the 6082 material was obtained by quasi-static uniaxial tensile test, and the curve was extrapolated by Swift-Hockett-Sherby (SHS) law. Secondly, quasi-static tests (shear, uniaxial, central hole, notch, three-point bending, cupping) under various stress states were carried out, and Gissmo failure parameters were obtained by numerical inversion of test combined with simulation. Finally, the quasi-static three-point bending test of 6082 aluminum alloy impact beam was designed to verify the reasonability of Gissmo model. The test result shows that the Gissmo damage failure model of 6082 aluminum alloy proposed in this research, including hardening curve, failure strain curve, instability curve and mesh-size regulation curve, can predict the failure behavior of 6082 impact beam.

In order to shorten the cycle of product, design and developent, procurement and production, construction of a flexible, efficient, low-cost and high-quality manufacturing operation system, digital twin technology is crucial. This article used an automotive welding production line as an example to elaborate the process of setting up a digital twin factory in Tecnomatix software. Using Tecnomatix series software, the digital model and process information were imported in the pre-planning process, the 3D process layout was carried out in advance, the accessibility of connection processes such as solder joints and gluing was simulated, the spatial static and dynamic interference as well as offline program output were analyzed and solved. Utilizing digital twin technology, the mapping and correlation of real factories in the simulation environment was realized. As a result, the on-site installation and commissioning was accelerated, the project cycle was reduced, the efficiency and quality of production line planning and design were improved.

In order to address the issue of failure fracture of balance suspension leaf spring seat of engineering vehicle, this paper analyzed the balance suspension leaf spring seat by process analysis, fracture analysis, metallographic examination, strength test, hardness test and material fatigue limit testing. The results show that the material used in the balance suspension leaf spring seat meets the standard requirements, and the failure modes include multi-source high stress and low cycle bending fatigue cracking, the crack originates from the rounded root between the balance suspension leaf spring seat and the U-bolt, which is thick and easy to produce defects like shrinkage and porosity in the production process. In the structure, this position is the balance suspension leaf spring seat under the greatest stress position and a dangerous section of the part.

The effects of alkyl acid surfactants with different carbon chain lengths (decanoic acid, dodecanoic acid, tetradecanoic acid, hexadecanoic acid, octadecanoic acid) on the properties of CeO₂-ZrO₂-Y₂O₃-La₂O₃ (CZ) materials were studied and analyzed, and the underlying mechanism of surfactants in building high performance CZ materials has also been revealed. The results of N₂-adsorption/desorption, OSC, H₂-TPR, and catalyst activity show that the addition of all surfactants with different carbon chain lengths during the nucleation stage of nanocrystals can increase the initial grain size of nanocrystals, thereby reducing the driving force of sintering. At the same time, the introduction of surfactants produces more oxygen vacancies in the material, thereby improving its redox performance. Among them, dodecanoic acid plays the most prominent effects improving the thermal stability and redox performance of CZ materials, the resultant CZ exhibits the lowest loss rate of specific surface area of 46.3%, the lowest reduction peak temperature of 497℃, the highest utilization rate of Ce of 39%, and consequently the best catalytic activity of its supported Pd-only TWC.

This paper conducted an in-depth study on the internal cavity corrosion of new energy control modules. The paper firstly analyzed the key factors contributing to corrosion in the cooling system cavity of conventional fuel vehicles. Through a plasma concentration orthogonal test, this study simulated the equivalent ion concentration of the cooling medium to identify the influential corrosion factors. Subsequently, by comparing the corrosion rates of aluminum substrates under different corrosive media, this paper demonstrated the applicability of traditional test methods to new energy control systems. A cavity blockage test was designed to verify the functional failure of the cooling system under affected conditions caused by corrosion. Finally, based on the investigation of internal cavity corrosion in new energy control systems, evaluation criteria for conducting internal cavity corrosion test within the company were developed.