This study focuses on the adhesive-rivet composite connection of automotive body dissimilar metal sheets. A finite element model of adhesive riveting and self-piercing riveting composite connection established using Simufact Forming software. The upper plate made of 1mm DC04 steel plate, and the lower plate made of 2 mm 5052 aluminum alloy plate. The adhesive-rivet composite connection process using epoxy resin structural adhesive simulated using finite element analysis. By analyzing the specific parameters of the internal locking value, nail head height, and remaining thickness of the adhesive-rivet composite joint by changing the height of the rivet, the depth of the concave mold, the height of the convex platform, and the pressing speed, it found that the optimal forming process achieved when the rivet height 5 mm, the diameter of the concave mold 10 mm, the depth of the concave mold 1.9 mm, the height of the convex platform 0.9 mm, and the pressing speed 45 mm/s. And the simulation results are verified through riveting equipment, and the trend of riveting force change in both results the same as the shear tensile failure mode. The error of joint characterization parameters within 10%, which further verified the high reliability of Simufact Forming software.

To improve numerical control plasma cutting appearance quality of longitudinal beam, the Lean Six Sigma DMAIC model is used as the research framework to analyze the factors leading to unqualified appearance quality of longitudinal beam numerical control plasma cutting. A test model is established, and data analysis and result prediction are carried out through Minitab software to identify the key factors leading to the abnormal appearance quality of longitudinal beam numerical control plasma cutting. The processing parameter setting scheme of longitudinal beam numerical control plasma cutting is determined. Trial production on the production site indicates that the optimization scheme can effectively reduce the unqualified rate of longitudinal beam numerical control plasma cutting appearance, and improve the production quality of longitudinal beam of heavy truck frame.

In order to improve the quality and efficiency of the DTS inspection for the automobile class-A-surface and assembly data, a DTS rapid inspection application is developed by using the Component Application Architecture (CAA) technology of CATIA, This application can quickly identify measurement objects, cancel the creation of auxiliary elements, automatically obtain the positions to be inspected, automatically measure gaps and flushes, and judge the qualification status so as to achieve intelligent inspection. The results show that the inspection efficiency is improved by more than 50% through verification.

To achieve lightweight and energy saving and emission reduction of heavy trucks, load bearing condition (displacement change, bending, pictures of Scanning Electron Microscope (SEM) and surface appearance) of Expanded Polypropylene (EPP) with different foaming ratios (10 times, 9 times and 8 times) is analyzed and studied based on the basic design criterion of EPP products. Through UG NX 11.0 simulation analysis software, the structural strength of different thicknesses (30 mm, 40 mm, 50 mm) is analyzed by finite element method, and combined with material properties and appearance surface effects, the optimal foaming ratio and thickness of EPP heavy truck sleeper are defined.

The problem of blowing white powder from the air conditioning box of the test car is analyzed by means of energy spectrum and metallographic analysis, and it is confirmed that white powder is an oxide of aluminum formed after corrosion of the evaporator. Through infrared and corrosion resistance test analysis, the results show that the serious corrosion is caused by the evaporator in a humid environment in which galvanic corrosion occurred under the catalysis of Cu. The solutions such as replacing materials and using passivation and hydrophilic chemicals with higher corrosion resistance are proposed so as to effectively solve the problem of blowing white powder in air conditioning boxes because of the evaporator’s corrosion.

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%。

In order to improve the flexibility of the welding production line for car body in white, this paper proposes a T-shaped automotive flexible switching system. Firstly, this article studies the composition of the T-type flexible switching system and the working process of each component, and proposes that this switching system can switch 2N+1 vehicle models. Secondly, the power and transmission parts of the switching system are studied, and the motor parameters, guidance and positioning schemes are determined. Moreower,the module division and interface design of the switching system is proposed, and a module division diagram is obtained. Finally, the working process of the switching system is simulated in the Tecnomatix environment. The results show that the design of the T-type flexible switching system is reasonable and can achieve switching between 2N+1 vehicle models.

Based on the thread slip-tooth occurred when the front suspension assembly upper support seat is assembled with the body in the assembly process, this paper analyzes the excessive contact gap between the front suspension support seat and the body, poor positioning angle of the front suspension assembly upper support seat, and the related supporting tools,. Correspondingly’ it is a so proposes an optimization scheme to improve the front suspension tray support tooling and the new front suspension upper support positioning tooling, which ultimately reduces the defect rate.

In order to study the effect of supply chain on vehicle whole life cycle carbon emission, this article collects the carbon emission data of the supply chain through China Industrial Carbon Emission Information System (CICES), aims to study and analyze the carbon emission of the whole life cycle of a vehicle. The results show that the upstream and downstream supply chains such as raw material production, parts production and the using stage of the vehicle are the main factors affecting the carbon emission of the life cycle of the vehicle, and suggestions on carbon emission management of the supply chain are put forward.

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.