In order to reduce stamping cost from perspective of material cost control, this article discussed the cost control strategy for automotive stamping material from three aspects: improving material utilization rate, applying new sheet metal manufacturing processes, and selecting materials rationally, combined with specific application cases. Firstly, material utilization can be improved by product collaborative development, stamping process optimization, and reusing stamping waste materials. Secondly, in the application of new sheet metal manufacturing processes, processes such as roller pressing and integrated heat forming can be used to replace the process of single stamping or multiple separate stamping followed by spot welding. Finally, in terms of rational material selection, principles for selecting steel with the same strength, using bake-hardening steel instead of interstitial-free steel, and recommendations for the application of high-strength steel are provided.

It is difficult to solve the problem of exterior quality control of PVC bubbles in doors and covers in the production process. To eliminate the drawbacks in PVC bubble quality by empirical qualitative management, a free sliding wooden plug closed space model for PVC bubbles generation was constructed, and combined with the Ideal Gas Law, the quantitative formula for characterizing the quality state of PVC bubbles was attained, and the formation mechanism of PVC bubbles was analyzed from the perspective of mathematical models. Based on mathematical model and quantitative characterization formulas, the impact of factors including original cavity volume of the sheet metal fold, the highest temperature of PVC drying room, PVC materials, and other environmental factors on the positive or negative correlation and degree of influence of PVC bubbles can be objectively reflected, thereby the direction of quality control of PVC bubbles is more explicit from design and process.

The aluminum alloy vacuum high-pressure die-casting technologies are gradually applied in the automotive industry. This paper studied and analyzed the material, process, product and the key issues at present stage of the vacuum high-pressure die-casting, summarized the physical characteristics, chemical compositions and mechanical properties of heat treatment materials and heat treatment free materials in detail, elaborated the technical process, production line, process design, process parameter and formability properties of vacuum high-pressure die casting, analyzed the main issues at present stage including product performance, thickness, dimensions, connection, repair and die. The paper also summarized the advantages of vacuum high pressure die-casting technologies and forecasted its development prospects.

The thermal conductivity adhesive, a key component of thermal management of power battery, was taken as the research object, and the simulation model of power battery was established by using simulation software Fluent. The coating area (85%~95%) of the thermal conductivity adhesive was simulated and calculated, and the influence of the use of thermal conductivity adhesive on the temperature field distribution and temperature consistency of power battery under typical working conditions was studied by bench test. It provides the basis for the selection and dosage of thermal conductivity adhesive in the design stage of thermal management scheme. The results show that as the coating area of the thermal conductivity adhesive decreases from 95% to 85%, the maximum temperature of the battery increases from 47.87 ℃ to 50.84 ℃, and the maximum temperature difference of the upper surface increases from 2.40 ℃ to 5.87 ℃. Considering the design criterion of power battery, it is determined that the use of 90% of the coating area of thermal conductivity adhesive can meet the design requirements of the highest temperature and temperature difference under three harsh working conditions of the power battery, avoiding the waste of raw materials caused by excessive heat conductivity adhesive in actual production, and achieving cost savings.

To address the issue of full lifecycle management of power battery, this article analyzed the different application scenarios and key functional requirements in the full life cycle management process of power batteries, designed an intelligent battery management system based on the Internet of Things for full life cycle management, and analyzed the operating mechanism of the model. The architecture and functions of the intelligent battery management system were designed, including the system architecture of the terminal battery management system, the selection of key sensors and the functions of cloud based battery management systems. Finally, the characteristics of intelligent battery management systems including compatibility, extendibility and intelligence, as well as the problems they face in application including data security, development and building of cloud based server, were summarized.

In order to solve the existing problems of too many processes in the In-Mold Graining Lamination (IMGL) process, the IMGL process based on Thermoplastic Olefin (TPO) skin was optimized and applied in practice. Compared with the existing problem of too long processes, this paper proposed the reduction of some processes and optimization of the forming equipment and mold, which were put in production. Compared with the existing IMGL process flow chart, the new flow reduced 6 processes, saved 35 m² production site, shortened the IMGL forming cycle by 15 s, reduced glue usage, and improved the utilization rate of glue by 90%.

To explore the differences in energy properties between natural gas commercial vehicles and traditional commercial vehicles (diesel), this paper described natural gas characteristics, the cost of refueling equipment, common leakage scenarios, and the emissions of pollutants and greenhouse gases from commercial vehicles, as well as their driving range, then analyzed and explained the gas cylinder and gas route structure and principles of the natural gas commercial vehicle supply system. Arrangement of gas supply system for a domestic heavy-duty commercial vehicle was dissected, and the assembly process and technical specifications for natural gas heavy duty commercial vehicle were developed. Finally, the paper studied the leakage test operation procedures of the GB 19239-2022 “Gas Vehicle Gas System Installation Specifications”, and summarized the nitrogen displacement operation procedures and production processes for natural gas heavy-duty trucks from assembly to storage.

In the existing automobile manufacturing process, multi-model and multi-platform co-line production has gradually become a trend. In order to improve the flexibility of the assembly line of automobile chassis system, combined with the characteristics of product structure and the actual situation of production site, the characteristics and requirements of the co-line production of automobile multi-link and torsion beam rear suspension structure were expounded from the aspects of assembly process, equipment form and quality assurance, for the co-line production of the two rear suspension structures were summarized, so as to better adapt to the flexible production needs of automobiles.

To ensure the adhesion reliability of door sealing strip in the whole life cycle of the product, the Failure Tree Analysis (FTA) model of door sealing strip degumming was established considering the whole process of part design, manufacturing, assembly etc., to analyze various failure events, and 40 corresponding bottom events were identified, which were used to conduct Failure Mode and Effect Analysis (FMEA), to evaluate risk index and Action Priority (AP) of each degumming mode. 2 high priorities and 4 medium priorities for improvement were identified that were implemented to solve degumming.

The life cycle assessment method was briefly introduced and applied to automotive painting process, the important environmental footprints including carbon footprint during painting production process were tracked, the impact of the use of materials, resources and energy as well as generated emissions on the ecological environment during the whole life cycle production activities of automotive painting process were quantitatively evaluated. The results show that energy consumption and generated emissions, utility power, topcoat and pretreatment electrophoresis processes, and grid power supply have more significant impacts on climate change and fossil resource depletion; material consumption and generated emissions, topcoat, sealant and pretreatment electrophoresis processes, and photovoltaic power supply have more significant impact on ecological toxicity and human toxicity.