This paper discussed the rationality of structural technology design of the parts from the aspects of modeling feature, slope and rounded corners, proposed precautions for process surface design from aspects such as process surface construction and settings, elaborated on blank design to solve the problem of low material utilization rate through laser cutting and layout, the paper also elaborated on the development risks and control involved in hot stamping formability analysis from CAE simulation process. The paper explored the hot stamping forming process technology involved in the development process of integrated door ring from the above 4 aspects, providing reference experience for the development of integrated door ring process technology, in order to solve the relevant problems in the development process, and also better reduce its development cost and shorten its development cycle.

Based on the exploration of the application of aluminum alloy in automobile parts, the basic situation of aluminum enterprise distribution, aluminum alloy composition elements, properties and processes are summarized. The commercialized application of aluminum in automobiles, especially in car bodies, is summarized. This paper proves the superiority and applicability of aluminum in automobile application, and summarizes the common methods of connecting aluminum parts with different and same materials. Research shows that the research and development of high-performance aluminum needs to be strengthened compared to foreign companies, and the diversification of automotive materials is constantly expanding in the field of lightweight, but the application of aluminum is still mainstream.

A complete visual inspection system based on YOLOv5 combining with PLC, RFID, Python, OpenCV and DingTalk, was designed to replace manual inspection and recognition of the installation status of automotive parts. Accuracy and recall rate of the sample models trained in this system are both above 98%. From actual operation observation, the probability of identifying and accurately reminding is above 99%, and it meets the requirements of production takt, superior to the actual results of current manual detection, with low cost and good economic promotion.

This paper elaborated the anti-loosening method of adjusting nuts for automotive rack and pinion steering gears, and studied the riveting point method using riveting head to damage the threads of adjusting nuts. In this paper, the number of riveting head, the distribution of riveting head, and the riveting pressure were used as control variables, and the loosening torque of the adjusting nut after riveting, the deformation of the pressure block hole of the steering gear housing were utilized as evaluation indicators. According to the test, when 6 riveting heads are evenly distributed on the pitch diameter circle of the adjusting nut thread circumferentially to rivet the steering gear nut, the deformation of the pressure block hole of the housing is less affected, and the locking torque of the adjusting nut is also less affected. Finally, the method of adjusting nut riveting point for steering gear is obtained, in which 6 rivet heads are uniformly distributed on the pitch diameter circle of the adjusting nut thread along the circumferential direction, with riveting pressure of 30 kN riveting pressure as optimal.

To enhance the product maturity and solve the problems found in manufacturability analysis, product manufacturability baseline and mechanism were established. The first version of baseline was established through clarifying the scope, developing template, identifying source, confirming dimension, refining content, process confirmation, design confirmation, release and maintenance. Relevant activities such as identification, analysis, evaluation, and accumulation were integrated with the product development process to ensure the procedural application of baseline in the project. Combined with the product development project, the effect of baseline establishment and application were verified, improving the standardization, accuracy, and comprehensiveness of manufacturability analysis, improving product quality and production efficiency, as well as reducing manufacturing costs. At the same time, future expectations for the digital application of baselines were proposed.

This paper elaborated the current situation of the application of aluminum alloy integrated die casting technologies in new energy vehicle enterprises and the planning of integrated die casting in mainstream new energy vehicle enterprises, it is concluded that the integrated die casting technology has obvious advantages in production efficiency, cost reduction, weight reduction and other aspects, and die casting machine will replace the welding robot as the core equipment of new energy vehicle manufacturing. It also indicates that the core of the integrated die casting technologies is the performance of large die casting machine, the formula of heat-free material, die casting die design and die casting process parameters. The research result shows that aluminum alloy integrated die casting will replace the manufacturing technology of body stamping and welding, the paper recommends that new energy vehicle enterprises that do not use integrated die casting should plan the integrated die casting technologies in advance.

This paper introduced the planning layout, equipment composition, process flow and application prospect of the workstation through survey and research on the CMT arc welding workstation of the new dual-machine coordinated robot with positioner. In combination with the application description of the emerging technology of arc welding quality tracing system and arc welding visual guidance system in arc welding process, this paper expounded how to solve the problems of low robot utilization rate, low welding efficiency and poor control of weld quality of traditional arc welding workstation. The purpose of improving and optimizing of arc welding process, in-depth research and development has been realized, and the efficiency and intelligence of arc welding workstation have been improved.

Based on the technologies of vision detection, Automated Guided Vehicle (AGV) transmission, industrial robot intelligent grasping and automatic tightening, the automatic assembly efficiency, assembly quality and flexibility of welding and adjusting door cover have been greatly improved. The multi-channel cameras were integrated on the grab, and the key feature points were identified and extracted by taking photos of the door cover and the body-in-white, and the clearance and difference of each position between the door cover and the body-in-white were calculated, and then the clearance and difference matching algorithm was adopted to calculate the best position of the door cover relative to the body in white, then the transfer robot was guided to grab the door cover to reach the best assembly position. The door cover was tightened automatically by the tightening robot carrying the tightening shaft. The door cover automatic assembly technology not only improves the assembly efficiency and quality, but also reduces the labor load and cost, and ensures the overall appearance quality of the body-in-white.

To solve the problems existing in the selection method of typical test conditions of the traditional load spectrum, this paper explored the potential relationship between process parameters by fuzzy clustering analysis, and realized the classification and primary selection of operating conditions data, meanwhile, the fuzziness of the classification process was fully considered and the subjective randomness of the preliminary selection of the scheme was avoided. On the basis of the preliminary selection results, the Analytic Hierarchy Process (AHP) was introduced to comprehensively consider the 4 comprehensive evaluation indexes, namely, the typicality and comprehensiveness of the selection of test conditions, the economy of the test and the amount of spectral data. The hierarchical structure model of the system was established, and the representative test conditions were selected by combining qualitative analysis and quantitative calculation, thus improving the scientificity and systematization of the selection of typical test conditions.

Bolt connection is the most commonly used connection technology in automobile industry, its connection failure is a common problem in automobiles, in particular, bolt looseness is the most common problem. Through the research on self-tapping locking bolt, it is found that it has the advantages of high connection reliability, repeated use and low system cost. Through the bolt assembly process development, the difference of torque-clamping force relationship with ordinary bolts was distinguished, the assembly process parameters were determined and reliable bolt connection was realized.