Based on the mainstream brand robots and the actual project, this paper deeply analyzed the influencing factors of the production pace, the difference of action time between different functions and different models of robots and their impact on the pace, and the load analysis method of robots under static and dynamic load conditions. Through theoretical calculation and actual project verification, it is concluded that in the same range of motion, the motion time of heavy loaded robot is 1.5 times or more than that of conventional loaded robot. According to the analysis, this paper recommended the motion time standards of heavy-duty robot and the method of load redundancy design for robot selection, and briefly described some misunderstandings and countermeasures in the process of robot selection at the conclusion of this paper.

In order to reduce the cost of the solder joint grinding process and control the grinding quality, this paper studies an automatic grinding tool held by a robot and its control system. The closed-loop control is realized through the force control sensor, the feedback is completed within 60 ms and drive the flexible control unit at the same time. Finally, the precision error of the output grinding force is less than 1 N, so that it can grind the complex surface of the body parts. According to the material characteristics of body parts, appropriate grinding apparatus are selected through experiments to ensure the grinding quality. The grinding process is designed according to the process characteristics of the production line, and finally the automatic grinding technology is applied in the production line.

In this paper, the flexible and efficient warehouse with combination of Rail Guided Vehicle (RGV) and lift was the research object. In order to solve the problem that the traditional high speed stacker spatial warehouse cannot meet the high beat capacity Jobs Per Hour (JPH) of 60 Units/h, this spatial warehouse adopted RGV conveying in the horizontal plane and lift conveying in the vertical direction. CAD software was utilized to plan and design the two-dimensional plan of the spatial warehouse, Catia software was adepted to design the three-dimensional model of the corresponding three-dimensional warehouse, and Plant Simulation software was used to verify whether the solution can meet the high beat capacity, and the economic investment was compared with that of the traditional stacker three-dimensional warehouse through cost calculation. The final conclusion is that this flexible and efficient three-dimensional warehouse can meet the JPH 60 Units/h beat capacity and the economic cost is lower than the traditional three-dimensional warehouse, which has wide application prospect.

This article introduced corner cracking of A-pillar hot-stamped part of a vehicle model. Simulation analysis reveals no cracking crisis in stamped part, whereas parts crack in actual industrialization. Cracking mainly incurs at the convex corner with long flange surface. The cause of cracking was analyzed by comparing forming status of parts at cracking position and stamping simulation & analysis parameters, the factors leading to corner cracking of hot-stamped parts were summarized, and simulation & analysis strategy of such parts in stamping was also summarized, the solution of corner cracking was introduced both in product and process perspectives.

Graphite composite bipolar plate was prepared by tape casting method. With electrical conductivity and mechanical properties as the main indexes, combined with Scanning Electron Microscopy (SEM) characterization technology, the slurry viscosity, slurry temperature, tape casting speed, scraper height and liquid level height were explored to study the tape casting process of the green billet of bipolar plate. The results show that, the suitable slurry viscosity is 5 500~6 500 mPa·s, the slurry temperature is 35~40 ℃, the slurry velocity is 0.5~0.6 m/min, the scraper roll height is 1.2~1.4 mm, and the liquid level height is 2.5~3.5 cm. In this case, the fluidized plate has high density of embryos, uniform adhesion, smooth surface and high smoothness.

The welding deformation of Body In White(BIW) directly affects the performance of the vehicle and perceived quality of the interior and exterior. In order to reduce the equipment investment dueto design change, human resources and gestation cycle caused by BIW welding deformation, this paper obtains an effective and feasible process scheme by summarizing typical BIW joints such as U-, Z- and T-shaped joints, combining with welding deformation simulation, physical verification and summarization, as well as comparing different welding process of typical joints. By simulating the welding deformation of typical joints of BIW, this paper obtains the welding sequence of each joint which is most conducive to ensuring the accuracy, and proposes reference for process design, equipment selection and shortening the process design cycle.

The new thin Al-Si coating hot-formed steel has some advantages in automobile application, such as improving the properties of bending angle and so on with the tensile strength, yield strength and elongation rate remain unchanged. This article studied the application properties of 1 500 MPa hot-formed steel with thin Al-Si coating, including formability, welding property, corrosion property and adhesive property. The results show that the thin Al-Si coating has no effect on the formability, it improves the welding performance, while the corrosion resistance degrades slightly, however the overall performance meets design specification, and the adhesive property has no obvious change. Therefore, the batch application of hot formed steel with thin Al-Si coating on car body can be promoted.

In order to effectively control the influencing factors in the process of laser brazing, ensure the stability of quality and efficiency in the welding process, this article, taking the laser brazing of the top cover of a vehicle model as an example, analyzed the factors affecting the stability of the laser brazing process from 2 aspects of laser brazing system, body precision and matching control system through the experience accumulation of optimization verification and problem handling in the process and related application practices in the industry. At the same time, the control measures of the associated system were formulated and the control requirements were formed, to promote the stability of the laser brazing application process and ensure the product quality and production efficiency.

In order to solve the problem of insufficient production capacity in the welding work shop, through the analysis and research on the production line production capacity bottleneck area, 2 process optimization methods, i.e. process rebalancing and process sequence optimization, were applied to reduce the station cycle time according to the characteristics of different stations. In the implementation process, the image motion analysis method was utilized for motion decomposition of each station, to reveal the small steps of every part. At the same time, ECRS principle was used to optimize the optimization points. Finally, the cycle time optimization was successfully implemented for the 2 spot welding stations. The cycle time reduction directly improves the production capacity of the production line. There was no parameter adjustment for the optimization of spot welding process, which provided another approach to reduce the cycle time of similar station.

This article introduced in detail the forming process, engineering logic and thinking methods of automotive dimensional engineering, discussed in depth the working object, work content, work flow, key technologies and management methods of dimensional engineering, as well as the key points of digital empowerment and transformation being carried out, the article also pointed out clearly the universal significance and practical engineering value of dimensional engineering technologies for geometric quality assurance of complex products in manufacturing industry.