Based on the actual project experience and the study of the actual cases, this article emphatically analyzed the requirements of the positioning system for the integrated automatic assembly system, sorted out the coordination relationship and structural characteristics between the 4 positioning systems of body floor Reference Point System（RPS） positioning system, body & sling positioning system, sling & assembly station positioning system and pallet & body positioning system, it also introduced the main process and physical elements of assembly planning, including but not limited to key planning elements such as floor layout, conveyor system, assembly system and tightening system, so as to provide reference for the planning and design of assembly process.

The self piercing riveting & bonding composite connection point with aluminum plate was taken as the research object. In the early stage, through the dynamic tensile test and CAE simulation modeling calibration of the connection point under 3 working conditions of tension shear, tear and forward tension, the parameters in the constitutive relationship of CAE simulation model were accurately obtained. Finally, the comparative verification test of CAE collision simulation and high-speed impact was carried out for T-shaped components with multiple working conditions, CAE simulation accurately predicted and realized the failure of the connection point, and the simulation accuracy reached 95.9%. It accurately characterized the deformation and failure behavior of the riveted-bonded composite connection point under mixed complex working conditions, which has high practicability in the CAE simulation of vehicle collision.

In order to improve the efficiency of the electric drive system for electric vehicles, this article summarized the solutions to improve the efficiency of the electric drive system in motor design, material selection, process assembly and other aspects. In the motor design, motor suitable for the electric vehicle was selected, and the control algorithm was optimized; in terms of materials, copper wires, silicon steel materials and high-frequency materials with high performance were selected; in process assembly, the application of flat wire winding process can improve the torque and efficiency of the motor, the core and stacking process were optimized to reduce the motor iron loss. The efficiency of motor drive system for electric vehicles can be improved by increasing the system output efficiency and reducing various losses.

By studying the principle of resistance spot welding and the actual state of field production, combined with the BOSCH controller, curve analysis of UIR and the splash statistics function, this article analyzed the causes of splash in resistance spot welding. According to the cause of splash, hardware adjustment, parameter adjustment and Bosch software function were adopted to reduce splash rate. The results show that the above experiment effectively reduces splash rate, guarantees welding quality, extends the service life of fixtures, grips and welding clamps and other equipment, and improves the field operation environment of welding.

This paper summed up the causes of chip and solutions through many practical cases of mold chip maintenance experience. The paper analyzed in detail the process from sheet metal to stamping parts, described the blanking, press equipment and die, in particular it analyzed the die from drawing chip, trimming and punching chip and flanging chip. Such analysis was reflected to matters for attention regarding material chip in the new project mold acceptance, and a set of chip maintenance standard process was formed, which can be directly used for reference when the chip appears.

At present, the disposal of waste solvent for water-borne paint cleaning is a problem of the automotive industry that is difficult to overcome for high disposal cost and high technological difficulty. In order to solve this problem, membrane separation material & recycling technology was invented, which separated and recycled the waste solvent produced in painting and color change and cleaning of painting equipment by membrane separation & recycling technology. In this process, 75% of water was recycled and reused in the painting line, while the paint was extracted to make renewable paint, the material was thus recycled and reused. The technology has been applied to Audi painting line for 2 years with reliable performance, the cost reduction of the 150,000 units painting line exceeded 5 million yuan.

Projection welding of M12 ring convex welding nut and 2.5 mm thick plate has the defect of faulty welding, using energy storage welding machine in place of power frequency convex welding machine can solve the defect of faulty welding. There is an optimal combination of welding voltage, tempering voltage and welding pressure in the welding parameters of the energy storage welder. The orthogonal test is suitable for optimizing the optimal welding parameters. The optimized parameters (welding voltage 650 V, tempering voltage 650 V, welding pressure 16 kN) were used for test welding to obtain a convex welding joint with ejection force of 33.55 kN, which was greater than the target value of 16 kN. The high strength joining between ring convex welding nut and thick plate is realized, proving that the capacitor energy storage welding machine has the advantages of energy saving, high efficiency and stable welding quality, which is suitable for the welding between large nut sizing over M10 and thick plate.

In view of the situation that existing CAPP system for engine valve is difficult to directly group and establish a database problem for the valve parts made by the enterprise, a valve part grouping program was developed based on grouping technology. For the problem that CAPP system characteristic cannot indicate clearly after matching the positions needing modification for the existing process files, the relationship between valve part characteristic and machining was simulated based on numerical control technology, and a new matching program of valve parts characteristic was developed.

This paper studied Radio Frequency Identification (RFID) technology, briefly summarized the basic definition, components and basic working principle of this technology, and elaborated in detail the application of SICK brand RFID in automatic welding production line, parameter setting method, hardware network composition principle, software control method and information analytic mode. The vehicle model information engraved in the tag is used to realize automatic identification and mixed flow production of high and low end models on the same production line, which has advantages of simple mounting type, fast identification, accurate information. The model production assignment is passed on from the principal computer to the line, which can remotely control model ratio, has high digitization production capability, and greatly improves production efficiency and automation level.

This paper described the phenomenon of punching delamination of hot-rolled steel plate 700L for frame side rails and its harm. Through macro and micro observation, combined with the blanking process principle, the factors of material, process and mechanism that lead to delamination in punching were analyzed. It is believed that severe plastic deformation during punching leads to serious fibrosis of the structure, and the fibrous structure delaminates or breaks under the action of shear stress and normal stress, forming a competitive mechanism with the generation and expansion of main cracks in the tear band. If the delamination and fracture of the fiber occur later than the crack of the tear band, the delamination or serrated fracture on the surface of the punched hole can be prevented. Using Theory of Inventive Problem Solving(TRIZ) theory, the prestressed punching process is designed and developed, which not only ensures the integrity of the punched hole surface, but also ensures the punch life.