To reduce production investment, this paper makes feasibility analysis of co-line welding production for heavy-duty trucks and pickup BIW from 4 aspects: platform compatibility (sharing similar modular architectures), process adaptability (employing compatible welding and gluing techniques), production line flexibility (utilizing highly adaptable robotic systems), and logistics management (leveraging diversified efficient logistics) —— all demonstrating strong viability for the co-production approach.

Physical Vapor Deposition (PVD) is an important means of metallization of plastic surface. This paper summarizes the concept and characteristics of PVD technology such as evaporative plating, sputtering plating and ion plating. It also elaborates production process of evaporation and sputtering plating, and compares the advantages and disadvantages with those of plastic plating. Moreover, the application of PVD technology in automotive interior parts and related test and verification projects are introduced and the development trend of PVD is summarized and prospected.

The auxetic honeycomb structures, due to their unique auxetic effect, have considerable potential for application in the field of energy absorption. To further improve their mechanical performance, this paper proposes a novel bio-inspired hierarchical origami auxetic honeycomb structure, combining bio-inspired hierarchical design and origami structure. Numerical simulations are conducted to systematically investigate the crashworthiness of the structures under axial compression. The results show that, compared with the traditional auxetic honeycomb structure, the energy absorption capacity of the novel bio-inspired hierarchical origami auxetic honeycomb structure is significantly enhanced. Moreover, the introduction of the origami design ensures more uniform deformation during the axial crushing process, and effectively reduces or even eliminates the initial peak force of the structures.

To improve the robustness of traditional brake disc surface defeet detection, an automatic detection instrument based on machine vision is designed. The defect features of brake discs are extracted using the Improved Gaussian Difference algorithm and Hough Transform algorithm (IGD-IHT). An identification method for brake disc surface defects is designed based on the Perception-based Image Quality Evaluator and Dempster rule-improved Bayes particle swarm optimization-Nonlinear echo state network to better identify defects. The experimental results show that accuracy of this method is more than 97%, the false alarm rate is less than 1.5%, and the missing alarm rate is less than 1.5%. The method described in this article is superior to traditional methods and improves the accuracy of brake disc surface defect recognition. Factory testing shows that this method can accurately identify almost all defects, and there are relatively few false positives or false negatives, and has high reliability and stability.

Integrated die-casting process is increasingly widely applied in the manufacturing of new energy vehicles due to its characteristics such as simplification, high efficiency, lightweight and high strength. However, because of short evolution time, immature and inconsistent design of process routes among various enterprises, there are significant differences both in cost and efficiency. This paper compares the advantages and disadvantages of various process routes and suggests adopting aluminum liquid direct supply scheme, automatic online measurement combined with automatic deburring, and using tapping instead of thread sleeve process as much as possible if conditions permit, which can significantly reduce production costs and improve production efficiency. However, this scheme still has many shortcomings in wide application. By exploring the advantages and disadvantages of process routes used in key processes of various enterprises, more efficient, more economic, high quality and stable process route are summarized deeply.

In order to study the contribution of intelligent connected automobile manufacturing factories to carbon emission reduction, this paper investigates energy consumption of conventional automobile manufacturing factories and intelligent connected automobile manufacturing factories in terms of construction, process, operation and management, and production process, calculated energy consumption and carbon emission indexes of the conventional factories and the intelligent connected factories and analyzes energy consumption and carbon emission. The study finds that the construction and operation of the intelligent connected automobile manufacturing factories can achieve effective control of total energy consumption and intensity and total carbon emission and intensity, reduce energy consumption and substantially reduce carbon emissions.

In order to compare the lubrication properties of the four pre-lubricants, this paper studies the influence of friction coefficient on the material thinning rate in the bulging process by numerical simulation. The results show that under the same other conditions, the smaller the friction coefficient is, the smaller the sheet thinning rate is, that is to say the better the lubrication effect is in the bulging test, the smaller the forming limit height of the sheet. Based on the numerical simulation results, four kinds of pre-lubricants are used to carry out bulging test to compare the lubrication properties. The results show that lubricating oil A has the best lubrication properties, followed by lubricating oil D and B, and lubricating oil C has the worst lubrication properties. In addition, it is found that lubricating effect of lubricating oil B weakens with the increase of coating amount, whereas that of lubricating oil C and D increases first and then decreases with the increase of coating amount.

The support base is an important structure for the stable operation of the plasma cutting dust removal device. In order to enhance operation stability this device, this paper makes a structural optimization analysis of the support base based on the ANSYS Workbench software, including sensitivity analysis for design parameter of each structure, and identified 3 factors which have the greatest influence on the stable operation of support base, namely upper wall thickness, support wall thickness and support height. A second-order mathematical response surface model is constructed based on the experimental design methods, and iterative optimization is made through multi-objective genetic algorithm. The simulation results show that the natural frequency of the bearing increases by 20.47% and the maximum stress concentration decreases by 6.57%. The optimal Pareto solution of the parameter variables is achieved within the design requirements and the durability of the beam is significantly improved, which meets the optimization requirements.

A list of 31 VOCs with risk limits for human health is obtained by sorting out the compounds in the in vehicle/indoor air quality guidelines of 11 countries. M1 type new vehicles are chosen as objects, a quantitative analysis of 104 volatile organic compounds in cabin of vehicle is conducted based on the summa canister gas chromatography-mass spectrometry method. The test results are compared with the list guidelines to screen for risk volatile organic compounds in cabin of vehicle. Except for the 8 items in the international standard, the screening result shows risk volatile organic compounds in the cabin of vehicle include dichloromethane (2.45~706 μg/m³), vinyl acetate (0.91~440 μg/m³), 4-methyl-2-pentanone (0.49~372 μg/m³), naphthalene 0~24.2 μg/m³), butadiene (0.14~4.80 μg/m)³, carbon tetrachloride (0~7.15 μg/m³), trichloroethylene (0~5.01 μg/m³), 1,2-dibromoethane (0~1.59 μg/m³). Suggestions for the subsequent revision of the national standard for vehicle air quality include expanding the management list of VOCs in the indoor air, reevaluating the limit values of 8 substances in the current national standard, and setting 2 limit values for preventive and hazardous concentrations.

In order to improve the quality of automotive DTS, a multi-level local datum system tolerance design is established on the vehicle body assembly according to the requirements of the whole vehicle DTS goals. By introducing local datum virtual fixtures in the 3D tolerance analysis software 3DCS, parts are assembled into different datum systems, and the tolerance correlation relationship between each level datum is established, achieving the rationality verification of the datum tolerance design at each level of the vehicle body. And the analysis results are incorporated into the design of the vehicle’s Coordinate Measuring Machining(CMM) and chimeric check fixture, as well as the requirements for testing tolerances, to ensure the rationalization of the evaluation of the manufacturing deviation of the vehicle assembly. The vehicle’s DTS goals have been achieved through virtual and real verification.