In order to reduce vibration and noise from central roof in commercial vehicles, 4 reinforcing films were added to the central roof at additional production costs, and the films were easy to fall off after painting. The root cause of vibration and noise in large cover parts is the weak rigidity of the part, the paper therefore proposed to increase the height of the reinforcing rib while meeting the thinning rate requirements. After stamping analysis, prototype production and road test, the final solution to improve the rigidity of the center roof was to increase the height of the reinforcing rib from 3.0 mm to 7.5 mm. The problem of corner cracking in drawing was solved to increase crimping forces and reduce residual stresses. The cost per vehicle is reduced by 45 yuan by eliminating the reinforcing film.

This paper elaborated a variety of states of wave defects of hand buckle sheet metal outside the door of automobile covering parts, deeply analyzed the causes of each state of defects, and proposed effective measures to solve them. A variety of debugging means were summarized, forming a set of methods to quickly solve the wave defects of hand buckle sheet metal, which can expand the idea of solution for future optimization of such defects.

This paper proposed improvement measures and methods to eliminate Volatile Organic Compounds (VOC) pollution inside vehicle through testing VOC in the product and raw material, impact analysis of manufacturing technologies and storage environment. The purpose of this study was to help enterprises carry out low VOC green design and development of automobile roof based on materials, parts and forming process, and provide traceability analysis of automobile roof for automotive OEMs and parts suppliers and solutions to low VOC material process.

This paper studied systematically the factors affecting acoustic absorption and insulation performance of double density felt based on impedance tube method and reverberation-anechoic method. The change rule of acoustic absorbing and insulation properties of flat plate materials were analyzed by impedance tube test with the density, thickness and adding sound insulation film of flat plate materials. The rule of change of the acoustic insulation performance of the molding material with its density and adding sound insulation film was analyzed by reverberation-anechoic test. The test results show that the sound absorption performance can be improved by increasing the surface density and thickness of the plate material without sound insulation film. Increase density to improve sound insulation performance. With the addition of sound insulation film, the sound insulation performance is improved. With the addition of felt density, the sound insulation performance of the plate material is improved, and the sound insulation performance of the molding part has no significant change. The material skeleton of the molding part changes due to the processing technologies, so it is necessary to further study the influencing parameters such as flow resistance and porosity of the sample.

This article elaborated the process layout of the advanced flexible main welding line of Body In White (BIW) for the high beat (60 JPH) 4-model fixed line in a China OEM, this welding line adopted advanced technologies such as automatic welding, automatic pre-assembly, OPEN GATE type main assembly frame, top cover laser brazing, automatic brushing of the top cover laser welding, automatic polishing, robot vision application, AGV automatic conveying, and online measurement, which can meet the requirements of mixed production of different BIW from cars to MPVs. In the high beat production process, the production line can meet the requirements of switching within 4 models without beat loss. The paper firstly elaborated the flexible solution for different stations in the main welding line, then, taking this production line as a case, interpreted the typical processes adopted by some main welding lines in terms of the solution and design of multiple vehicle mixed lines. At the end of this paper, the key points in design and planning of the main welding line were elaborated and analyzed.

This paper compared the difference between laser scanner welding and traditional contact welding, proposed a setting method of robot coordinate system with laser scanner welding optic. This method can shorten modeling time and reduce tooling development cost. Robot virtual tool calibration is different from physical tool. A new calibration method suitable for such virtual tools was developed based on the calibration method of traditional physical tools of robot. This method can shorten process debugging time to eliminate welding seam deviation, rapidly solve tool deviation which frequently occurs in series production, therefore has broad application in automobile production.

In order to improve the automation of the ultrasonic punching process of automobile bumpers, improve personnel efficiency and reduce production costs, the ultrasonic punching process has been upgraded intelligently. Through the innovative design of the ultrasonic punching concave die structure, a visual inspection system and a unified traceability system have been introduced, and the manual coating and quality inspection of traditional primers have been canceled, and the functions of input and traceability of quality and production information have been completed. The integrated operation of bumper ultrasonic punching and coating process has been realized, laying a solid foundation for intelligent manufacturing and digital transformation.

The development of digital intelligent welding tong system is a technological development direction with broad application prospects. The developed digital intelligent welding tong system is a mode breakthrough of the traditional welding tong that is fitted with various intelligent sensors and data collectors on the basis of traditional welding tong, so that they have key big data collection capabilities. Through the development of SCADA system with intelligent welding tong data, welding controller data and workpiece data analysis, to achieve intelligent welding tong condition monitoring, predictive maintenance, solder joint online quality monitoring and trace warning and workpiece quality report push function, the upgrading demand of digital and intelligent transformation of the traditional welding tong is realized on the welding line.

In the era of rapid development of digital transformation, machine vision is widely applied in most of industries. This paper introduced the visual acquisition method and processing method, on this basis it explained the advantages of machine vision compared with traditional artificial vision via workshop demonstration. It is proved that this method fundamentally solves the problem of labor cost and makes the automobile manufacturing higher quality, lower cost and more flexible in the aspects of visual guided parts, visual guided assembly, visual inspection, and visual online measurement.

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.