First, the basis of the process - concept
1, the process
That is, the method (means, process) of processing the product. It is a method of processing raw materials, blanks, and semi-finished products by using production tools to change their geometry, shape, surface state and internal structure.
2, the process specification
Process regulations (documents) that specify the manufacturing process and operating methods of the product or component.
3, process documents
Various technical documents that guide workers' operations and for production and process management. It is an important technical parameter for enterprises to organize production, plan production and conduct accounting.
4, process parameters
In order to achieve the expected technical indicators of processed products, the relevant quantities selected and controlled in the process, such as current, electrode pressure and so on.
5, process equipment
A general term for the various tools used in the manufacturing process. Including tools, fixtures, molds, measuring tools, inspection tools, accessories, bench tools and station equipment.
6, craft card (or work instructions)
A process document prepared at a certain stage of the product's zero. He uses the process as a unit to specify the process number, process name, process content, process parameters, operation requirements, and equipment and process equipment of the product (or zero, component) at a certain process stage. Including stamping process cards, welding process cards, paint process cards, assembly process cards.
7, bill of materials (BOM)
A file that describes the structure of a product in a data format.
8. Outsourcing parts list
A process file that fills in the drawing number, name, and processing content of all the parts in the product.
9, outsourcing tools list
Fill in a process file for the name, specifications, and accuracy of all tools and gauges that the product needs to purchase during the production process.
10, material consumption process quota schedule
Fill in a process file for the name, grade, specification, weight, etc. of the various materials that each part of the product consumes during the manufacturing process.
11. Material consumption process quota summary table
A process document that summarizes the various materials in the Material Consumption Process Quota Schedule by a single product.
12 parts transfer card
Fill in a process for each assembly process zero, part drawing number (code) name specification, etc.
The stamped body panels are partially heated or simultaneously heated and pressurized to form a body assembly. The most widely used in the manufacture of automobile bodies is spot welding, which directly affects the strength of the body.
The automobile body is a structural member composed of a thin plate, and the stamped and formed sheet material is assembled and welded to form a body shell (white body), so the welding is the key to the body forming. The welding process is a major part of the body manufacturing process.
The automobile body shell is a complex structural part, which is formed by welding, riveting, mechanical coupling and bonding of more than one hundred or even hundreds of (for example, car) sheet metal stamping parts. Since the material of the body stampings is mostly low carbon steel with good welding performance, welding is the most widely used coupling method in modern body manufacturing.
The body welding assembly is as follows:
Final assembly process
The final assembly is the process of assembling the parts of the entire vehicle, such as the body, the engine, the transmission, the instrument panel, the lamp, and the door, to produce the whole vehicle.
a, car assembly concept and its characteristics
Automobile assembly is the final step in the entire manufacturing process of the automobile. It is to combine the tens of millions of parts that have passed the inspection, and to combine the assembly, assembly and vehicle according to the specified accuracy standards and technical requirements. Test the program to confirm that it is qualified for the entire process. Automotive products require good power, economy and durability to achieve the carrying functions in a variety of complex environments. Modern automotive products require safety, reliability, aesthetics, comfort and environmental protection. These requirements are ultimately guaranteed by the assembly process. If it is not properly assembled, qualified parts manufactured at an expensive price may not be able to hold a qualified car. Therefore, assembly is an important part of ensuring product quality. The characteristics of the car assembly are many types of parts, large quantities, and complex work contents. In addition to the engine, drive train, body, suspension, wheels, steering, brakes, air conditioning, etc., there are a large number of interior and exterior trim, electrical appliances, wiring harnesses, hoses, tubes, glass, and various types. Oil filling, etc. The total vehicle workload accounts for about 20% to 25% of the total manufacturing workload. The operation includes interference fit, welding, riveting, inlaying, piping, wiring, threaded connections, and various types of oil filling.
b, assembly method
1, thread connection method
Screw and bolt connection are the basic methods of mechanical assembly. It accounts for 31% of the assembly work of the car. The manual connection of the threaded parts of the individual parts is more commonly used, such as pneumatic wrenches or electric wrenches and electric screwdrivers.
2, bonding method
The parts to be bonded, the interior parts are generally padded, sound-proof materials, decorative panels inside the door, and the exterior parts generally have windshields, lights, signs, and the like. Bonding method: small pieces are pre-coated with adhesive on the body, and large parts are directly coated with adhesive on the parts.
3, filling method
It refers to the method of assembling engine oil, transmission gear oil, radiator coolant, brake fluid, power steering hydraulic oil, air conditioning refrigerant, windshield washer fluid, fuel oil and other liquids.
c, assembly equipment
1. Ground conveyor (shallow chain)
2, overhead aerial hanging conveyor
3, plate conveyor chain
d, automobile assembly process
Zhitang Kiln Town, Changshu City, Jiangsu Province (204 National Road Kiln Town)
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