1 Automobile Body Welding Assem-bly is one of the important projects in the manufacture of complete vehicles. Automotive body, especially car body manufacturing, has always been a relatively high-tech application. Its main features are: Welding Assembly Lines, which are composed of a large number of welding robots and computer-controlled automated welding equipment. . Although the domestic automobile body welding robot welding line was established more than 15 years later, the development speed is fast and the technical starting point is high. In recent years, almost all domestic large-scale car body manufacturers have adopted welding robot body welding lines, and several of them reflect the world's advanced technology. 1.1 The car body structure includes the bottom plate (PLATFORM), the side wall, the door (Doors) and other parts and parts (Body Parts) and the body in white (Assembly) (see Figure 1), the frame (Flame), etc. (See Figure 2). 1.2 Automobile body welding refers to the welding and assembling of various parts and body-in-white assemblies, mainly by welding process and using modern automated welding equipment. Among them, resistance spot welding process, CO2 arc arc welding process is the main process; also supplemented by TIG welding, MIG welding, MAG welding and other arc welding processes and including modern development of laser welding and cutting processes. The modern automated welding equipment used mainly refers to industrial robots that perform resistance spot welding and CO2 arc welding (see Figure 3). Spot Welding Robots and CO2 Gas Shelded Arc Welding Robots. In the picture below (see Figures 4, 5, 6, and 7), it is the welding of the bottom plate of the body, the side wrapping, the door assembly, and the welding of the body-in-white assembly. According to statistics, each car body (body assembly and body parts) has about 3,000 to 4,000 resistance spot welds and intermittent welds of more than 3 m. In the automotive body welding process, the spot welding robot is the leading and CO2 arc welding robot, and the application of the welding robot accelerates the process of flexibility, production and automation of the body manufacturing. For bodybuilders to reach an annual output of more than 200,000 units, almost all robotic welding lines must be used. This is not only the vehicle body and component productivity requirements, but also the flexibility of the robotic welding production line, which adapts to the market demand for car body modification and production, and the welding quality is guaranteed (see Figure 8). The new technologies and new materials in the high-tech achievements are firstly actively tested in the automobile manufacturing industry, and the results are rapidly promoted, such as laser welding, laser brazing, laser cutting, laser surface modification and other laser thermal processing. The process has been successfully applied in the automotive body welding and auto parts manufacturing, and the corresponding robotized automation equipment has also been followed up with development and application; aluminum alloy materials, coated steel sheets (mainly galvanized, lead plate) And fine-grained high-strength steel sheets have entered the stage of popularization and application of technology (see Figure 9). AUDI A8 and AUDI A2 are aluminum alloy bodies. AUDI and BMW have successfully applied robot welding technology such as TIG, MAG and YAG lasers (see Figure 10). Since the welding deformation of the aluminum alloy body is much larger than that of the steel, the three-coordinate measurement and the on-line measurement of the laser are used (see Fig. 11). 2 Types of automobile body welding line The technical level and productivity of a car body factory welding line are mainly based on the type of main spot welding equipment used on the welding line. Common types are: 2.1 Hanging spot welder + fixed multi-point welder type In this type of body shop welding line, 80% of spot welders are suspended spot welders (see Figures 12 and 13). Secondly, there are several sets of fixed multi-point welders (see Figure 11) and supplemented by several fixed-station single-point welders (see Figure 17). The main advantage of the body welding line using the traditional hanging single spot welding machine and the fixed multi-point welding machine is that the investment in the line is small, so it is mostly used in the early stage of construction of a large factory or in a small factory. The biggest disadvantage is that the body welding is basically manual, labor-intensive, and the quality is disturbed by human factors. The advantages of the fixed multi-point welder are high production efficiency and low welding distortion. The disadvantage is that it can not be adapted to the production of a variety of models, that is, not "flexible", can only be used for the manufacture of a vehicle body (see Figures 14, 15, 16); because for the fixed welding line, once The shape of the body must be changed. All the spot welding stations on the welding line must be from the electrode pressurization system, the pneumatic system, the hydraulic system used in the multi-point welder, and the secondary power supply system of the welding transformer - including the welding transformer. Side cable, welding transformer secondary current and voltage and other welding parameters measurement system, all electrodes, welding transformer, high-power thyristor in the main circuit of the cooling system and control system (control box) must be fully This is actually very difficult to change. 2.2 Hanging spot welder + local spot welding robot type In this type of body shop welding line, most spot welders are still hanging spot welders (see Figure 16), only in key work A spot welding robot is used on the position (for example, the body assembly). The purpose of this is to make full use of human resources and save one investment. Due to the national conditions rich in domestic human resources, this type has been adopted by many domestic auto body factories. 2.3 Full-spot welding robot type The whole workshop is realized by spot welding robot, arc welding robot, and handling robot specializing in loading and unloading materials, as well as various transmission chains and automatic welding fixtures. The entire line of body welding is “flexible†(see Figure 18). The production method is multi-variety and large-scale mixed flow production. It is fully adapted to the modern large-scale, multi-variety and high-volume production methods, which reduces the cost and can effectively support the automobile produced by the company to participate in the market competition. This model is used almost exclusively by body builders with an annual output of more than 300,000 vehicles.
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