轿车车身尺寸控制与夹具工艺设计分析
摘要
汽车制造业已经成为全球性重要支柱产业,汽车车身制造又是汽车制造业中的一项最关键工程,随着国内外市场竞争日趋激烈,消费者对汽车的质量要求也越来越高,轿车白车身的质量直接影响到整车的外观、性能和安全。焊装作为汽车生产过程的四大工艺之一,焊接质量的高低对轿车车身尺寸的影响至关重要,可以说,在车身制造过程中,焊装是关键工序,是整个车身制造的核心,白车身焊接质量的优劣决定了整车的制造质量。焊接夹具是保证车身焊接质量的最重要因素,焊接夹具的主要作用就是保证所有焊接冲压件之间的相对位置以及焊接件的尺寸精度,合理的夹具设计、焊点规划、焊钳选择,可以确保焊接质量,降低生产成本,提高生产效率。
本文阐述了轿车车身尺寸偏差产生的原因,特别是制造过程中产生的偏差,介绍了车身质量评价方法及车身尺寸控制方法,车身尺寸控制的主体在于夹具的设计,分析了焊装夹具的结构组成、定位原理,一般设计步骤及定位可靠性设计方法。结合国内某微型轿车,研究了利用夹具设计的有效性来控制车身尺寸,首先进行夹具工艺方案设计,根据生产纲领确定生产节拍,焊点规划,把车身结构划分为七大分总成,然后进行焊接工艺设计,完成了焊接树状图,根据产品工艺分析,结合整个流水线的均衡化设计,同时保证人流物流畅通,规划出焊装线方案,根据机舱分总成的结构特点,分析出定位点及夹紧支撑的数量及位置,确定焊点分布及定位夹紧方式。利用CATIA软件对夹具进行计算机辅助设计,设计出基板、L座、定位销、压紧块等,这样既提高了设计精度,又缩短了研发周期,并在CATIA软件中将机舱分总成数据和夹具装配在一起,模拟其装夹,分析夹具方案的可行性及操作方便性。简单介绍了检具的设计原则,将在改进后的夹具上焊接完成的机舱分总成放在检具上进行检测,并和车身数据进行对比,验证了改进后的夹具对车身尺寸控制的有效性。
The automotive industry have become an important pillar of the global industry, automotive body manufacturers in the automotive industry is one of the most critical projects, with the increasingly competitive domestic and foreign markets, consumer automotive quality requirements have become more sophisticated, cars BIW vehicle directly affects the quality of the appearance, performance and security. Welding production process as a vehicle one of the four processes, the level of welding quality on body size of car is essential, can be said that the manufacturing process in the body, welding is the key process is the core of the whole body manufacturing, white body determines the merits of quality welding vehicle manufacturing quality. Body welding welding fixture to ensure the quality of the most important factor, the main role of welding fixture to ensure that all welding is the relative position between the stamping and welding parts for dimensional accuracy, and reasonable fixture design, solder joint planning, welding clamp selection, to ensure weld quality, reduce production costs and increase productivity.
This article describes the size of the deviation, especially in the process, introduced the quality evaluation methods and the size of the control method to control the size of the body in the design of the means, and analyze the structure of the means of welding, location, design principle steps and positioning of reliability design methods. combine domestic a miniature, the use of fixture design effectiveness to control the size, to begin with a fixture design and craft. Production programme to identify production and welds planning, the bodywork is divided into seven points assemblies and soldering process design and finished the fig tree shapes, according to the soldering process analysis of the product, the whole assembly of a balanced design, while ensuring people, logistics planning was clear that welding line, according to the point of features analysis of the anchor up and up the number and position to determine the welds distribution and niche between the way. Catia jig of the software used in computer-aided designing, one seat for, locating and pressing of waiting, raised design, precision and shorten the period, and software in the assembly will catia data and fixture in the assembly process with the scheme, the jigs the feasibility of operating convenience. a simple introduction to design principles, if the improved means of a soldering on the assembly on the testing if available, And the data be verified by the improved means to control the size of effectiveness.
本文阐述了轿车车身尺寸偏差产生的原因,特别是制造过程中产生的偏差,介绍了车身质量评价方法及车身尺寸控制方法,车身尺寸控制的主体在于夹具的设计,分析了焊装夹具的结构组成、定位原理,一般设计步骤及定位可靠性设计方法。结合国内某微型轿车,研究了利用夹具设计的有效性来控制车身尺寸,首先进行夹具工艺方案设计,根据生产纲领确定生产节拍,焊点规划,把车身结构划分为七大分总成,然后进行焊接工艺设计,完成了焊接树状图,根据产品工艺分析,结合整个流水线的均衡化设计,同时保证人流物流畅通,规划出焊装线方案,根据机舱分总成的结构特点,分析出定位点及夹紧支撑的数量及位置,确定焊点分布及定位夹紧方式。利用CATIA软件对夹具进行计算机辅助设计,设计出基板、L座、定位销、压紧块等,这样既提高了设计精度,又缩短了研发周期,并在CATIA软件中将机舱分总成数据和夹具装配在一起,模拟其装夹,分析夹具方案的可行性及操作方便性。简单介绍了检具的设计原则,将在改进后的夹具上焊接完成的机舱分总成放在检具上进行检测,并和车身数据进行对比,验证了改进后的夹具对车身尺寸控制的有效性。
The automotive industry have become an important pillar of the global industry, automotive body manufacturers in the automotive industry is one of the most critical projects, with the increasingly competitive domestic and foreign markets, consumer automotive quality requirements have become more sophisticated, cars BIW vehicle directly affects the quality of the appearance, performance and security. Welding production process as a vehicle one of the four processes, the level of welding quality on body size of car is essential, can be said that the manufacturing process in the body, welding is the key process is the core of the whole body manufacturing, white body determines the merits of quality welding vehicle manufacturing quality. Body welding welding fixture to ensure the quality of the most important factor, the main role of welding fixture to ensure that all welding is the relative position between the stamping and welding parts for dimensional accuracy, and reasonable fixture design, solder joint planning, welding clamp selection, to ensure weld quality, reduce production costs and increase productivity.
This article describes the size of the deviation, especially in the process, introduced the quality evaluation methods and the size of the control method to control the size of the body in the design of the means, and analyze the structure of the means of welding, location, design principle steps and positioning of reliability design methods. combine domestic a miniature, the use of fixture design effectiveness to control the size, to begin with a fixture design and craft. Production programme to identify production and welds planning, the bodywork is divided into seven points assemblies and soldering process design and finished the fig tree shapes, according to the soldering process analysis of the product, the whole assembly of a balanced design, while ensuring people, logistics planning was clear that welding line, according to the point of features analysis of the anchor up and up the number and position to determine the welds distribution and niche between the way. Catia jig of the software used in computer-aided designing, one seat for, locating and pressing of waiting, raised design, precision and shorten the period, and software in the assembly will catia data and fixture in the assembly process with the scheme, the jigs the feasibility of operating convenience. a simple introduction to design principles, if the improved means of a soldering on the assembly on the testing if available, And the data be verified by the improved means to control the size of effectiveness.
引文
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[5]林忠钦,连军,倪军,来新民,陈关龙.基于小样本的车身装配尺寸质量动态高精度评价方法.机械工程学报,2001.11：62-65
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[7]颜书毅.覆盖件焊装变形数值模拟.西华大学硕士学位论文,2009年
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[12]Kulankara Krishnakumar,Shareyes N.Melkote,Machining fixture layout optimization using the genetialgorithm.International Journal of Machine Tools&Manufacture,2000,40(4):579-598
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[14]罗来军,朱军,林忠钦等.汽车覆盖件焊装夹具虚拟设计参数库的开发.机械科学与技术,2002,21(5)：840-843
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[22]周志强.轿车白车身测点布置及优化方法研究.上海交通大学硕士学位论文,2002
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[29]周志强,陈关龙,朱平等,用于车身制造质量控制的白车身测点布置及优化.汽车工程,2003,25(1),88-92
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[32]韩根云.汽车车身焊接夹具的设计[J].新技术新工艺,2001,(8)
[33]王玫,由俐,李靖.自动焊接装置的设计[J].汽车工艺与材料,2001,(3)
[34]覃庆泽.装焊夹具柔性设计及改造的几点体会[J].广西机械,2000,(4)
[35]陈猛,郭钢等.汽车焊接夹具CAD系统研究与开发[J].汽车科技,2001(1)
[36]徐礼锋.浅议汽车焊接夹具的结构设计.职业圈,2007,(2)
[37]黄威,黄运尧.FAS可重组柔顺性装配夹具的应用研究与设计.中国机械工程,19967(6)：77-79
[38]李坤宏.基于CATIA的汽车焊装夹具计算机辅助设计.重庆大学工程硕士学位论文2007
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[53]李坤宏.基于CATIA的汽车焊装夹具设计方法应用研究.重庆大学硕士学位论文,2007年
[2]庄明惠.汽车制造2mm工程的实施方法的探讨.汽车工艺与材料,2004(4)：11-14
[3]林忠钦,胡敏,陈关龙.轿车车体装配偏差研究方法综述.机械设计与研究,1993.3：82-84
[4]来新民,林忠钦等.轿车车体装配尺寸偏差控制技术.中国机械工程,2000.11：1215-1220
[5]林忠钦,连军,倪军,来新民,陈关龙.基于小样本的车身装配尺寸质量动态高精度评价方法.机械工程学报,2001.11：62-65
[6]邱富深,靳君锋,王红刚.汽车车身装焊误差产生的原因及控制.城市车辆,2007.10：55
[7]颜书毅.覆盖件焊装变形数值模拟.西华大学硕士学位论文,2009年
[8]CeglarekD.,etal. Variation Reduction for Assembly:Methodologiesand CaseStudies Analysis[R].Technical Report of the"2mm"Program,University ofMichigan,Ann Arbor,1994
[9]陈卫国.汽车车身焊装夹具设计的关键技术研究.华中科技大学硕士学位论文,2007年
[10]Menassa,Devies W.Optimization Methods Applied toSelecting Support Positionsin Fixture Design[J].ASME J.of Engineering for Industry,1991(113):412-418)
[11]W.Cai, S.J.Hu, J.X.Yuan. Deformable sheet metal fixturing:principles,algorithms and simulations[J].Journalof Manufacturing Science and Engineering,1996,118(8):318-324.
[12]Kulankara Krishnakumar,Shareyes N.Melkote,Machining fixture layout optimization using the genetialgorithm.International Journal of Machine Tools&Manufacture,2000,40(4):579-598
[13]陈猛,郭钢,冯卫等.汽车焊接夹具CAD系统研究开发.汽车科技,2001(1)：11-13
[14]罗来军,朱军,林忠钦等.汽车覆盖件焊装夹具虚拟设计参数库的开发.机械科学与技术,2002,21(5)：840-843
[15]岁波,都东,常保华等.车身装焊过程的可视化工艺信息模型.焊接学报,2003,24(5)：25-28
[16]刘海江,罗生斌.白车身侧围工位焊接机器人路径优化研究.制造业自动化,2005,27(7)：35-38
[17]熊晓萍,金权东.车身焊接夹具智能化设计方法的研究.机械设计与制造,2006(11)：84-86
[18]顾凌韬.任意尺寸分布的公差分析及其在整车配合中的应用.上海交通大学硕士学位论文,2007年
[19]刘麟魁,黄振泉.小样本测量值正态分布的检验与可疑值得取舍.赣南师范学院学报,1997.3：62-68)
[20]金隼.基于功能尺寸的车身检测体系优化设计及其应用.上海交通大学博士学位论文,2001
[21]高建刚.基于基准点系统与功能尺寸的轿车车身制造质量控制.上海交通大学硕士学位 论文,2001
[22]周志强.轿车白车身测点布置及优化方法研究.上海交通大学硕士学位论文,2002
[23]胡仕新.美国汽车车体装配与焊接研究现状.中国机械工程,1997.8(1)：24-26
[24]刘麟魁,黄振泉.小样本测量值正态分布的检验与可疑值得取舍.赣南师范学院学报,1997.3：62-68
[25]马祥宁.基于Bootstrap方法的车身制造质量控制.上海交通大学硕士学位论文,2007
[26]魏国旗,陈南琦.白车身的焊接质量检验及判定.重型汽车,2000(6).20-21
[27]连军,姚福生,林忠钦等.数据挖掘技术在轿车白车身装配偏差溯源中的应用.汽车技术,2002(9).31-34
[28]佟静,RPS理论在车门上的应用[硕士学位论文].吉林：吉林大学,2003
[29]周志强,陈关龙,朱平等,用于车身制造质量控制的白车身测点布置及优化.汽车工程,2003,25(1),88-92
[30]林忠钦,胡敏,陈关龙等,轿车车体装偏差研究方法综述.机械设计与研究,1999,(3)：58-60
[31]张永伟.先进机械制造技术及发展模式[J].山东电大学报,2001,(1)
[32]韩根云.汽车车身焊接夹具的设计[J].新技术新工艺,2001,(8)
[33]王玫,由俐,李靖.自动焊接装置的设计[J].汽车工艺与材料,2001,(3)
[34]覃庆泽.装焊夹具柔性设计及改造的几点体会[J].广西机械,2000,(4)
[35]陈猛,郭钢等.汽车焊接夹具CAD系统研究与开发[J].汽车科技,2001(1)
[36]徐礼锋.浅议汽车焊接夹具的结构设计.职业圈,2007,(2)
[37]黄威,黄运尧.FAS可重组柔顺性装配夹具的应用研究与设计.中国机械工程,19967(6)：77-79
[38]李坤宏.基于CATIA的汽车焊装夹具计算机辅助设计.重庆大学工程硕士学位论文2007
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