Car Manufacturing: Fast Track Towards Mass Production

  Enquire / contact me

Transferring new parameters directly to serial production

Car Manufacturing: Fast Track Towards Mass Production
Car Manufacturing: Fast Track Towards Mass Production

More and more varieties of automotive models are pene- trating the market, product lifespans are getting shorter, and energy costs are soaring. Above all, the protracted ramp-up time in auto body assembly are causing problems for manufacturers: They have to adapt production systems to each of the new parts and assemblies, which is highly time-intensive.

In order to put together individual elements, such as a door or a side panel, the manufacturers clamp the individual parts into model-specific clamping devices and weld them together. In doing so, precision is absolutely critical. "The not yet completely welded door is an unstable structure - if you adjust it at one point, then it deflects a different one. The employees have to calibrate the devices exactly, in order to set the part," says Marco Breitfeld of the Fraunhofer Institute for Machine Tools and Forming Technology IWU in Chemnitz. It can last several months for each new vehicle model until the system is set optimally. The pilot production run does not help in this regard. Because the fixtures used there have nothing in common with the ones used later.

The new device engineered at IWU allows already determined parameters to be directly transferred to serial production. "We hope to be able to reduce the start-up times by up to 50 percent," Breitfeld indicates. The procedure used is called "try-out," and is already applied to the reshaping process at the pressing plant. Special try-out presses determine, for example, the regulating variables for quality production beyond the serial process already - without interrupting the production process. The presses simulate the process parameters and the production environment of the regular system. Now, the scientists have transferred the process to car body assembly. "We are really breaking new ground here, and have transferred the principle of the presses to the clamping devices," the researcher says.

These contain four functional elements that are assembled similarly to a construction kit. With height modules, the console heights can be adjusted flexibly; the angle modules determine the angle of the clamping elements. Shim modules, specific surfaces of varying thickness, are used for fine-tuning. Workers have a maximum of ten millimeters of leeway in any direction. Through the modulus of rigidity, the researchers simulate how rigid the device would be if it were made of steel, aluminum or synthetic material.

Posted on February 4, 2014 - (275 views)
by
Related articles
Intelliconnect at Electronica 2018
Verigo Model PB3 Reusable Temperature Data Logger
Fischer Shows its Connectivity Solutions at Electronica
Advancing the Expansion of the Grid
Getting Started with the Industry 4.0 Journey
Positioning with Large Reading Window
Industrial Humidity Transmitter EE23
All Levels of Digital Integration
Data Highway for the Internet of Things
High-Pressure Flowmeter Measures Liquid Refrigerants
New JD Mini for Maximum Efficiency
Sensing Innovation in Process and Control
Connect Everything with e-Factory
System-based High Precision Linkages
Ultrasonic Flowmeter for Air
Reflowable Thermal Switch
Mobile, Multi-protocol Diagnostics Mercury
Microscope Optics for IR cameras
Level Switches RFS-9 and RFS-12
Digital Multimeter, Gas Soldering Iron and Carrying Case
Verigo Model PB3 Reusable Temperature Data Logger
Compact Power Modules
Modular Compact CPU Board
Absolute Modular Encoders
Connector for Data Transmission
Mass Flow Controller FMA-2600A Series
High-Performance Box PC
Compact True Color Sensor
A new performance class in inductive displacement measurements
Positioning System
Verigo Model PB3 Reusable Temperature Data Logger
Ultrasonic Flowmeter for Laboratory
Co-Creating the Industry of the Future
Ultra-Low Power Accelerometer for IoT
New JD Mini for Maximum Efficiency
Bonfiglioli BSR Synchronous Reluctance Motors
Reflowable Thermal Switch
Measuring the Position of Hydraulic and Telescopic Cylinders
AI Convention Europe Presents KAPTAIN
Ultrasonic Flowmeters for Compressed Air