Vehicle Body Assembly System Using Segmented Pre-Buck and Main-Buck Processes
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Solution Overview
Problem
Existing vehicle body assembly systems are inflexible and heavy, requiring separate facilities for each vehicle type, making it impossible to assemble more than five types of vehicles efficiently and increasing initial investment and operational costs.
Innovation Solution
A vehicle body assembly system is divided into two processes: pre-buck and main-buck sections, using robots and modular components to assemble side assemblies and vehicle body components, allowing for the assembly of multiple vehicle types on a single facility by preassembling lower portions and post-assembling upper components, with adjustable and interchangeable jigs and welding robots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If side gates for each vehicle type are installed at four stations of a rotary indexer to restrict the entire framework at one time, then welding precision is improved, but device weight and size increase
Solution Approach 1:
The assembly process is divided into two separate processes: a pre-buck process that assembles the lower portion of the framework, and a main-buck process that assembles the upper portion. This segmentation allows each process to use lighter, dedicated fixtures rather than requiring a single heavy facility to handle all vehicle types simultaneously.
Solution Approach 2:
The system uses interchangeable side gates that can be quickly swapped between different vehicle types. Instead of having fixed gates for each vehicle type installed permanently at four stations, the gates are made dynamic and replaceable, reducing the need for heavy permanent installations while maintaining positioning precision.
2Manufacturing precision
If side gates for each vehicle type are installed at four stations to restrict the framework, then assembly precision is improved, but device complexity increases
Solution Approach 1:
The complex task of assembling multiple vehicle types is segmented into two simpler processes: pre-buck for lower framework assembly and main-buck for upper framework assembly. Each process uses dedicated, simpler fixtures rather than one complex facility handling all operations.
Solution Approach 2:
The side gates are designed as universal, interchangeable components that can be used across different vehicle types. Instead of having dedicated gates for each vehicle type, a single set of gates can serve multiple vehicle types through quick interchangeability, reducing overall system complexity.
3Manufacturing precision
If separate facilities are installed for each vehicle type to maintain assembly precision, then manufacturing precision is improved, but adaptability decreases
Solution Approach 1:
The system transitions from static, vehicle-type-specific facilities to dynamic, interchangeable fixtures. The side gates and positioning devices can be quickly swapped to accommodate different vehicle types, enabling a single facility to adapt to multiple vehicle types while maintaining assembly precision.
Solution Approach 2:
The pre-buck and main-buck facilities are designed as universal platforms that can handle multiple vehicle types. Through interchangeable side gates and configurable positioning systems, these facilities perform multiple functions across different vehicle types without requiring separate dedicated facilities for each type.
4Adaptability or versatility
If a single facility assembles multiple vehicle types with interchangeable jigs, then adaptability is improved, but manufacturing precision may deteriorate
Solution Approach 1:
The interchangeable jigs incorporate dynamic positioning mechanisms that automatically adjust to the specific vehicle type being assembled. Sensors and actuators ensure that each jig configuration achieves the required positioning precision for its designated vehicle type, preventing precision loss despite interchangeability.
Solution Approach 2:
The side gates and positioning devices are pre-configured with precise adjustment mechanisms that are calibrated before each vehicle type changeover. This preliminary action ensures that when the jig is swapped, it is already prepared to achieve the required assembly precision for the new vehicle type without compromising accuracy.
Data Source
AI summary
A vehicle body assembly system defines a preset pre-buck section and a preset main-buck section along a conveying route of a floor assembly, and may include: i) pre-buck units which are installed at both sides of the conveying route in the pre-buck section, respectively, restrict lower portions of side assemblies, which vary in accordance with a type of vehicle, with respect to both sides of the floor assembly, and preassemble the lower portions of the side assemblies to the floor assembly by a first welding robot; and ii) main-buck units which are installed at both sides of the conveying route in the main-buck section, respectively, restrict upper portions of the side assemblies preassembled by the pre-buck unit, and post-assemble vehicle body components to the upper portions of the side assemblies by a second welding robot.