轿车白车身焊接生产线设计及虚拟设计技术应用研究
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摘要
轿车白车身是汽车的重要组成部分,是构成汽车的四大部分之一,是以“钢结构”为主的汽车零部件载体。车身焊接是白车身制造工艺中最重要的工艺过程之一,车身焊接的质量、精度、生产效率对整车的质量、精度、生产效率有着直接的影响。在大规模制造方式下,生产流水线是提高产品质量和生产效率的有力工具,在白车身焊接生产过程中也不例外。
本文在结合国内多款白车身焊接生产线研制过程中的基础上,系统的阐述了白车身焊接生产线的设计方法和虚拟制造这一新技术在实际生产过程中的应用,已完成的主要工作有:
1.系统的研究了白车身焊接生产线的设计方法,论述了白车身焊接生产线的整体规划设计;完成了自车身焊接生产线具体设备的结构设计。
2.论述了白车身焊接生产线平衡设计方法,并应用这一方法实现了某车型主焊接生产线的平衡设计。
3.论述了生产线布局设计的原则、生产线布局的类型,采用了基于虚拟制造技术的布局设计方法并实现了某车型侧围外板手动焊接工位的布局设计。
4.对白车身焊接生产线的输送装置设计进行了详细的论述,解决了输送装置设计过程中的动力设计、缓冲设计等难点问题,实现了某车型主焊接生产线的输送装置设计。
5.系统了介绍白车身焊接夹具的设计方法和设计特点,对在白车身焊接夹具中应用广泛的摆动汽缸连杆机构进行了优化设计。
6.详细的探讨了虚拟制造这一新技术,介绍了虚拟制造技术应用于白车身焊接生产线的基本技术原理和实现方案,最后基于虚拟仿真平台ROBCAD实现了某车型手动焊接工位的虚拟仿真。
Car Body-In-White, which is a "steel-structure", is an important component of a car, it is one of the four main components of a car and the most important load-carrier of a car. Welding is one of the most frequently manufacturing methods during the process of car Body-In-White making. The quality, accuracy and productivity of car body welding have a direct influence for that of a car. Under the mass production, production line is a helpful tool for improving the quality and the productivity which is still helpful for the car Body-In-White welding process.
This thesis researched on the methods of the design for Car Body-In-White welding line and the application of Virtual Manufacturing in line design, the research based on the result of several welding lines' design work. The work have done are as follow:
1. The methods of the design for Car Body-In-White welding line has been discussed systematically, the methods for total plan design and detail equipments design are discussed respectively.
2. The welding line balance design methods for Car Body-In-White was proposed and it has been carried out in the design of a main welding assembly line for a car.
3. The principle and type of the line layout design has been discussed, then a new line layout design method which is based on Virtual Manufacturing has been proposed and a layout design for a manual welding cell has been realized.
4. The design of conveyor system for welding line has been discussed in detail, the problems, which are difficult for Car Body-In-White welding line design, of power design and shock-absorption have been solved and a main welding line conveyor system design has been realized based on the solution.
5. The design method for Car Body-In-White welding fixture and design distinguishing has been discussed. The optimum design of oscillating cylinder link mechanism, which is very frequently used in welding fixture, has been realized.
6. The Virtual Manufacturing and its application have been discussed and the fundamentals and program and for Car Body-In-White welding line design based on VM have been proposed. At last, the virtual simulation of a manual welding station for a car's body-side outer has been realized based on ROBCAD.
本文在结合国内多款白车身焊接生产线研制过程中的基础上,系统的阐述了白车身焊接生产线的设计方法和虚拟制造这一新技术在实际生产过程中的应用,已完成的主要工作有:
1.系统的研究了白车身焊接生产线的设计方法,论述了白车身焊接生产线的整体规划设计;完成了自车身焊接生产线具体设备的结构设计。
2.论述了白车身焊接生产线平衡设计方法,并应用这一方法实现了某车型主焊接生产线的平衡设计。
3.论述了生产线布局设计的原则、生产线布局的类型,采用了基于虚拟制造技术的布局设计方法并实现了某车型侧围外板手动焊接工位的布局设计。
4.对白车身焊接生产线的输送装置设计进行了详细的论述,解决了输送装置设计过程中的动力设计、缓冲设计等难点问题,实现了某车型主焊接生产线的输送装置设计。
5.系统了介绍白车身焊接夹具的设计方法和设计特点,对在白车身焊接夹具中应用广泛的摆动汽缸连杆机构进行了优化设计。
6.详细的探讨了虚拟制造这一新技术,介绍了虚拟制造技术应用于白车身焊接生产线的基本技术原理和实现方案,最后基于虚拟仿真平台ROBCAD实现了某车型手动焊接工位的虚拟仿真。
Car Body-In-White, which is a "steel-structure", is an important component of a car, it is one of the four main components of a car and the most important load-carrier of a car. Welding is one of the most frequently manufacturing methods during the process of car Body-In-White making. The quality, accuracy and productivity of car body welding have a direct influence for that of a car. Under the mass production, production line is a helpful tool for improving the quality and the productivity which is still helpful for the car Body-In-White welding process.
This thesis researched on the methods of the design for Car Body-In-White welding line and the application of Virtual Manufacturing in line design, the research based on the result of several welding lines' design work. The work have done are as follow:
1. The methods of the design for Car Body-In-White welding line has been discussed systematically, the methods for total plan design and detail equipments design are discussed respectively.
2. The welding line balance design methods for Car Body-In-White was proposed and it has been carried out in the design of a main welding assembly line for a car.
3. The principle and type of the line layout design has been discussed, then a new line layout design method which is based on Virtual Manufacturing has been proposed and a layout design for a manual welding cell has been realized.
4. The design of conveyor system for welding line has been discussed in detail, the problems, which are difficult for Car Body-In-White welding line design, of power design and shock-absorption have been solved and a main welding line conveyor system design has been realized based on the solution.
5. The design method for Car Body-In-White welding fixture and design distinguishing has been discussed. The optimum design of oscillating cylinder link mechanism, which is very frequently used in welding fixture, has been realized.
6. The Virtual Manufacturing and its application have been discussed and the fundamentals and program and for Car Body-In-White welding line design based on VM have been proposed. At last, the virtual simulation of a manual welding station for a car's body-side outer has been realized based on ROBCAD.
引文
[1]凯墨尔,沃而夫.现代车身结构分析(,陈励志译).北京:人民交通出版社,1997
[2]卢抗美,王小宝.国外汽车工业焊接技术与设备的现状及发展趋势.电焊机.1995,25(2):1-5
[3]陈旭辉.汽车装焊生产线优化设计:[硕士学位论文].南京:南京航空航天大学,2006:11-11
[4]肖田元,韩向利,王新龙.虚拟制造的定义与关键技术.清华大学学报(自然科学版).1998,38:102-106
[5]Wiens.G.J.An overview of virtual manufacturing.Virtual manufacturing proceeding of 2nd agile manufacturing conference(AMC'95),Albuquerque,New Mexico,USA 1995.ERI Press.233-243
[6]Kimura F.Product and process modeling as a kernel for virtual manufacturing environment.Annual of the CIRP,1993,42(1):85-93
[7]刘战强,艾兴.虚拟制造技术及其应用的现状与发展展望.山东大学学报.2002,32(3):211-217
[8]刘美珍,刘剑雄,刘伟达.虚拟制造技术及其应用综述.机电产品开发与创新.2006,19(1):88-90
[9]王爱云.虚拟制造技术研究现状及展望.矿山机械.2007,35(12):148-150
[10]陈晓川,张暴暴,刘晓冰等.虚拟制造技术研究概括综述.机械制造.1998,12:8-10
[11]汪成为,高文等.灵镜(虚拟现实)技术的理论/实现及应用.北京:清华大学出版社,1996
[12]陈定方,罗亚波等.虚拟设计.北京:机械工业出版社,2002:25
[13]Jayaram S,Connacher H,Lyons K.Virtual Assembly Using Virtual-reality Techniques.Computer Aided Design,1997,8(29):575-584
[14]宁汝新,郑轶.虚拟装配技术的研究进展及发展趋势分析.中国机械工程.2005,16(15):1398-1403
[15]刘宏增,黄靖远.虚拟设计.北京:机械工业出版社,1999:27-28
[16]严隽琪,范秀敏,姚健.虚拟制造系统的体系结构及其关键技术.中国机械工程.1998,9(11):60-64
[17]J.G.Cherngatel.Feature-based part modeling and process planning for rapid response manufacturing.Computers in Industrial Engineer.1998,34(2):525-530
[18]吴瑞荣,张玉云,王先逵等.面向对象的可制造性评价系统.清华大学学报.1998,38(2):72-75
[19]国家自然科学基金委员会.先进制造技术基础.北京:高等教育出版社.1998
[20]刘春荣,齐元胜,杨明忠.现代制造系统中的人因工程.机械设计与制造工程.2002,31(1)
[21]谷正气.轿车车身.北京:人民交通出版社.2002
[22]Adil Baykasoglu.Lale Ozbakir,Stochastic.U-line balancing using genetic algorithms,Int J Adv Manuf Technol.2007,32:139-147
[23]黄洁.基于资源的汽车白车身装配CAPP及仿真系统的研究与实现:[硕士学位论文].成都:电子科技大学,2007:52-53
[24]Tompkins J A.Facility Planning:2nd edition.New York:John Wiley,1996
[25]龚全胜.基于遗传算法的制造系统虚拟设备布局设计:[硕十学位论文].武汉:华中科技大学,2004:13-14
[26]李火生,李志华等.生产车间设备布局线性模型及算法研究.计算机工程与应用.2002,11:221-222
[27]吴耀华,李德军.现代物流系统的布局与规划,工程设计.1997,3:30-31
[28]钱志勤,滕弘飞.复杂布局设计问题的算法.中国机械工程.2002,13(8)
[29]钟诗清,王文德.汽车车身制造工艺学.北京:机械工业出版社,1992
[30]邓仁珍.范淼海,汽车车身制造工艺学.北京:北京理工大学,2003
[31]吴新泉,罗裕明等.人造板多层热压机.北京:中国林业出版社,1985:208
[32]徐灏等.机械设计手册.北京:机械工业出版社,2006:49-131
[33]沈鸿等.机械工程书册.北京:机械工业出版社,1982
[34]徐灏等.机械设计手册.北京:机械工业出版社,2006:42-31
[35]张质文,虞和谦等.起重机设计手册.北京:中国铁道工业出版社,1998:477-478
[36]孟庆波,黄克正.新型汽车焊装夹具CAD系统的初步研究与开发.机电一体化.2005,11(6):58-60
[37]齐国强等.汽车工程手册编辑委员会.汽车工程手册制造篇.北京:人民交通出版社,2001:502-527,693-701
[38]胡学斌,王炳乐,景政基.最佳传动角对心摆动油缸机构的综合方法.机械.1998,3(25)
[39]郭仁生.基于MATLAB和Pro/ENGINEER优化设计实例解析.北京:机械工业出版社,2007
[40]孟兆明,常德功.机械最优化设计技术.北京:化学工业出版社,2002
[41]朴永杰,朱振友等.汽车前梁总成机器人点焊柔性加工单元.电焊机,2003,(7)
[42]Carvalho G C,SIqueira M L,Absi-Alfaro S C.Off-line Programming of Flexible Wetting Manufacturing Cells.Journal of Materials Processing Technology.1998.(78):24-28
[43]王健强,杜辉,于澎.机器人点焊工作站在汽车制造中的应用.机器人技术与应用,2006(4)
[44]Wan Dong,Hui Li,Xiaoting Teng.Off-line programming of Spot-weld Robot for Car body-in-White Based on Robcad.Proceedings of the 2007 IEEE International Conference on Mechatronics and Automation.2007.8:763-764
[2]卢抗美,王小宝.国外汽车工业焊接技术与设备的现状及发展趋势.电焊机.1995,25(2):1-5
[3]陈旭辉.汽车装焊生产线优化设计:[硕士学位论文].南京:南京航空航天大学,2006:11-11
[4]肖田元,韩向利,王新龙.虚拟制造的定义与关键技术.清华大学学报(自然科学版).1998,38:102-106
[5]Wiens.G.J.An overview of virtual manufacturing.Virtual manufacturing proceeding of 2nd agile manufacturing conference(AMC'95),Albuquerque,New Mexico,USA 1995.ERI Press.233-243
[6]Kimura F.Product and process modeling as a kernel for virtual manufacturing environment.Annual of the CIRP,1993,42(1):85-93
[7]刘战强,艾兴.虚拟制造技术及其应用的现状与发展展望.山东大学学报.2002,32(3):211-217
[8]刘美珍,刘剑雄,刘伟达.虚拟制造技术及其应用综述.机电产品开发与创新.2006,19(1):88-90
[9]王爱云.虚拟制造技术研究现状及展望.矿山机械.2007,35(12):148-150
[10]陈晓川,张暴暴,刘晓冰等.虚拟制造技术研究概括综述.机械制造.1998,12:8-10
[11]汪成为,高文等.灵镜(虚拟现实)技术的理论/实现及应用.北京:清华大学出版社,1996
[12]陈定方,罗亚波等.虚拟设计.北京:机械工业出版社,2002:25
[13]Jayaram S,Connacher H,Lyons K.Virtual Assembly Using Virtual-reality Techniques.Computer Aided Design,1997,8(29):575-584
[14]宁汝新,郑轶.虚拟装配技术的研究进展及发展趋势分析.中国机械工程.2005,16(15):1398-1403
[15]刘宏增,黄靖远.虚拟设计.北京:机械工业出版社,1999:27-28
[16]严隽琪,范秀敏,姚健.虚拟制造系统的体系结构及其关键技术.中国机械工程.1998,9(11):60-64
[17]J.G.Cherngatel.Feature-based part modeling and process planning for rapid response manufacturing.Computers in Industrial Engineer.1998,34(2):525-530
[18]吴瑞荣,张玉云,王先逵等.面向对象的可制造性评价系统.清华大学学报.1998,38(2):72-75
[19]国家自然科学基金委员会.先进制造技术基础.北京:高等教育出版社.1998
[20]刘春荣,齐元胜,杨明忠.现代制造系统中的人因工程.机械设计与制造工程.2002,31(1)
[21]谷正气.轿车车身.北京:人民交通出版社.2002
[22]Adil Baykasoglu.Lale Ozbakir,Stochastic.U-line balancing using genetic algorithms,Int J Adv Manuf Technol.2007,32:139-147
[23]黄洁.基于资源的汽车白车身装配CAPP及仿真系统的研究与实现:[硕士学位论文].成都:电子科技大学,2007:52-53
[24]Tompkins J A.Facility Planning:2nd edition.New York:John Wiley,1996
[25]龚全胜.基于遗传算法的制造系统虚拟设备布局设计:[硕十学位论文].武汉:华中科技大学,2004:13-14
[26]李火生,李志华等.生产车间设备布局线性模型及算法研究.计算机工程与应用.2002,11:221-222
[27]吴耀华,李德军.现代物流系统的布局与规划,工程设计.1997,3:30-31
[28]钱志勤,滕弘飞.复杂布局设计问题的算法.中国机械工程.2002,13(8)
[29]钟诗清,王文德.汽车车身制造工艺学.北京:机械工业出版社,1992
[30]邓仁珍.范淼海,汽车车身制造工艺学.北京:北京理工大学,2003
[31]吴新泉,罗裕明等.人造板多层热压机.北京:中国林业出版社,1985:208
[32]徐灏等.机械设计手册.北京:机械工业出版社,2006:49-131
[33]沈鸿等.机械工程书册.北京:机械工业出版社,1982
[34]徐灏等.机械设计手册.北京:机械工业出版社,2006:42-31
[35]张质文,虞和谦等.起重机设计手册.北京:中国铁道工业出版社,1998:477-478
[36]孟庆波,黄克正.新型汽车焊装夹具CAD系统的初步研究与开发.机电一体化.2005,11(6):58-60
[37]齐国强等.汽车工程手册编辑委员会.汽车工程手册制造篇.北京:人民交通出版社,2001:502-527,693-701
[38]胡学斌,王炳乐,景政基.最佳传动角对心摆动油缸机构的综合方法.机械.1998,3(25)
[39]郭仁生.基于MATLAB和Pro/ENGINEER优化设计实例解析.北京:机械工业出版社,2007
[40]孟兆明,常德功.机械最优化设计技术.北京:化学工业出版社,2002
[41]朴永杰,朱振友等.汽车前梁总成机器人点焊柔性加工单元.电焊机,2003,(7)
[42]Carvalho G C,SIqueira M L,Absi-Alfaro S C.Off-line Programming of Flexible Wetting Manufacturing Cells.Journal of Materials Processing Technology.1998.(78):24-28
[43]王健强,杜辉,于澎.机器人点焊工作站在汽车制造中的应用.机器人技术与应用,2006(4)
[44]Wan Dong,Hui Li,Xiaoting Teng.Off-line programming of Spot-weld Robot for Car body-in-White Based on Robcad.Proceedings of the 2007 IEEE International Conference on Mechatronics and Automation.2007.8:763-764
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