基于3DCS的动力电池包装配偏差分析

Assembly Deviation Analysis of Power Battery Pack based on 3DCS

为达到最佳的底盘空间利用效果,某车型创新性地将电池包的安装点设置在底盘结构件上,但此安装方式在小批量生产验证阶段偶发安装错孔等干涉风险,因此该文采用3DCS软件建立了电池包装配合车的仿真模型,并对问题场景进行了仿真分析,结果表明分析值与实际统计结果基本吻合,证明了模型真实可靠。为有效解决装配干涉问题,建议采用单边双限位销等措施提高扭梁安装支架合车装配定位的稳健性,以显著减少正态分布带宽(6σ)值;同时,对尺寸链环上贡献度较高的零部件进行尺寸规格优化,以进一步降低装配错孔风险;将以上优化措施应用于实际生产中,并持续监控约1000辆下线车辆,期间未发生电池包安装错孔等装配问题,改善效果明显,可有效满足产线生产要求。

In order to achieve the best utilization effect of chassis space,a certain model innovatively sets the installation point of battery pack on the chassis structural parts,and the production line feedback the interference risk of accidental installation of wrong holes in the small-batch production verification stage.In this paper,the 3DCS software is used to establish a simulation model of battery pack matching with the car,and simulation analysis on the problem scenario is also conducted.The results show that the analysis values are basically consistent with the actual statistical results,which proves that the model is real and reliable.In order to effectively solve the problem of assembly interference,it is recommended to adopt measures such as single side and double limit pin to improve the robustness of the assembly positioning of the torsion beam mounting bracket,which can significantly reduce the 6STD value,and at the same time optimize the size specifications of the parts with high contribution on the dimensional chain link,further reducing the risk of assembly mis-holes.After the above optimization measures are applied in actual production,through continuous monitoring about 1000 off-line vehicles,it is shown that no assembly problems such as battery pack installation wrong holes occurred,thus the improvement effect is obvious,and it can effectively meet the production line production requirements.