A physical value mapping （PVM） algorithm based on finite element mesh from the stamped part in stamping process to the product is presented, In order to improve the efficiency of the PVM algorithm, a search way from...A physical value mapping （PVM） algorithm based on finite element mesh from the stamped part in stamping process to the product is presented, In order to improve the efficiency of the PVM algorithm, a search way from the mesh of the product to the mesh of the stamped part will be adopted. At the same time, the search process is divided into two steps： entire search （ES） and local search （LS）, which improve the searching efficiency. The searching area is enlarged to avoid missing projection elements in ES process. An arc-length method is introduced in LS process. The validity is confirmed by the results of the complex industry-forming product.展开更多
The process characteristics of heat treatment of aluminum alloy auto body sheet and the working principle of air cushion furnace were introduced.The process position and irreplaceable role of air cushion furnace in th...The process characteristics of heat treatment of aluminum alloy auto body sheet and the working principle of air cushion furnace were introduced.The process position and irreplaceable role of air cushion furnace in the aluminum alloy auto body sheet production was pointed out after the difficulty and key points in the whole production process of auto body sheet were studied.Then the development process of air cushion furnace line of aluminum alloy sheet was reviewed,summarized and divided to two stages.Based on the research of air cushion furnace,the key technology of it was analyzed,then the key points on process,equipment and control models of air cushion furnace for aluminum alloy auto body sheet in future were put forward.With the rapid development of automotive industry,there will be certainly a new upsurge of research and application of air cushion furnace for heat treatment of aluminum alloy auto body sheet.展开更多
This article presents a systematic research methodology of modular design for conceptual auto body frame by hybrid optimization method.A modified graph-based decomposition optimization algorithm is utilized to generat...This article presents a systematic research methodology of modular design for conceptual auto body frame by hybrid optimization method.A modified graph-based decomposition optimization algorithm is utilized to generate an optimal BIW assembly topo model composed of“potential modules”.The consistency constraint function in collaborative optimization is extended to maximize the commonality of modules and minimize the performance loss of all car types in the same product family simultaneously.A novel screening method is employed to select both“basic structures”and“reinforcement”modules based on the dimension optimization of the manufacturing elements and the optimal assembly mode;this allows for a more exhaustive modular platform design in contrast with existing methods.The proposed methodology is applied to a case study for the modular design of three conceptual auto body types in the same platform to validate its feasibility and effectiveness.展开更多
The welding fixtures are the most important devices for an auto body welding assembly line. The current special fixtures used by many automotive manufactures are only fit for one or several specific welding processes,...The welding fixtures are the most important devices for an auto body welding assembly line. The current special fixtures used by many automotive manufactures are only fit for one or several specific welding processes, and the dimensional problem in the circle due to several variation sources accumulation has no adjustment. The active error compensating welding fixture system for auto body is designed and manufactured. The detecting model, coordinate transformation model, and adjusting model based on auto body coordinate system are presented. The dowel pin modular design is adopted in the structure of the fixture to suit different workpieces with some similar characteristics. The online detection and adaptive control system using eddy current sensors and adaptive adjusting devices is analyzed. Three kinds of the left rear wheel covers SGM60 are selected to test workpieces of the developed system, and the active error compensating experiments are performed in the lab for many times. Test results show the validity of mechanism reconfigurations, on-line detections and error compensations of the developed welding fixture.展开更多
For auto-body product, assembly dimensional quality evaluation using tolerance analysis method is a challenging task because there are plenty of elements impacting on the variation stack-up and propagation during asse...For auto-body product, assembly dimensional quality evaluation using tolerance analysis method is a challenging task because there are plenty of elements impacting on the variation stack-up and propagation during assembly process. Traditional method of dimension chain generation based on tolerance charting technique can not suit the case of auto-body assembly. This paper proposed a method to generate dimension chain based on developing a jot chain model of assembly, which can be integrated with important information needed for variation analysis, such as joints types and assembly sequences. The implementation of such a procedure will contribute to rapid evaluation of body dimensional quality in the design stage.展开更多
A method of 3-D measuring fixture automatic assembly for auto-body part is presented. Locating constraint mapping technique and assembly rule-based reasoning are applied. Calculating algorithm of the position and pose...A method of 3-D measuring fixture automatic assembly for auto-body part is presented. Locating constraint mapping technique and assembly rule-based reasoning are applied. Calculating algorithm of the position and pose for the part model, fixture configuration and fixture elements in virtual auto-body assembly space are given. Transforming fixture element from itself coordinate system space to assembly space with homogeneous transformation matrix is realized. Based on the second development technique of unigraphics（UG）, the automated assembly is implemented with application program interface （API） function. Lastly the automated assembly of measuring fixture for rear longeron as a case is implemented.展开更多
基于中国保险汽车安全指数25%偏置碰撞工况,对某新能源汽车A柱的结构设计方案进行了研究。对比分析了基础结构、复合车身解决方案(Composite Body Solutions,CBS)胶块增强结构、热气胀形管梁增强结构对碰撞安全性的影响,介绍了CBS胶块...基于中国保险汽车安全指数25%偏置碰撞工况,对某新能源汽车A柱的结构设计方案进行了研究。对比分析了基础结构、复合车身解决方案(Composite Body Solutions,CBS)胶块增强结构、热气胀形管梁增强结构对碰撞安全性的影响,介绍了CBS胶块和热气胀形的制造工艺,并对热气胀形工艺进行了仿真分析,对比分析2种增强结构的工装投入和单件成本。研究发现,在均能实现小偏置碰撞安全性优秀等级的前提下,1500 MPa热气胀管梁方案在单件成本及轻量化方面比CBS胶块方案更具优势。展开更多
Lumbar vertebra motion analysis provides objective measurement of lumbar disorder. The automatic tracking algorithm has been applied to Digitalized Video Fluoroscopy (DVF) sequence. This paper proposes a new Auto-Trac...Lumbar vertebra motion analysis provides objective measurement of lumbar disorder. The automatic tracking algorithm has been applied to Digitalized Video Fluoroscopy (DVF) sequence. This paper proposes a new Auto-Tracking System (ATS) with a guide device and a motion analysis to automatically measure human lumbar motion. Digitalized Video Fluoroscopy (DVF) sequence was obtained during flexion-extension lumbar movement under guide device. An extraction of human vertebral body and its motion tracking were developed by particle filter. The results showed a good repeatability, reliability and robustness. In model test, the maximum fiducial error is 3.7% and the repeatability error is 1.2% in translation and the maximal repeatability error is 2.6% in rotation angle. In this simulation study, we employed a lumbar model to simulate the motion of lumber flexion- extension with the stepping translation of 1.3 mm and rotation angle of 1°. Results showed that the fiducial error was measured as 1.0%, while the repeatability error was 0.7%. The sequence can be detected even noise contamination as more as 0.5 of the density. The result demonstrates that the data from the auto-tracking algorithm shows a strong correlation with the actual measurement and that the Vertebral Auto-Tracking System (VATS) is highly repetitive. In the human lumbar spine evaluation, the study not only shows the reliability of Auto-Tracking Analysis System (ATAS), but also reveals that it is robust and variable in vivo. The VATS is evaluated by the model, the simulated sequence and the human subject. It could be concluded that the developed system could provide a reliable and robust system to detect spinal motion in future medical application.展开更多
基金This project is supported by National Natural Science Foundation ofChina(No.l9832020) and National Outstanding Youth Science Foundation ofChina(No.10125208).
文摘A physical value mapping （PVM） algorithm based on finite element mesh from the stamped part in stamping process to the product is presented, In order to improve the efficiency of the PVM algorithm, a search way from the mesh of the product to the mesh of the stamped part will be adopted. At the same time, the search process is divided into two steps： entire search （ES） and local search （LS）, which improve the searching efficiency. The searching area is enlarged to avoid missing projection elements in ES process. An arc-length method is introduced in LS process. The validity is confirmed by the results of the complex industry-forming product.
文摘The process characteristics of heat treatment of aluminum alloy auto body sheet and the working principle of air cushion furnace were introduced.The process position and irreplaceable role of air cushion furnace in the aluminum alloy auto body sheet production was pointed out after the difficulty and key points in the whole production process of auto body sheet were studied.Then the development process of air cushion furnace line of aluminum alloy sheet was reviewed,summarized and divided to two stages.Based on the research of air cushion furnace,the key technology of it was analyzed,then the key points on process,equipment and control models of air cushion furnace for aluminum alloy auto body sheet in future were put forward.With the rapid development of automotive industry,there will be certainly a new upsurge of research and application of air cushion furnace for heat treatment of aluminum alloy auto body sheet.
基金This work was funded by the Innovation Foundation of GAC R&D Center.
文摘This article presents a systematic research methodology of modular design for conceptual auto body frame by hybrid optimization method.A modified graph-based decomposition optimization algorithm is utilized to generate an optimal BIW assembly topo model composed of“potential modules”.The consistency constraint function in collaborative optimization is extended to maximize the commonality of modules and minimize the performance loss of all car types in the same product family simultaneously.A novel screening method is employed to select both“basic structures”and“reinforcement”modules based on the dimension optimization of the manufacturing elements and the optimal assembly mode;this allows for a more exhaustive modular platform design in contrast with existing methods.The proposed methodology is applied to a case study for the modular design of three conceptual auto body types in the same platform to validate its feasibility and effectiveness.
基金Shanghai Leading Academic Discipline Project,China(No.B602)Patent Second Development Project of Science and Technology Commission of Shanghai Municipality,China(No.05dz52038)
文摘The welding fixtures are the most important devices for an auto body welding assembly line. The current special fixtures used by many automotive manufactures are only fit for one or several specific welding processes, and the dimensional problem in the circle due to several variation sources accumulation has no adjustment. The active error compensating welding fixture system for auto body is designed and manufactured. The detecting model, coordinate transformation model, and adjusting model based on auto body coordinate system are presented. The dowel pin modular design is adopted in the structure of the fixture to suit different workpieces with some similar characteristics. The online detection and adaptive control system using eddy current sensors and adaptive adjusting devices is analyzed. Three kinds of the left rear wheel covers SGM60 are selected to test workpieces of the developed system, and the active error compensating experiments are performed in the lab for many times. Test results show the validity of mechanism reconfigurations, on-line detections and error compensations of the developed welding fixture.
基金National Natural Science Foundation of China(No.50375092)
文摘For auto-body product, assembly dimensional quality evaluation using tolerance analysis method is a challenging task because there are plenty of elements impacting on the variation stack-up and propagation during assembly process. Traditional method of dimension chain generation based on tolerance charting technique can not suit the case of auto-body assembly. This paper proposed a method to generate dimension chain based on developing a jot chain model of assembly, which can be integrated with important information needed for variation analysis, such as joints types and assembly sequences. The implementation of such a procedure will contribute to rapid evaluation of body dimensional quality in the design stage.
文摘A method of 3-D measuring fixture automatic assembly for auto-body part is presented. Locating constraint mapping technique and assembly rule-based reasoning are applied. Calculating algorithm of the position and pose for the part model, fixture configuration and fixture elements in virtual auto-body assembly space are given. Transforming fixture element from itself coordinate system space to assembly space with homogeneous transformation matrix is realized. Based on the second development technique of unigraphics（UG）, the automated assembly is implemented with application program interface （API） function. Lastly the automated assembly of measuring fixture for rear longeron as a case is implemented.
文摘基于中国保险汽车安全指数25%偏置碰撞工况,对某新能源汽车A柱的结构设计方案进行了研究。对比分析了基础结构、复合车身解决方案(Composite Body Solutions,CBS)胶块增强结构、热气胀形管梁增强结构对碰撞安全性的影响,介绍了CBS胶块和热气胀形的制造工艺,并对热气胀形工艺进行了仿真分析,对比分析2种增强结构的工装投入和单件成本。研究发现,在均能实现小偏置碰撞安全性优秀等级的前提下,1500 MPa热气胀管梁方案在单件成本及轻量化方面比CBS胶块方案更具优势。
文摘Lumbar vertebra motion analysis provides objective measurement of lumbar disorder. The automatic tracking algorithm has been applied to Digitalized Video Fluoroscopy (DVF) sequence. This paper proposes a new Auto-Tracking System (ATS) with a guide device and a motion analysis to automatically measure human lumbar motion. Digitalized Video Fluoroscopy (DVF) sequence was obtained during flexion-extension lumbar movement under guide device. An extraction of human vertebral body and its motion tracking were developed by particle filter. The results showed a good repeatability, reliability and robustness. In model test, the maximum fiducial error is 3.7% and the repeatability error is 1.2% in translation and the maximal repeatability error is 2.6% in rotation angle. In this simulation study, we employed a lumbar model to simulate the motion of lumber flexion- extension with the stepping translation of 1.3 mm and rotation angle of 1°. Results showed that the fiducial error was measured as 1.0%, while the repeatability error was 0.7%. The sequence can be detected even noise contamination as more as 0.5 of the density. The result demonstrates that the data from the auto-tracking algorithm shows a strong correlation with the actual measurement and that the Vertebral Auto-Tracking System (VATS) is highly repetitive. In the human lumbar spine evaluation, the study not only shows the reliability of Auto-Tracking Analysis System (ATAS), but also reveals that it is robust and variable in vivo. The VATS is evaluated by the model, the simulated sequence and the human subject. It could be concluded that the developed system could provide a reliable and robust system to detect spinal motion in future medical application.
