2.1.1 Product Blocking
The blocks of the same type are basically the same (the general body is composed of the floor, side wall, front/rear wall, door, top cover, etc.), but the connection and order between the assemblies are often different. A reasonable block can guarantee the assembly and welding of the body. For example, the assembly sequence of the liberation flat head cab is special, first forming a side rear circumference welding assembly (left/right side and rear circumference forming a welding assembly), and then forming a cab assembly.
2.1.2 Determination of the benchmark
The design, manufacture and inspection of the entire body are based on the same coordinate system. In the design of the body, the reference (hole, surface) required for assembly, welding, assembly and handling, and the whole process of body welding are generally considered. Must be based on a certain benchmark to ensure the geometry and size of the vehicle, and these benchmarks are also the basis for fixture design, manufacturing, adjustment, inspection and maintenance. The following aspects should be noted when determining the benchmark:
a. The uniformity of the benchmark, the benchmark is gradually transmitted during the welding process;
b. The reference should be easy to measure;
c. The benchmark shall ensure the accurate positioning of the parts;
d. The benchmark should be considered for ease of welding operations.
2.1.3 Determine the geometric accuracy of the body assembly and the reference plane for inspection
A geometric reference is an obvious part of a part or part that determines the theoretical position of the part in the X, Y, Z coordinate system; the exact part reference position is used to ensure the accuracy of the assembly geometry, so the reference position It is very important for the assembly work. Before the welding process is studied, the reference of the component needs to be carefully analyzed. The analysis of the geometry must be done with the user. The user determines the reference position or obtains the user's consent after the designer determines it.
In order to keep these benchmarks accurate, the following aspects must be strictly controlled during fixture manufacturing and installation. a. adjust (detect) when manufacturing the welding fixture; b. check the final geometry of the assembled parts during production; C. Test when repairing the welding fixture.
2.1.4 Determine the assembly sequence
Each stamping, sub-assembly and assembly of the body is assembled and welded in a strict sequence to complete the entire body welding. The assembly order of each part must ensure that all welding work is completed and welding is facilitated.
2.1.5 Solder Joint Analysis
It indicates that the main parameters of the solder joint (number, position, amplitude, and importance of the solder joint) are determined at the time of product design, but at present some of the owners only provide the product model and no product drawings. At this time, the main parameters of the solder joint need to be determined by the process designer.
2.1.5.1 Determination of shaped solder joints
The welding between relatively complex workpieces often requires assembly and repair welding. At the assembly station, it is impossible to complete all the welding work due to the limitation of production tempo, the space required for the arrangement of the equipment, and the effective space occupied by the fixture. However, some solder joints must be completed. These solder joints should ensure the shape and size of the workpiece when it leaves the fixture. This part of the solder joint is called a shaped solder joint. In general, the shaped solder joint accounts for about 1/3 of the total solder joint.
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