JP3242420U - Truck body renewal system - Google Patents

Abstract

A truck body renewal system is provided that increases the durability of a truck body, reduces the amount of carbon dioxide gas emitted by renewal compared to purchasing a new vehicle, and prevents deterioration of the global environment. A renewal system that renews (renovates) the whole of a truck body separated from a driving system including an engine, and uses a repair material that enhances the strength of parts requiring repair. We measure the weight of the repair material and calculate the reduction rate of greenhouse gas (CO2) emissions from the difference from the new vehicle weight. When the repair is completed, measure the thickness of the coating film and plate thickness to improve quality. If the body passes the post-repair inspection, the quality is guaranteed by issuing a certificate showing that it is a renewed body. This renewal will increase the durability as a truck trailer and achieve a cost reduction compared to purchasing a new vehicle. [Selection drawing] Fig. 1

Description

This invention relates to a truck body renewal system, more specifically, to a truck body renewal system for renewing (regenerating/renewing) the truck body of an aged carrier car or the like.

About 7 million trucks are used in the country. In addition, annual production of new trucks is said to be 920,000 units. In addition, truck transportation is increasing year by year.
There are many kinds of tracks for each application. For example, there are flat bodies in which the driver's seat and the loading platform are integrated, packer trucks, container trucks, vehicle transport trucks, and the like. This carrier car (vehicle transport vehicle) is of the truck type, and is of the trailer type, in which a trailer portion towed by a tractor is constructed as a truck chassis or a truck frame.
In these many types of trucks, the parts other than the driver's seat and the tractor are recognized as truck bodies. As the truck body deteriorates over time, rust and failures occur in various parts of the body. Due to this rust, the strength of the car body is reduced, and the transportation quality of the loaded vehicle is deteriorated. At the time of the repair, it is necessary to cancel the scheduled operation and change the setup.
When the trailer deteriorates, it is conceivable to purchase a new carrier car, but the carrier car is a special vehicle and cannot be mass-produced, and each car is made to order. As a result, the purchase cost rises, and it takes a long period of about two years to deliver the product.
As a solution to this problem, instead of individually repairing rust and breakdowns on aging carrier cars (truck bodies), they should be renewed (regenerated) in the same way as general-purpose ordinary cars. is considered (for example, Patent Document 1).
In this case, the carrier car is separated into a truck body and a truck chassis (truck frame). Parts of the truck body requiring repair are repaired according to a manual that includes strict procedures, and after the repair is completed, an exposure test is conducted.
In this case, the truck body to be repaired includes the cargo bed and upper goods of general trucks and special trucks, as well as trailers towed by tractors. That is, it includes a truck chassis and a truck frame.
Renewal of a truck body restores and regenerates the truck body (body) of a vehicle that has been used for a predetermined number of years to the same level as a new vehicle. The idea is to significantly reduce the materials required to manufacture a new car body.
This is to update and renovate the truck body instead of manufacturing a new car, which is equivalent to reducing greenhouse gases compared to manufacturing a new car, and is an initiative that contributes to the conservation of the global environment.

Utility Model Registration No. 3211353

However, the carrier car (truck body) is a special vehicle. For this reason, inspection points and maintenance that are different from ordinary passenger cars, such as corrosion of the exterior, presence of rust juice, distortion and twisting of the floor and car body, failure of the lifting device, deterioration of the electrical system, operation of the cargo binding machine, etc. must be done. In other words, it is important to establish the regeneration technology for carrier cars (truck bodies).

Therefore, as a result of intensive research, the inventor found that in order to renew the carrier car (truck body) efficiently at low cost, the vehicle body including the damaged part was inspected, then the caulking grease was removed from the vehicle body, and further A truck with equipment for stripping the exterior paint of the car body, repairing the damaged parts of the car body (including frame correction), anti-corrosion treatment of the outer car body after repair, and painting the outer car body after rust prevention. We found that a body renewal system would solve all of the above problems, and completed this idea.
In addition, refurbishing a truck body leads to a reduction in greenhouse gas (CO2) emissions compared to purchasing a new car, and objectively demonstrating the reduction rate is currently an extremely effective social initiative. It has become.

The purpose of this invention is to enable the continued use of a renewed vehicle at a lower cost than purchasing a new vehicle, to enable the renewal in a short period of time, and to reduce greenhouse gas (CO2) emissions to a certain extent. To provide a truck body renewal system capable of obtaining an effect.
This device can be applied not only to carrier cars, but also to various special vehicles (upper items and cargo beds).In addition, it is possible to repair parts that require repair, which are different for each vehicle body, by reinforcing them before repair. By doing so, the purpose is to make it possible to further extend the service life.

The device according to claim 1 comprises vehicle body weight measuring means for measuring the weight of the truck body at the time of acceptance and after completion of repair, repair means for repairing a portion of the truck body requiring repair using a repair material, and repair part checking means for inspecting completion of repair of the repair part; repair material weight calculation means for calculating the weight of the used repair material; This is a truck body renewal system including CO2 emission reduction rate calculation means for calculating the reduction rate of CO2 emission in the above repair.

In this case, "truck body" is a concept that includes the parts of a carrier car (vehicle carrier) excluding the tractor, the cab of the truck, the cargo bed or upper part excluding the chassis (frame), and the towed vehicle towed by the tractor. is.
Further, "renewal" is a concept of refurbishing and renewing a truck body that has been used for a predetermined period of time so that it is in the same state as a new car or in a state reinforced more.
``Measure the weight of the truck body at the time of acceptance'' means measuring the weight of the vehicle (truck) to be renewed at the factory during the acceptance inspection process of the truck body, for example, using a truck scale. becomes. Weight measurement after completion of repair is also weight measurement after completion of repair and passing the inspection (check).
Truck scales shall include ground truck scales, embedded truck scales, axle weight scales, and the like.
Here, the vehicle weight of the carrier car at the time of purchase, measured by a truck scale, is subtracted from the weight of the carrier car when it was purchased new. etc.

Further, it is assumed that the weight of the truck body at the time of new construction (new vehicle) has also been acquired as information from a vehicle sales company or the like.
This system is applied to various types of trucks. For example, in cab-over type trucks, only the cargo bed is subject to renewal. Similarly, for special vehicles, if it is a sprinkler truck, it will be renewed only for the top of the truck.
This repair is a concept that includes a shot blasting process, a subsequent rust prevention treatment, a subsequent spray coating (electrostatic coating), welding of a repair plate material for the portion requiring repair, and the like.
Checking completion of repair includes inspection of coating film thickness and checking of plate thickness of repair plate material. Repair materials include welded plates, replenished paints, caulks, and the like.

According to a second aspect of the invention, the repair portion checking means includes a coating thickness measuring device for measuring the coating thickness of the portion to be repaired, and a plate thickness measuring device for measuring the plate thickness of the portion to be repaired. Item 1. A truck body renewal system according to Item 1.
The thickness of the coating film reapplied after repair is measured with a coating film thickness measuring instrument. For example, 100 microns is used as a standard.
The plate thickness of the portion requiring repair is measured with a plate thickness measuring instrument.
When the coating thickness and plate thickness reach at least their set values, the repair can be completed.

A device according to claim 3 is the truck body renewal system according to claim 1 or claim 2, wherein the repair material includes a wear-resistant steel plate, a skeleton pipe whose inner surface has been treated for rust prevention, or a hot-dip galvanized material.
For repair materials, wear-resistant steel plates are cut and pressed to be used as grooves and angles, and frame pipes (rectangular in cross section) whose inner surfaces are treated to prevent rust are used as part of the frame. In addition, by using a hot-dip galvanized material, it is possible to improve the corrosion resistance and strength of the repaired portion. One of the features of this system is to improve durability.

According to a fourth aspect of the present invention, there is provided a truck body renewal system according to any one of the first to third aspects, wherein the repair means includes a welding device, a blasting device, an antirust processing device, and a painting device. be.
Welding, blasting, anti-corrosion treatment, painting, etc. are included as part of the repair. In these cases, equipment, machines, and instruments for each processing and treatment are used.

A carrier car, which is an example of a truck body, is a truck for transporting passenger cars, construction vehicles, and the like. Carrier cars in this case include a single-car type (truck type) and a multi-car type (trailer type).

Damaged parts (parts requiring repair) include, for example, a frame (chassis), a lifting device, an electric system, a load binding machine, a connecting part, a brake, and a part of a vehicle body such as around an axle.
In the vehicle acceptance inspection, for example, a carrier car is towed and a running test is performed, and a self-potential measuring device is used to inspect the degree of corrosion of the exterior.
Inspection items in the vehicle acceptance inspection include, for example, corrosion of the exterior, presence of rust juice, deterioration in strength of the vehicle frame, distortion and twisting of the floor and vehicle body, work test of the lifting device, deterioration of the electrical system, operation condition of the loading machine. , inspection of connecting parts, inspection of brakes and axles, etc.

A repair device is appropriately selected according to the content of the repair. For example, a welding device is used for welding steel plates, and a paint gun is used for anti-corrosion treatment.
In painting, the paint is atomized by static electricity, and the electrostatic atomization method adheres these particles to the object to be coated by electrostatic force. Use an electrostatic coating machine such as an air atomization type. The drying temperature of the paint after coating is, for example, 60 to 70°C.
Use a seal removal tool to remove caulking from the vehicle body.
Grease removal uses, for example, a scraper.
Shot blasting equipment uses various automatic blasting equipment.

The CO2 (greenhouse gas) emission reduction rate calculator calculates the weight of the repair material used for the renewal from the total weight of the truck body immediately after acceptance and after the completion of the renewal work. Then, the weight of the repair material is subtracted from the previously obtained new vehicle weight, and the value obtained by dividing this difference value by the new vehicle weight is obtained as the emission reduction rate. The amount of CO2 equivalent emissions is the value obtained by multiplying the amount of activity by the emission factor (see the Ministry of the Environment, Greenhouse Gas Emissions Calculation Formula). In some cases, the emission factor is set as a value obtained by dividing the amount of CO2 emissions by the amount of electricity sold.

The advantage of the renewal system according to this invention is that the cost is lower than purchasing a new car, and the truck body (carrier car) can be renewed in a short period of time.
In addition, the weight of the carrier car at the time of purchase measured by the truck scale is subtracted from the weight set at the time of purchase of the new carrier car. , the amount of paint used for anti-corrosion treatment and painting, etc. can also be determined. As a result, the renewed carrier car will have the same vehicle weight as when the new car was purchased, and the maximum load capacity based on the vehicle inspection certificate can be secured.

1 is a block diagram showing the configuration of a truck body renewal system according to Embodiment 1 of the present invention; FIG. FIG. 2 is a flow sheet showing each step of the truck body renewal system according to the first embodiment of the present invention; FIG.

An embodiment of a truck body renewal system according to this invention will be described below. Here, a renewal system for a trailer-type truck body for six passenger cars will be described as an example.

In the block diagram of FIG. 1, the vehicle body weight measuring means 20 is, for example, a truck scale, which measures the weight of the truck body at the time of acceptance and the weight of the truck body after repair. The repair means 30 includes a blasting device 31, an antirust processing device 32, a painting device 33, a welding device 34, and the like. The means 40 for checking a portion to be repaired after repairing is completed comprises a coating thickness measuring device 41 and a board thickness measuring device 42 . The means 50 for calculating the weight of the repair material uses, for example, a personal computer, and calculates based on the vehicle body weight measurement values at the time of receipt and at the time of completion of repair. Then, the CO2 emission reduction rate of the truck body at this point in time is obtained by calculating the vehicle weight measurement value obtained in advance at the time of manufacturing the new vehicle.

In the flow sheet of FIG. 2, reference numeral 100 denotes a truck body renewal system according to this embodiment. This truck body renewal system 100 includes a vehicle acceptance inspection process 101 for inspecting the vehicle body (truck body) including the damaged portion of the carrier car to be refurbished, and a skeletal correction for repairing the damaged portion of the vehicle body including joining of steel plates. Step 105, a sealing removal step (caulking stripping device) 102 for stripping caulk from the vehicle body, a step (scraper) 103 for removing grease from the vehicle body, and spraying an abrasive against the entire vehicle body to remove the A shot blasting step 104 for stripping the outer surface coating, a rust prevention treatment step 106 for applying rust prevention treatment to the entire outer surface of the car body after repair, and painting (spray painting) the entire outer surface of the car body after the rust prevention treatment. and a painting step 107 for applying.
Furthermore, the acceptance inspection process 101 of this system includes a car body weight measurement process 101a, a coating film thickness measurement process 101b at the time of acceptance, a determination process 101c of a part to be regenerated (damaged part) by visual inspection, etc., and a member necessary for repair. and other preparation (procurement) steps 101d. In addition, after the antirust treatment, a sealing application step 106a, a painting step 107 after that, and an assembly step 108 for safety parts and the like are provided. If the measured values are as designed in step 109 for measuring the thickness of the coating film and step 110 for measuring the plate thickness of the repaired portion (repaired plate), the process proceeds to the completion inspection and exposure test step 111 . After that, the weight of the repair material is calculated from the difference between the weight of the car at the time of acceptance and the weight of the car after the repair is completed, and the emission reduction rate is calculated and determined from this value and the weight of the new car. becomes (emission reduction rate calculation step 112). These calculation steps use a computer including a CPU. For the truck body obtained through these processes, a "Linibo certificate", which will be described later, is issued to prove that it is a renewed body.

A method of regenerating a carrier car (truck body) to which this renewal system is applied will be described below.
First, the received carrier car (trailer portion excluding the tractor) to be recycled is subjected to an acceptance inspection by the vehicle acceptance inspection device 101 (investigation, analysis, and measurement of the deterioration state of the vehicle body).
Specifically, in the body shop, the vehicle weight of the carrier car is measured 101a, exterior corrosion, presence of rust juice, deterioration in strength of the car frame, etc., distortion and twisting of the floor and car body, operation test of the lifting device, electrical We will check the deterioration of the system, the operation condition of the load binding machine, the connection part, the brake and the axle area, etc., and consider the renovation and restoration contents that are most suitable for the usage environment.
A truck scale 20 is used for weighing, and the difference from the weight at the time of manufacturing a new vehicle is confirmed. If it increases, there is a possibility that it is a new part that is retrofitted to a new car.
Inspect whether the skeleton (frame) is corroded or lacks strength due to reduced wall thickness, etc. This is done by non-destructive inspection using an ultrasonic measuring device.
In addition, it is inspected whether the coating is thickly applied and whether the amount of oils and fats is appropriate. Measure the thickness of the coating film.
This acceptance inspection is performed using a reference value of deterioration wear for each part. The acceptance inspection includes an appearance inspection with the vehicle body in a flat position, an underside inspection with the vehicle body lifted, and a loading inspection when luggage or vehicles are loaded.
These are pre-disassembly inspections. Therefore, it is not possible to grasp all the causes of malfunctions of each device and the internal conditions of the skeleton/functional parts.

Specifically, the vehicle weight of the carrier car is measured by a ground-type truck scale 20 . This measured value is compared with the weight value set at the time of purchasing a new carrier car (preliminarily obtained and recorded data) (subtracting the measured value from the set weight value), and the obtained weight value is adjusted to zero. , the size (thickness and area) of the steel plate used for vehicle body repair, the amount of paint used for anti-corrosion treatment and painting, etc. As a result, the carrier car after renewal will have the same vehicle weight as when it was purchased new, and the maximum load capacity based on the vehicle inspection certificate can be secured.
After that, a plurality of workers inspect the car body based on the contents of the check sheet to see how much rust liquid is generated due to corrosion, whether the strength is reduced, and whether the appearance is defective. At this time, if necessary, a self-potential measuring device is used to inspect the degree of corrosion of the exterior.
In addition, the yard car and the carrier car are connected, and the carrier car is actually operated to check the operating conditions, speed, ability, natural descent, etc. during cargo handling work.
In addition, check the condition of electrical wiring, hydraulic hoses, solenoid valves, etc. (replace if deteriorated). In addition, the undercarriage of the carrier car will be inspected to confirm that there are no problems with the brake system, shock absorber, running device, etc.

During the vehicle acceptance inspection, the front, back, top, bottom, right side and left side of the entire vehicle including the damaged parts of the carrier car and each part of the vehicle are imaged by an imaging camera. is stored in the storage means of the vehicle acceptance inspection device (composed of a personal computer or the like). In particular, for damaged parts, the captured camera image is magnified, and the magnified magnified image data is added and stored in the storage means. The imaging data stored in the storage means is displayed on a display provided in the vehicle acceptance inspection apparatus.
As a result, when the inspector evaluates the received carrier car, it is possible to perform a more accurate evaluation by referring to the detailed imaging data of each part of the vehicle body stored in the storage means.

As the next step, we will create a rough estimate for this renewal work.
In creating a rough estimate, we will create a detailed specification sheet specifying the replacement of parts and consumables that need to be recycled, and the details of the renovation of functionality and safety devices.
The estimate will include a rough description of the work and an estimate of the CO2 emissions reduction rate.
In the case of carrier cars, the reduction rate of CO2 emissions is about 90-98%.
In this estimate, we will disclose and explain the truck body renewal concept, work details, and the process. Unlike a new car, a "renewed truck body" does not replace all parts with new parts, and its skeleton is not reborn.

Next, purchase parts and materials necessary for repair. Obtain genuine parts from the manufacturer.
Next, measure the hydraulic hose. Carrier cars differ in the number and length of hydraulic hoses used, depending on the model and manufacturer. The pressure resistance of the hydraulic hose in the manufacturer's genuine product is 140 kg/cm2, but the pressure resistance of the hydraulic hose used in this renewal is set to 210 kg/cm2.

Next, the accessories are removed.
A carrier car requires about 12 to 20 tie-down wires to secure loaded vehicles. remove these. Disassemble and remove the lighting system such as tail lamps, marker lamps, work lights, switches, sensors, wiring cords, etc. that operate lifting work.

Next, we move on to maintenance and skeleton correction work for defects found in the acceptance inspection.
Overhaul oil-leaking hydraulic cylinders, replace hydraulic pipes, replace solenoid valves, replace hinge pins and bushes at the connecting part of the lift floor, and replace the slide plate in the slide column.
In addition, remove a large number of cargo binding machines and wires from the cargo bed. After that, repair the car body such as corrosion, cracks, wear and twist of the skeleton. At that time, in order to confirm the abnormality and restore it properly, it is essential to respond after knowing the technical information from the vehicle manufacturer, design drawings, failure investigation know-how, various reference values, purchase of genuine parts, etc. be.
As a specific repair method, a welding device is used to weld a steel plate of a predetermined size to the corroded portion. In addition, change the routing of the load binding wire. In addition, we also perform detachment work of hydraulic pipes and hoses necessary when performing these replacement work.
Skeletal correction is the work of cutting and replacing members such as pillars, cross members, floors, and frames that make up the vehicle body (truck body). In that case, if the material to be replaced is currently lacking in strength, use a "higher grade" material and plate thickness than the conventional product. For example, a wear-resistant steel plate such as "ABREX (registered trademark)" is used instead of iron material.

If necessary, the inner surface of the steel material is treated with a rust-preventing material to suppress the progress of rust inside the steel material, and to achieve a state in which the rust-preventing effect is even greater than when the vehicle was new. In addition, we use materials with excellent technology such as anti-corrosion coating inside the pipe.
The comparison between this in-pipe anticorrosive coating and hot-dip galvanizing is as follows.
A fine thin film of rust is formed on the galvanized surface, making it difficult for subsequent corrosion to progress. A fine thin film of rust acts as a protective film.
The zinc layer has a hardness of about 1/3 that of steel, is soft, absorbs external force, and has a stable oxide film that reduces corrosion weight loss to 1/20 or less. Hot-dip galvanized products are 10 times more corrosion resistant than steel when compared to new cars.
Therefore, when hot-dip galvanized material is used in frame renewal and compared with a new car, its durability is about 10 times higher.
As described above, in the renewal of the truck body, each part is restored to the same condition as a new one, improving the rust resistance and strengthening the frame.
In addition to vehicles and trailers that are subject to renewal, this system can also be applied to special vehicles such as watering tanks and snow plows for snow removal.

Remove the caulking (waterproof sealing material) from the truck body that has finished the skeleton repair. Remaining caulking affects the quality of subsequent blasting work. At the same time, remove various stickers and anti-slip tape (peel off or burn). After that, clean the grease that has been applied and injected to each operating part.
Then, the car body moves to curing work for blasting. Cure the cylinder, cabin, and system parts. If the cylinder is damaged by blasting, oil will leak.
For the curing of cabins and system parts, if the target vehicle is other than a trailer, for example, for a special body such as a wet salt spray vehicle, a water sprinkler vehicle, or a sign vehicle, the main work processes are cab accessories, sign devices, and water sprinklers. Ancillary equipment for tanks (hoses, valves, etc.), ancillary equipment for wet salt tanks (belt conveyors, poppers), collision interference devices, lights, PATLITE (registered trademark) rotating lights, bodies, cabs, propeller shafts, missions, engines, chassis Remove frame accessories, front axle and rear axle.
Regarding the chassis frame, shot blasting is performed and the strength is determined. Then, the frame is subjected to antirust coating, which will be described later.
Strength is verified with strength analysis software. Reinforce the chassis frame according to the results. For example, a laser processing machine cuts and bends a "wear-resistant steel plate". Attach the processed reinforcing material to the relevant part of the frame, calculate the strength, and verify again.
Comparing with the situation at the time of new car, we will verify the ability of renewal beyond the time of new car and digitize it. The information of the analysis software is stored and managed on a dedicated personal computer (PC).

After that, the rust on the truck body is removed by shot blasting.
In this work, the vehicle body (truck body) is first moved to the blast room. Next, shot blasting work is performed on the entire vehicle body by a shot blasting device.
In a large shot blasting booth, an air compressor is used to blow abrasive material over the entire vehicle body, removing the old paint film and putty, exposing the steel plate base. Before blasting, the floor for spraying is set at a height that is easy to work on, and the cabin, cylinder rods, axles, safety parts, etc. that you do not want to be blasted are masked with a hard vinyl sheet.
After that, the car body is lifted up, the lower part is blasted, and the upper floor, the lower floor side, and the finishing flow are performed.
After blasting, an inspector inspects to make sure there is no rust remaining. After the inspection, an air blow is performed to blow off the abrasive adhering to the vehicle body. After the blasting process is completed on the entire surface, blow off the dust with an air blower and inspect.

After the shot blasting process is completed, the parts are promptly moved to the painting factory before return rust occurs, and move on to the antirust treatment process.
After blasting, the surface of the car body is rough, so first smooth it with sandpaper.
After that, the vehicle is moved to the painting booth, where three types of anti-corrosion paint are applied.
As a confirmation item before painting, check the temperature and humidity of the day. The frequency of description is about 2 to 3 times, and the points of change are grasped. Since the finish of painting changes depending on the temperature and humidity, the blending ratio of the solvent in the paint is adjusted accordingly.

Anti-corrosion treatment is applied within 4 hours after blasting. The anti-corrosion treatment shall be a 3-layer coating of anti-rust paint. In addition, vehicles with specifications for cold climates will have a 4-layer coat.
The first layer is a high-performance anti-corrosion coating (zinc-rich primer), the second layer is a substrate adjustment reducing material (rust shut), and the third layer is an epoxy resin-based anti-corrosion coating (ultect primer). A hand spray gun is used for the 1st and 2nd layers, and an electrostatic coating gun is used for the epoxy anticorrosive coating to apply spray coating to every corner of the vehicle.
For vehicles from salt-damaged areas, chipping coat is applied to enhance rust prevention.
A buried lift is installed in the booth to lift the car body and carry out this work, and the underside is also treated to prevent rust.
Specifically, the carrier car after blasting is moved to a paint shop, and the side of the frame of the car body is sanded. Fine unevenness appears on the surface of the car body after blasting, and this should not adversely affect the coating film during painting.
When the third layer is spray-coated, heat drying is performed at 65 to 70°C to speed up the drying of the coating film.
For anti-corrosion paints, use verified paints. The antirust paint exposure test was verified with three types of exposure: normal exposure, metal immersed in salt water, and metal immersed in calcium chloride and exposed.

Under the lifted state of the car body, conduct an intermediate inspection of the appearance. Inspect defective parts found by blasting. Mark the defective area with masking tape.
After that, the vehicle is moved to the body shop, and skeleton correction is performed according to the instructions.

Furthermore, at this point, the film thickness of the rust preventive coating is measured and recorded.
Film thickness is measured at symmetrical parts of the vehicle body (framework), and about 44 points are measured at a frequency of n=5. The target film thickness is 90-100 microns. Anything less than 60 microns is rejected.
A film thickness meter is used for this coating film measurement. Use a film thickness gauge with a calibration certification period. External or in-house calibration shall be managed based on the Measuring Equipment Management Regulations.

When the skeleton correction is completed, the dirt, oil, iron powder, etc. that adhered to the vehicle body during this correction work are washed and removed with a high-pressure washer (hot water). High-pressure cleaning is highly effective as the grinding material from blasting penetrates into gaps in the frame.
Once the car body is dry, it is ready for painting. First of all, regarding the welding in frame correction and the heat effect, sanding (covering with paper) and redoing the rust-preventive paint at the spots where the rust-preventive paint has peeled off using a grinder etc. At the same time, the side of the car body Putty is applied to the surface, and the unevenness caused by corrosion is flattened.
A caulking material is injected into the skeleton joints to enhance the rust prevention and waterproof effects.
Move on to masking. Considering the order in which the car body is painted in the specified color, masking work is performed.
Large vehicles are very large, and even if the body is painted in one color, the paint is dispersed. This is for the purpose of reducing the physical fatigue and burden of workers and for taking measures against mist on the painted surface. It leads to quality improvement. An electrostatic gun is used in the same manner as the anti-rust coating above.
When painting the car body in two colors, masking work and painting work increase.
The painting here is finished in four layers. Finally, a clear coating is applied to give the surface a glossy finish.
After painting, the inside of the booth is kept at about 70°C, heat is applied for about 1 hour, and then it is cooled to promote drying of the paint. The purpose is to improve the adhesion of the coating and to speed up drying so that the next day's work can be done.
In the case of a vehicle equipped with a vehicle, paint the loading guide line on the upper and lower floors. The body of the carrier car will be painted with a line that is a guideline for safely loading the product car on the floor.
In addition, small parts such as wheel chocks, set pins, handles, opening/closing levers, and aluminum road boards are painted in yellow and red.
And in the finishing work of the painting, the surface drips, bumps, and film thickness are adjusted.
In the case of water sprinkler vehicles, wet salt spray vehicles, sign vehicles, etc., paint the chassis frame, cab, and body separately.

Next, safety standard parts, cargo handling parts, electric system parts will be renewed, and safety devices will be renewed and installed.
After the painting work, we move on to assembly work such as parts. Here, we will update the electrical system parts, the hydraulic related equipment, the safety parts, and the safety equipment.
Next, the assembly work of each part is performed.
Here, non-slip tapes, cushion tapes, buffer tapes, lashing wires, cargo tighteners, reflective tapes, drop lid rubbers, wheel stoppers, thick road boards, floor slide sheets, etc. are attached to the vehicle body.
In addition, grease up is also performed at the same time.
Furthermore, the hydraulic hose may be manufactured and replaced.
At the time of assembly work, we will renovate cargo handling, durability, and safety.
For cargo fastening wires, use plated wires, apply a lot of reflective tape and non-slip tape to improve visibility, and use LED lighting to save energy and increase illuminance.
When the assembly is completed, the assembly work is confirmed. Here, it is important to check the tightening of the hydraulic hose. This is to prevent hydraulic fluid from leaking. Check the tightening torque of each hose one by one.
For special bodies such as wet salt spray trucks, water sprinkler trucks, sign trucks, etc., the main work processes are rear and front axle assembly, chassis frame accessory installation, engine installation, transmission installation, propeller shaft installation, Complete the assembly process by installing the cab, installing the body, and installing accessories.
Along with the removal and installation of the engine and transmission, oil-related replacement and element-related replacement are also performed at the same time. Along with the removal and installation of the radiator, replace the cooling water and check for water leaks at the same time.
Renewal "Linivo (registered trademark)" other than in-vehicle vehicles uses genuine parts as the service factory of the manufacturer. Also, retighten the mounting bolts one by one.
Quality assurance in each process is based on the QC process chart.

Completion inspections and exposure tests are then performed.
First, in the case of a carrier car, the loading test of the vehicle begins. For loading, 2 or 3 company cars are loaded in order from the 1st floor of the carrier car. Check the free fall of the cylinder.
That is, the vehicle (merchandise vehicle) is actually loaded on the carrier car, and the quality is inspected based on the check sheet for final inspection.
The items to be inspected using the check sheet are (1) whether the floor is tilted or caught in the up and down, (2) whether the lifted floor will drop naturally due to the load, (3) whether there is any abnormality in the coating, (4) hydraulic hoses (5) Is there contact, etc.? (6) Is the hydraulic pressure appropriate? Is the ABS normal? (7) Is the commercial vehicle sufficiently lashed? and so on.
If any abnormalities are found during this inspection, repairs will be carried out immediately.

In addition, we check the appearance of the car body to check for any unpainted paint, sagging, scratches, unevenness, film thickness, etc., and confirm the implementation status of the assembly work.
The film thickness is measured using a film thickness meter with a prescribed proof of calibration period in the same manner as described above. In the case of other special vehicles where measurement is performed on the symmetrical position of the frame, the function is checked for operation. A water truck actually sprays water. Check the water pressure, water volume, water leakage from the tank, operational problems, etc.
In addition, a running test (trial run) will be conducted on public roads. We also check for engine and transmission abnormalities and oil leaks at the same time. Quality assurance is based on the QC process chart.
Details of defects found in the loading test shall be recorded on the loading inspection check sheet. This loading inspection check sheet shall be stored for 10 years as stipulated in the record management regulations to ensure traceability.
Check items other than the above visual inspection include hydraulic pressure measurement, limit switch and electrical signal pass/fail inspection, air leak inspection for air tanks, air pipes, air valves, etc., looseness of mounting bolts, attachment condition and damage of accessories. , inspection for missing items, etc.

Next, the weight of the carrier car is measured.
Through the above-described steps, the vehicle weight is measured with a truck scale in the state of a completed vehicle.
The measurement is carried out by the operator based on the truck scale indicator all-wheel load measurement work procedure, and a measurement certificate is issued. As for the measurement results, record them on the weighing slip and on the computer as a history, and create an environment with a well-established management system.
Then, it is inspected how the weight has changed after completion compared to the weight before starting work, and whether the weight has returned to the proper weight.
Also, by subtracting the weight of the vehicle body (truck body) after completion from the weight of the vehicle body (truck body) at the time of acceptance, the weight of repair materials (skeletal correction wear-resistant steel plate, anti-rust paint, etc.) is calculated.
Further, the value obtained by subtracting the weight of the repair material from the weight of the new vehicle is divided by the weight of the new vehicle, and the ratio between them indicates the reduction rate of CO2 emissions.

After the loading test and trial run, a "Linivo" caution plate is attached to a part of the car body as proof of "Linivo (registered trademark)". For caution plates, the type, installation number, date of installation, and reduction rate of CO2 emissions are stamped.

Then move on to the exposure test.
First, the entire vehicle body is washed and cleaned with hot water using a high-pressure washer. This cleaning washes away paint mist and oil that adheres when replacing hydraulic hoses. Also, the degree of adhesion of the coating can be checked by applying a high pressure. Air blow after high pressure washing to remove moisture.
In addition, after the carrier car is finished, it is rained or showered for several days to check whether it actually rusts. Caulking and thin portions of the paint film found by this test should be repaired and painted again.
Doing this work after completion is very important for quality control. If there is an abnormality, rust juice will come out and the defective part will be discovered.

After the exposure test, the final finishing process begins. A final inspection of the exterior and other aspects of the vehicle body is carried out on a sunny day to confirm that there are no leaks or defects.
Next, a pre-shipment inspection is performed. Based on inspection sheet. The main items to be inspected are loose cargo binding wires, oil leaks, image storage, installation of repair kits, presence or absence of loading position stickers, unpainted parts, installation of cargo, and so on.
At this time, functionality and safety are part of quality assurance. In addition, records of renewal work results shall be preserved for 10 years to maintain traceability.
After completing all of these, the vehicle information is entered in the Linibo management ledger when the vehicle leaves the garage. For the management ledger, information such as the date of receipt, the date of acceptance inspection, the start time of the car body process, the start time of blasting, the start date of anti-rust painting, the completion date of repair after blasting, the completion date of painting, the date of loading inspection, the date of delivery, etc. Describe.
At the same time, it issues a “Linivo” certificate.
Evidence documents for the "Linibo" certificate include caution plate information, paint film thickness measurement report, paint film thickness inspection report, renewal part detail sheet, measurement certificate, paint film thickness meter calibration certificate, safety confirmation data sheet ( SDS), ultrasonic diagnostic instrument calibration certificate, calibration certificate for plate thickness measurement, QC process chart, etc. are attached.
We will attach images of multiple parts of the car body at the time of acceptance, during work, after repairs, etc., and establish a quality assurance system based on the "Linivo" production system flow chart.
In the case of a "Linivo" certificate other than a carrier car, additionally attach a chassis frame thickness measurement report, a chassis frame strength analysis report, etc.
As described above, "Linivo" performs quality control based on each QC process chart.

As described above, the significance of "Linibo" is to contribute to the reduction of CO2 emissions and to ensure the quality of the renewed vehicle body. When these are united, it becomes the "Linibo" declaration. This includes calculation of CO2 emissions reduction rate, coating thickness measurement, plate thickness measurement, SDS (safety confirmation sheet), measurement certificate, calibration certificate for coating film measurement, calibration certificate for plate thickness measurement, all It is a concept that includes the QC process chart in the process.

This idea is useful as a technique for renewing an aged truck body.

100 truck body renewal system,
20 car body weight measuring means (truck scale),
30 remedial measures,
31 blasting equipment.
32 antirust treatment equipment,
33 coating equipment,
34 welding equipment,
40 repair part check means,
41 coating thickness measuring instrument,
42 board thickness measuring instrument,
50 repair material weight calculation means,
60 CO2 emission reduction rate calculation means.

A device according to claim 4 is the truck body renewal system according to claim 1 or claim 2, wherein the repair means includes a welding device, a blasting device, an antirust processing device, and a painting device.
Welding, blasting, anti-corrosion treatment, painting, etc. are included as part of the repair. In these cases, equipment, machines, and instruments for each processing and treatment are used.

Claims (4)

vehicle body weight measuring means for measuring the weight of the truck body at the time of acceptance and after completion of repair;
a repair means for repairing a portion of the truck body requiring repair using a repair material;
a repair part checking means for inspecting whether the repair of the repair required part has been completed;
Repair material weight calculation means for calculating the weight of the used repair material;
and CO2 emission reduction rate calculation means for calculating a CO2 emission reduction rate in the repair based on the weight of the repair material and the weight of the new truck body. 2. The truck body renewal according to claim 1, wherein said repair portion checking means includes a coating film thickness measuring device for measuring the coating thickness of the portion requiring repair, and a plate thickness measuring device for measuring the plate thickness. system. 3. The truck body renewal system according to claim 1, wherein the repair material includes a wear-resistant steel plate, a skeleton pipe whose inner surface has been treated for rust prevention, or a hot-dip galvanized material. The truck body renewal system according to any one of claims 1 to 3, wherein the repair means includes a welding device, a blasting device, an anticorrosive processing device, and a painting device.

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