KR20230149977A - Automotive Vehicle Assembly Syetem - Google Patents

Abstract

A vehicle assembly system is provided that can flexibly respond to changes in multiple vehicle types and production quantities. The mobile platform 100 moves to the completion line (4) through the trim line (1) and the door line (3), and workers move the assembly lines (1, 3, and 4) with the mobile platform (100) to Perform assembly. After completing the work on the trim line (1), the car body is moved from the mobile platform (100) to the chassis line (2), and the mobile platform (100) passes through the door line (3) and then moves the car body with the work completed on the chassis line (2). Load it and enter the completion line (4).

Description

Automotive Vehicle Assembly System {Automotive Vehicle Assembly Syetem}

The present invention relates to a vehicle assembly system and method of operating the same for assembling units and parts such as chassis, interior and exterior trims, and electrical systems into a vehicle body.

The vehicle production process consists of a press process, body process, painting process, assembly process, and inspection process. A car body (body in white) is obtained by welding and assembling various panels made through press processing. After painting this car body, various units and parts are assembled into the car body to obtain a finished car. Next, an inspection is performed on the finished car. do.

The assembly process is a process in which interior and exterior materials and mechanical parts are assembled on the painted car body, and electrical components, wiring, and piping work are performed. It is also collectively called the design process. The assembly process consists of a trim line, a chassis line, and a final line. In the trimming process, the door is removed from the car body to facilitate interior work, and electrical wiring, headlining, instrument panel, lamps, etc. are installed on the car body. The engine, muffler, suspension, steering system, brake system, tires, etc. are installed on the car body that has gone through the trim process in the chassis process. In the completion process, doors, seats, windows, etc. are installed on the car body that has gone through the chassis process.

In modern industry, the conveyor production method has played a leading role in the machinery industry. The conveyor production method is suitable for the production of internal combustion engine vehicles consisting of more than 20,000 parts, and is especially optimal for uniform mass production of a single vehicle model. However, the conveyor production method is very inefficient when there are frequent changes in vehicle type or production quantity. The conveyor production method is operated according to the process that takes the longest among various processes. This creates a bottleneck process, and it is not easy to distribute work time equally between processes.

In the global market, customer demand is becoming more diverse and diversified. Companies are developing products that meet consumer needs and seeking production methods that can increase profitability. In the case of vehicles, the development cycle of new vehicle models is accelerating. If you fail to respond quickly to changes in consumers' consumption trends or desires, there is a realistic management threat that you may not be chosen by consumers and be left out of the competition.

Electric vehicles are close to electronic products that are modularized with batteries, motors, and electronics. Modular electric vehicles are much more advantageous for small quantity production of a wide variety of products compared to internal combustion engine vehicles. Electric vehicle production methods are expected to develop in a clearly different direction from internal combustion engine vehicle production methods.

In order to keep up with and lead the rapidly changing consumer trends, vehicle manufacturers are required to develop a small quantity production method that is efficient and cost-saving. In addition, in order to meet the needs of a rapidly changing market, future vehicle assembly methods need to be designed and developed to flexibly respond to small-type mass production, multi-type small-scale production, and multi-type mass production.

Recently, smart factories based on information and communication technology (ICT) are becoming more common across industries. The vehicle assembly process is also becoming more automated and unmanned.

The present invention is based on the recognition of the prior art as described above, and the present invention seeks to provide a vehicle assembly system that can efficiently respond to the production of multiple vehicle types.

Additionally, the present invention seeks to provide a vehicle assembly system that can flexibly respond to changes in production quantity.

The problems to be solved by the present invention are not necessarily limited to the matters mentioned above, and other problems not yet mentioned may also be understood by the matters described below.

The above objectives are achieved by the inventions and configurations described in the claims. Characteristically, the vehicle assembly system according to the present invention includes an assembly line including a trim line, a chassis line, a door line, and a completion line; A mobile platform configured to move circularly through the trim line, door line, and completion line, and to load the car body and parts to be assembled into the car body; and a circular overhead line connecting a first point between the trim line and the door line, a second point between the door line and the completion line, and the chassis line.

The car body on the mobile platform that has passed the trim line at the first point is transferred to the overhead line. At a second point the car body on the overhead line is transferred to a mobile platform. Workers move along the assembly line with a mobile platform and assemble parts loaded on racks into the car body. Assembly work on the chassis line and assembly work on the door line are carried out in parallel.

According to the present invention, the mobile platform includes a car body loading unit, a rack on which parts to be assembled to the car body are loaded, and a door holder where the door removed from the car body is stored.

As described above, the vehicle assembly system according to the present invention is suitable for producing multiple types of vehicles.

Additionally, the vehicle assembly system according to the present invention can flexibly respond to changes in vehicle type and production quantity.

Additionally, the vehicle assembly system according to the present invention is capable of responding to small quantity production and mass production of multiple vehicle types.

Additionally, according to the vehicle assembly system of the present invention, parts can be supplied to the assembly line according to production quantity or speed, thereby reducing the need for excessive inventory accumulation and enabling efficient warehouse operation.

In addition, according to the vehicle assembly system according to the present invention, the risk of bottleneck processes is low, and even if there is a temporary bottleneck, return to normal operation can be rapid and workers in other processes may not be placed on standby. .

In addition, according to the vehicle assembly system according to the present invention, the chronic decline in work efficiency of workers due to simple and repetitive work on the conveyor can be prevented or reduced, and further, the management of assembly quality has been leveled upward through work manualization and standardization. is possible.

1 is a flowchart of a vehicle assembly process according to an embodiment of the present invention.
Figure 2 shows the layout of a vehicle assembly system according to an embodiment of the present invention.
3 shows a mobile platform of a vehicle assembly system according to an embodiment of the present invention.
Figure 4 is a lateral view of the mobile platform shown in Figure 3;

Hereinafter, we will look at examples in more detail so that we can understand various characteristic aspects of the present invention. In the drawings, identical or equivalent components may be indicated by the same symbols, and the drawings may be exaggerated or schematically shown for intuitive understanding of the features of the present invention.

In this document, unless otherwise specified or inherently impermissible, expressions to describe the relationship between two elements, such as 'phase' and 'connection', refer to the two elements being in direct contact with each other. Of course, a third element is allowed to be inserted between the first and second elements. Directional indications such as front and back, left and right, or up and down are only for convenience of explanation.

Referring to FIG. 1, the vehicle assembly process according to the embodiment includes a trim process (S1), a chassis process (S2), a door process (S3), and a completion process (S4). As a preferred example, vehicle assembly begins with the trim process (S1), the chassis process (S2) and the door process (S3) are performed in parallel, and then the completion process (S4) is performed. After the completion process (S4), the inspection process (S5) is performed.

In the trim process (S1), interior and exterior materials are installed on the car body. The car body is transferred to the trim process (S1) after going through the press process, body process, and painting process. Painting is usually carried out in the order of base coat, middle coat, and top coat. Moving parts, including doors, are installed on the painted car body, and the doors are removed from the car body for interior work.

Interior work includes mounting the cockpit module, including the cowl cross member and instrument panel, to the body, and various main electrical wiring works. In addition, for example, lamps such as headlamps and taillamps, as well as mounting members for mounting these parts, such as engine mounts, bumper mounting brackets, bumper impact bar nuts, and wiper linkages, are installed and mounted on the car body.

Door removal can be performed at a previous stage in a separate space from the installation work of interior and exterior materials. To increase space utilization, door removal and interior/exterior material installation can be performed on one line, but if necessary, door removal and interior/exterior material installation can be performed in separate spaces. The trim process (S1) includes both the former and the latter cases.

In the chassis process (S2), modules and parts for driving and driving the vehicle are installed on the car body. In the case of an internal combustion engine, for example, a powertrain, suspension, wheels, tires, brake system, etc. are mounted on the vehicle body. In the case of electric vehicles, a drive motor and battery will be installed instead of the powertrain. These parts are relatively bulky and heavy and are mainly mounted on the lower part of the car body, and for this purpose, an overhead conveyor is used in the chassis process (S2).

The door process (S3) is a process in which door modules including window regulators, door trims, switches for controlling windows, seat heat, and mirrors, and door handles are installed on doors removed from the vehicle body. The door removed from the car body is an assembly of an inner panel and an outer panel, and an impact beam is usually installed between these panels. The door trim is mounted on the inner panel.

It is difficult to perform the door process (S3) on the same line as the chassis process (S2). To eliminate bottleneck processes and improve overall process efficiency, the door process (S3) is performed in parallel while the chassis process (S2) is performed. For this parallel performance, the assembly line and work schedule need to be designed and managed so that the door process (S3), the chassis process (S2), and the next completion process (S4) can be efficiently linked and performed. Examples related to this will be described later.

In the completion process (S4), the seats, front and rear bumpers, doors and windows that have gone through the door process (S3) are installed on the car body, and vehicle assembly is completed. Lamps, tires, etc. were installed on the car body in the previous processes (S1, S3), but these parts can be installed on the car body in the completion process (S4). In addition, parts can be assembled according to the work environment, vehicle model, and each company's work manual, etc. It needs to be understood that the order can be changed in many ways.

From the inspection process (S5) to the completion process (S4), it is inspected whether various electrical parts, mechanical parts, units, etc. of the assembled vehicle are operating properly.

Figure 2 shows the arrangement of an assembly line according to an embodiment. 3 and 4 show a mobile platform 100 according to an embodiment. The assembly line includes a trim line (1), a chassis line (2), a door line (3), and a completion line (4). The mobile platform 100 moves between lines 1 to 4, carrying a car body thereon for vehicle assembly.

Referring to Figure 2, the trim process (S1), chassis process (S2), door process (S3), and completion process (S4) are respectively trim line (1), chassis line (2), door line (3), and completion. This is done at line (4). Let's look at the arrangement of these assembly lines (1 to 4).

The painted car body is transported to the trim line (1). The mobile platform 100 may be used for this transfer, or another transport vehicle may be used. As a preferred example, multiple mobile platforms 100 circulate through the trim line 1, chassis line 2, door line 3, and completion line 4, and the car body that has completed the painting process is moved and circulated. It is loaded onto the mobile platform 100. As one example, the car body is loaded onto the mobile platform 100 upstream of the trim line 1, or somewhere between the completion line 4 and the trim line 1.

The moving platform 100 circulates along the moving line 10 through the trim line 1, the door line 3, and the completion line 4. The moving line 10 includes a first line 11 connecting the trim line 1 and the door line 3, a second line 12 connecting the door line 3 to the completion line 4, and a completion line ( 4) and a third line (13) connecting the trim line (1). A first point P1 is disposed approximately in the middle of the first line 11, and a second point P2 is disposed approximately in the middle of the second lines 12 and 14.

In the chassis line (2), the car body is transported along the overhead line (20). The overhead line 20 is a first overhead line 20 extending from a first point P1 of the moving line 10 to the chassis line 2, and a first overhead line 20 extending from the chassis line 2 to the second point P2. It includes a second overhead line 22, and a third overhead line 23 extending from the second point P2 to the first point P1. At a first point (P1), the car body on the mobile platform (100) is moved to the first overhead line (21) and enters the chassis line (2), and at a second point (P2) from the second overhead line (22). The vehicle body is moved back to the mobile platform 100. The overhead line 20 is equipped with an overhead conveyor and a hanger for picking up and holding the car body. A number of hangers circulate the overhead line 20.

Referring to FIG. 2, let's look at an example of vehicle assembly performed along the trim line (1), chassis line (2), door line (3), and completion line (4).

The painted car body is placed on the moving platform 100 that circulates along the moving line 10 and enters the trim line 1. The location of the mobile platform 100 is tracked, and LOT tracking and automated production management are performed by a production management system (hereinafter referred to as 'MES'). When the mobile platform 100 enters each assembly line 1 to 4, the corresponding vehicle body information is input to the MES using tags attached to the vehicle body. MS displays work instructions on monitors placed on each assembly line (1 to 4), and workers perform assembly work according to the work instructions.

Workers perform all or nearly all assembly tasks. As an example, four workers are placed on the mobile platform 100 as a group, and these four workers move with the mobile platform 100 and perform the necessary tasks at the trim line (1), door line (3), and completion line (4). Perform assembly tasks. Workers may move on the mobile platform 100 or on foot if the distance between the lines 1 to 4 is not long. To increase efficiency, the chassis process (S2) and the door process (S3) are performed in parallel. As an example, the chassis process (S2) is performed by four separately assigned workers, and the work on the door line (3) is performed by workers who move with the moving platform (100). The number of workers, placement for each process, etc. may be changed in various ways as needed.

Unlike the conventional conveyor-type production method, according to this embodiment, workers perform almost the entire process of assembling a finished vehicle. In the conventional case, the problem was that workers' concentration decreased due to continuous repetition of the same task. In the case of the embodiment, quality control and production motivation can be promoted through manualized work instructions, step-by-step production training for workers, and operation of a master certification system. Because workers perform almost the entire assembly process, their work satisfaction and motivation for the quality of the finished car are high. Additionally, according to the embodiment, it is possible to produce small quantities of multiple models. Additionally, it is possible to flexibly respond to changes in production quantity without reducing workers, changing tasks, or making additional arrangements.

The mobile platform 100 includes parts to be assembled to the car body in the remaining processes (S1, S3, and S4) except the chassis process (S2) (hereinafter, unless otherwise expressed, the parts to be assembled to the car body are collectively included). ) All or many parts are included. Since the parts to be assembled in the chassis process (S2) are generally large in volume, it is preferable to provide logistics directly to the chassis line (2) rather than being transported on the mobile platform (100). Some of the work tools to be performed in the processes (S1 to S4) are transported on the mobile platform 100, and some are placed on each assembly line (1 to 4). For production management, the location and use of tools (e.g., electric tools) are monitored.

In the processes S1, S3, and S4, parts to be assembled to the car body are loaded on the mobile platform 100 together with the car body before the trim line 1. These parts are divided into racks according to classification standards for each vehicle type and supplied in bulk. At least some of the racks are movable and are configured to be pushed and docked on the mobile platform 100. As another example, parts to be assembled to the vehicle body in processes S1, S3, and S4 may be loaded on the mobile platform 100 when the mobile platform 100 enters the trim line 1.

In the trim line (1), a cockpic module is typically installed on the car body, and various wiring work is performed. For the convenience of these tasks, the doors are removed from the car body in advance. The hinge bolts of the four doors on the front, rear, left, and right sides are removed from the vehicle body, and the removed doors are loaded on the door holder provided on the moving platform 100.

As another example, removal of the doors may be performed in advance before the vehicle body is placed on the mobile platform 100. Removal of the doors may be performed in a factory other than the vehicle assembly plant equipped with assembly lines (1 to 4), and may be transported to the vehicle assembly plant separately from the car body. In this case, the car body, parts to be assembled, and removed doors may be carried on the moving platform 100 and entered into the trim line 1.

When the work is completed at the trim line (1), the mobile platform 100 starts from the trim line (1) and moves along the first movement line (11). Workers on the trim line (1) are transported together on the mobile platform (100). The car body on the mobile platform 100 at the first point P1 is transferred to the overhead line 20 for chassis processing S2. As an example, the hanger of the overhead line 20 is configured as a scissor type. The car body is picked up by a hanger and transported along the first overhead line 21, and enters the chassis line 2.

In the chassis line (2), parts for driving and running the vehicle are installed. Representative examples are powertrain and suspension system. In the case of an electric vehicle, it would be a drive motor and battery. These are referred to as drivetrain components. Four dedicated workers separately assigned to the chassis line (2) perform the necessary work according to work instructions. In the chassis line (2), the brake system, wheels, tires, etc. are also installed on the car body.

The mobile platform 100 with the car body unloaded at the first point P1 moves along the first movement line 11 and enters the door line 3. Workers on the trim line move to the door line (3) on the moving platform (100).

Door modules are typically mounted on doors stored in door holders of the mobile platform 100 in the door line 3. In addition, door trim, various switches, door handles, etc. are assembled to the door in the door line (3). The door holder is designed to facilitate the storage of the door as well as the installation of door modules, etc. For this purpose, the door holder is configured to adjust the angle at which the door is placed. For example, a door holder can be folded and unfolded, or its angle can be adjusted around a vertical axis.

The door process (S3) is carried out in parallel with the chassis process (S2). This parallel progress aims for the mobile platform 100, which handed over the car body to the chassis line 2 at the first point (P1), to hand over the car body again at the second point (P2). Considering that there may be a difference between the working time in the door line (3) and the working time in the chassis line (2), the door process (S3) must be carried out in parallel with the chassis process (S2) at exactly the same time, 1 :1 It may not be matching.

As another example, jobs on the chassis line 2 may be performed by workers (trim line workers) who move with the moving platform 100. In this case, exclusive workers for the door process (S3) are placed on the door line (3). As another example, some dedicated workers may be placed on the chassis line 2 and/or the door line 3. Some of the workers moving with the mobile platform 100 may perform the chassis process (S2), and the remaining part may move with the mobile platform 100 to perform the door process (S3). Workers can be flexibly assigned according to changes in workload for each process depending on the vehicle type. Since parts assembled to the car body in the chassis process (S2) can affect driving safety, their skills can be taken into consideration when assigning workers.

When tasks are completed in the door line 3, the mobile platform 100 moves along the second mobile line 12 and waits at the second point P2. Workers move with the mobile platform 100.

Once the work on the chassis line (2) is completed, the car body is transported along the second overhead line (22). At the second point (P2), the vehicle body is moved onto the waiting mobile platform (100). The hanger holding the car body is unfolded downward and the car body is loaded onto the moving platform 100. The mobile platform 100 carrying the car body moves along the second movement line 12 and enters the completion line 4. The hanger at the second point (P2) moves to the first point (P1), picks up the car body on the mobile platform (100) that has passed the trim line (1), and transfers it to the chassis line (2).

In the completion line 4, the doors that have been completed on the door line and stored in the door holders are assembled into the car body. Before assembling the doors, the seat is assembled inside the vehicle body. In addition, bumpers, windows, interior trim, etc. are assembled into the car body.

An inspection process (S5) is performed on the finished vehicle obtained after the assembly work is finally completed up to the completion line (4). The mobile platform 100 carrying the finished vehicle in the completion line 4 may be moved for the inspection process (S5). However, for smooth performance of the inspection process (S5) and logistics of the assembly line, the finished vehicle is transferred to another transport vehicle and moved for the inspection process (S5). For example, the finished car on the mobile platform 100 is unloaded at the third point P3 of the third mobile line 13, and the parts to be assembled into the car body are loaded on the mobile platform 100 at the fourth point P4. do. Since a plurality of mobile platforms 100 circulate in the mobile line 10, the mobile platform 100 loaded with the car body and parts may be waiting to enter the trim line 1 at the fourth point P4.

3 and 4 show a mobile platform 100 according to an embodiment.

Referring to FIGS. 3 and 4 , the mobile platform 100 may be moved by being carried on an automated guided vehicle (ASV), or may be towed and moved by an automated guided vehicle (ASV). The mobile platform 100 itself may be equipped with a drive system, but considering cost economics and increased utilization of autonomous guided vehicles (ASVs), providing its own drive system is not preferred.

The vehicle body loading unit 102 is disposed at the center of the floor 101 of the mobile platform 100. The loading unit 102 is configured to partially restrain the vehicle body or stably support it. The car body placed on the loading unit 102 does not entirely contact the floor 101 but floats to some extent.

A door holder 41 is disposed at a square corner of the mobile platform 100. The door holder 41 is configured to facilitate storage of the door and installation of a door module. For example, the door holder 41 is configured to be unfolded and folded using a rack and pinion structure, or configured to be rotated about a vertical axis.

Racks 31 and 32 are disposed at the rear end and both ends of the mobile platform 100. The parts to be assembled to the car body are grouped and stored in kit boxes 33 and 34 for efficient assembly. The kit boxes 33 and 34 are mounted on the shelves of the racks 31 and 32. Workers pull out the necessary kit boxes (33, 34) according to the work details and assemble the parts stored in the kit boxes into the car body.

At least some of the racks 31 and 32 are movable and are preferably of a docking type. The racks 31 arranged at both ends of the mobile platform 100 are of the docking type. This docking type rack 31 is movable and is configured so that an operator can push the rack 31 in the horizontal direction and place it on the mobile platform 100. As an example, the docking type rack 31 has wheels 31, and the legs with the wheels 31 are foldable. When the docking type rack 31 is pushed and hits the mobile platform 100, the legs are folded and the rack 31 is seated on the floor 101.

Several docking type racks 31 loaded with parts may be stored somewhere around the trim line 1, and parts may be loaded into these racks 31 in real time in accordance with the start of the trim process (S1). You can. The rack 32 at the rear end of the mobile platform 100 is a fixed type that is simply seated on the mobile platform 100. Parts that are needed in various processes (S1 to S4) or that are difficult to group and sort into relatively large units can be loaded on the fixed type rack 32 as needed. The fixed type rack 100 may be carried on a carrier and placed on the mobile platform 100.

Embodiments of the present invention have been described above, and these embodiments will be helpful in understanding various aspects and features of the present invention. The features or elements introduced in these embodiments may be combined in various forms, and such combinations may provide another embodiment that has not yet been described in this document.

The scope of the invention sought to be protected is set forth in the claims. The elements described in the claims may be variously changed, modified, and replaced with equivalents without departing from the essence or scope of the invention. The reference numerals in the claims, if provided, are only intended to facilitate easy and intuitive understanding of the claimed inventions or their elements and do not limit the scope of the claimed inventions.

1: Trim line 2: Chassis line
3: Door line 4: Finish line
10: moving line 20: overhead line
31,34: Rack 32,33: Kit box
41: door holder 100: mobile platform

Claims (4)

Assembly line including trim line, chassis line, door line and completion line;
a moving platform configured to move circularly through the trim line, door line, and completion line, and to load the vehicle body and parts to be assembled into the vehicle body; and
a circular overhead line connecting a first point between the trim line and the door line, a second point between the door line and the completion line, and a chassis line;
The car body on the mobile platform that has passed the trim line at the first point is transferred to the overhead line, and the car body on the overhead line is transferred to the mobile platform at the second point,
A vehicle assembly system in which workers move along the assembly line with the mobile platform and assemble parts loaded on racks into the vehicle body, and assembly work on the chassis line and assembly work on the door line are carried out in parallel. The vehicle assembly system according to claim 1, wherein the moving platform includes a vehicle body loading unit, a rack on which parts to be assembled to the vehicle body are loaded, and a door holder for storing a door removed from the vehicle body. The vehicle assembly system according to claim 2, wherein the rack is movable and configured to be docked on a moving platform by pushing in a horizontal direction. The vehicle assembly system according to claim 2, wherein the door holder is configured to adjust the angle at which the door is placed to facilitate storage and removal of the door and assembly of parts to the door.