Professional Documents
Culture Documents
201620096
1. underbody components, such as the floor pan and the motor component are
built up as sub assemblies. This is accomplished by taking individual sheet metal
components of varying sizes, fixturing them into a precise location and then RSW
(resistance spot welding) them into their final location. Here's the starting point:
2. finished subassemblies are assembled and added to the floor pan and motor
compartment. At the beginning a vehicle body starts flat, additional assembles
add some length, but also all the components that give a vehicle body height,
things like the firewall separating the motor from the passenger compartment
and the waterfall section between the backseat and the trunk.
3. at this point you have the rough shape of a car, but still lack the external body
panels that make it look like the final product, lack a roof, and have none of the
swing metal parts: doors, hood, deck lid (what you call a trunk/ boot in an
automotive factory)
4. In one of the more complex operations in the body shop the body sides are
placed onto the vehicle. This is typically the largest single piece of sheet metal
used in a vehicle.
5. Roof time. A roof panel is placed on top of the sheet metal layer cake that
you've created and welded into place. Depending on which company you work
for, this is one of the defining features of a vehicle since many of the previous
steps are common between manufacturers. Whether your car has a "ditch
molding" on the roof or simply a smooth continuous roof is an easy way to tell the
difference between cars. The ditch molding is a simpler method where a panel is
placed on top of your vehicle and has an offset surface that allows RSW. The
more complex methods have either brazing or laser welding to produce a
continuous flat surface over the entirety of your roof.
6. Swing metal time. Doors were built up in separate sub-assembly lines and are
placed on a conveyor to be mounted onto the rest of the body. Doors are lifted
via a specially designed piece of tooling to lift them and locate them accurately to
the car body. Bolts are torqued, and verified, to a specific value to mount the
doors. This (along with deck-lids and hoods) are typically the the only threaded
fastener in the entire Body Shop everything else is welded into location.
9. Transfer to paint shop. Depending on the size of the factory this takes a few
forms, usually your BIW gets to ride on some form of conveyor or AGV
(automatic guided vehicle), ride up an elevator or hoist of some sort, and ride
another conveyor before arriving in the paint shop.
There are other additions :
1. Paper work are the first stage ,drawing of the car and finalising
it(BODY DESIGN) .
2. Later the dimensions length breadth of the car , then the required
CHASSIS design .
7. Engine is designed as per the body weight of the car ,and what kind of
car it suppose to be ( SUV ,SEDAN ,HATCHBACK ) .
10. CHASSIS of the car is made , now day's robots construct the chassis
for eliminating error .
12. Buffing processes are carried out to eliminate any rough particle ,
before going for a paint job .
13. Outside body comes in place and doors are fixed for trial which will be
removed simultaneously for other fittings .
14. Then its goes for primer coating which will help for a smooth finish in
the car's paint job later .
15. Then the painting process once again robots ( high end cars are not
painted robots totally hand made like ROLLS ROYCE ) .