Research And Application Of The Synchronization Engineering Method For Painting In The Body Structure Design Of Medium And Heavy Truck

In order to study the method of domestic commercial vehicle manufacturing in the field of medium and heavy truck painting synchronization engineering,this paper carried out a detailed research and analysis of synchronization engineering method in the painting of medium and heavy truck body structure design process,and the results have been applied in the practical application.The main purpose of this paper is to make the medium and heavy truck painting synchronization engineering form a formal system,let the medium and heavy truck painting research method of synchronization engineering become regularized,standardized,and more scientific and reasonable in the body structure design of medium and heavy truck.In the process of new product development,it needs the smallest changes of the structure and the exterior parts of the body,the shortest time in design cycle,the minimal transformation of production lines and the lowest cost in order to meet the product quality target with the best painting,appearance design and product quality of painting,and bring the better products for the experience and visual enjoyment of users.The main contents of this paper are as follows: at first,the painting methods of synchronization engineering for the medium and heavy truck body structure have been investigated,such as the simulation analysis,model analysis,prediction and experimental methods of the production line passing,general method,and decomposition method of automotive body;in addition,the painting synchronization engineering methods for heavy truck exterior parts structure have also been studied for instance the model analysis,prediction and experimental method of the production line passing,and general method.In the software simulation analysis method,the actual production situations have been simulated to the medium and heavy truck body model by using the electrophoretic simulation software,and the electrophoresis film effect has been achieved through the analysis.The levels of the electrophoretic film effect can reflect the problems existing in the body structure design.For the synchronizationengineering of painting,the existing problems in the stage of body structure virtual design can be solved by the optimization and adjustment of them,and then improved before the preproduction.This method applied in the painting synchronization engineering for the medium and heavy duty truck is a novel and creative.In the model analysis method,the problems,such as the characteristics of quality and operating convenience existing in the body structure of medium and heavy truck,have been found mainly through the analyses of quality characteristics,for instance,the throwing rate,drain and exhaust,and the analyses of operating convenience,for instance,the sealant,chip-resistance paint spraying,paint spraying effect and the leveling property,and then them can be solved by the optimization and adjustment in the painting synchronization engineering.The prediction and experimental methods of the production line passing have been studied mainly through the analyses of the medium and heavy truck products in the sections of existing production line,such as the pretreatment and electrophoresis tank,non-standard chamber body,mechanical transmission equipment.Each problem that affects on the passing ability has been investigated and analyzed,and then found the best solution in the change of product structure and the improvement of the production with the lowest cost,in order to achieve product quality targets and the passing ability of production line.After the completion of the changes,the durability build test has been carry out to verify the effect.The general method analyzes the property of facilities such as tooling equipment,materials,production tools,and automatic control system used in a variety of the medium and heavy truck products,as far as possible to meet the generality in tooling equipment,materials and so on.For those that cannot be used repeatedly,the tooling equipment should be redesigned and the materials should be changed,and then the verification experiment should be carried out.The decomposition method focuses on the decomposition,observation,measurement and analysis of body structure after electrophoresis once the durability build test is finished.The painting quality should be verified after the optimization of electrophoresis simulation and observation,and for those that are still not satisfied inquality,the body structure should be improved.All above methods have been applied in a new product development of Faw Jiefang Automotive Company,and achieved satisfied results.It shows that the painting synchronization engineering method is very necessary for the design of medium and heavy truck body structure,which can effectively eliminate the defects existing in body structure in the phase of product development,and ensure the achievement of the quality objectives of the product.The methods discussed in this paper and applied for the painting synchronization engineering of medium and heavy truck products have established a foundation to improve and develop the related methods and form a routine standardization of process.