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Development of a Highly Flexible Geometry Station for Versatile Production Systems in Automotive Body Construction: A Station designed for Joining of Body-in-White Assemblies duringan Integration of Electric Vehicles
KTH, School of Industrial Engineering and Management (ITM), Production Engineering.
2018 (English)Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesisAlternative title
Framtagning av en högflexibel geometristation för mångsidiga produktionssyteminom fordonsindustrin (Swedish)
Abstract [en]

The research in this report seeks to develop a highly flexible geometry station for joining futureBody-in-White (BiW) assemblies. The goal is to eliminate the need for a complete reconstructionof a production line during integration of new car bodies in a contemporary production.Today's BiW production is performed in sequential lines, where joining equipment is arranged ina specific order for each model geometry. An increasing model portfolio forces manufacturers todevelop production systems that allow an integration of new models. Electrified alternatives ofexisting models are now developed and put into production. These models have similarappearance as conventional models, but with a completely different principle of driveline due tothe propulsion. This means that new interfaces and platforms have to be developed and mustnow be integrated into a current production. Today's production lines are not prepared forcoming changes, and current stations can only handle a limited number of variants. Integration ofnew geometries into a contemporary production line is not sufficiently efficient from aproduction perspective. The goal of the future is to make such an integration possible.Initially, current and future production scenarios were studied. Based on this, four types ofproduction scenarios, which a highly flexible geometry station can be integrated into, were set up.An integration can take place in different ways depending on how a highly flexible geometrystation is compounded, therefore, different cases were created and compared in a case study.Internal and external benchmarking of production systems were made to compare the availablesolutions for increasing stations flexibility in a BiW production.As reference for the project, a concept for a highly flexible geometry station has been developedand is therefore described initially before an additional depth has been realized. The furtherconceptualization of a highly flexible geometry in this report is presented in the form of amorphological composition of technologies that can increase a station's flexibility, as well asvisualization of a station principles through layouts and cycle time charts. The result of theanalysis generated several concepts that hold different degrees of capacity, footprint andflexibility. The focus was to achieve a high level of flexibility for integration of new models, withnew geometries, in a current production. The conclusion was that the highly flexible geometrystation can, in a contemporary production, produce independently in low volumes. Alternatively,produce higher volumes when it is integrated as a complement in a novel, not yet implemented,production concept.

Abstract [sv]

Forskningen i denna rapport syftar till att utveckla en högflexibel geometristation för fogning avkommande Body-in-White-karosser (BiW). Målet är att eliminera behovet av en fullständigrekonstruktion av en produktionslinje under integrering av nya bilar i en samtida produktion.Dagens BiW-produktion sker i sekventiella liner, där fogningsutrustning är arrangerad i enspecifik ordning för respektive modellgeometri. Ett ökande antal modellalternativ drivertillverkare till att utveckla produktionskoncept som möjliggör integration av nya modeller.Elektrificerande alternativ till befintliga modeller utvecklas kontinuerligt. Dessa modeller ärutseendemässigt lika de konventionella modellerna, men med en helt annan princip för drivlina.Det innebär att nya gränssnitt och plattformar har tagits fram och måste nu integreras i ennuvarande produktion. Dagens produktionslinjer är inte förberedda för kommande förändringaroch nuvarande geometristationer kan endast hantera ett begränsat antal karosstyper. Integrationav nya karosstyper i en befintlig produktionslinje är inte är tillräckligt effektivt ur ettproduktionsperspektiv. Framtidens mål är att göra en sådan integration möjlig.Inledningsvis studerades nuvarande- och kommande produktionsscenarion. Utifrån det beskrevsfyra produktionstyper, vilket en högflexibel geometristation kan komma att integreras i. Enintegration kan ske på olika vis beroende på hur en högflexibel geometristation tillämpas, därförjämfördes olika fall av det i en Case-studie. En intern och extern benchmarking avproduktionssystem gjordes för att jämföra de lösningar som finns för att öka flexibiliteten i enBiW-produktion.Som referensunderlag till projektet har ett koncept för en högflexibel geometristation tagits framoch är beskrivet inledningsvis innan en ytterligare fördjupning har realiserats.Konceptualiseringen av en högflexibel geometristation i denna rapport är presenterad i form aven morfologisk sammansättning av teknologier som kan öka en stations flexibilitet, samtvisualisering av en principiell station genom layouter och cykeltidsdiagram. Resultatet av analysengenererade flera koncept som innehar olika grad av kapacitet, fabriksyta och flexibilitet. Fokus varatt uppnå en hög flexibilitetsnivå för integration av nya modeller, med nya geometrier, i ennuvarande produktion. Slutsatsen var att den högflexibla geometristationen kan, i en nutidaproduktion, producera självständigt i låga volymer. Alternativt producera högre volymer då denintegreras som ett komplement till ett ännu inte implementerat nytt produktionskoncept.

Place, publisher, year, edition, pages
2018. , p. 150
Series
TRITA-ITM-EX ; 2018:553
Keywords [en]
BiW; Body-in-White; Car body; Automobile Industry; Electric Vehicle (EV); New Product Integration; Flexibility; Changeability; Versatility; Modularity; Flexible Manufacturing System; Sub-assembly; Joining; Self-Piercing Riveting (SPR); Resistance Spot Welding (RSW)
National Category
Mechanical Engineering
Identifiers
URN: urn:nbn:se:kth:diva-232578OAI: oai:DiVA.org:kth-232578DiVA, id: diva2:1235677
External cooperation
Daimler AG, Sindelfingen
Supervisors
Examiners
Available from: 2018-07-26 Created: 2018-07-26 Last updated: 2018-07-27Bibliographically approved

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