Automotive Body-In-White & Chassis Assembly System Supplier

Modular design with tooling and machine manufacturing capabilities

With more than 24 years of experience in designing, manufacturing and integrating automotive body-in-white and chassis assembly systems, our company has been serving global vehicle makers and automotive Tier 1 suppliers with integral automated assembly system for their factories.

The automotive body-in-white assembly system consists of quality checking fixtures, hemming system which incorporates nine patented hemming technologies, and welding assembly system that uses several joining technologies such as spot welding, laser welding, and sealing. Having the in-house capability to do layout design, tooling design, machine manufacturing and full system integration gives us an advantage as a leading body-in-white and chassis assembly line system provider.

Automotive Body-In-White and Chassis Assembly System | Modular Design with tooling and machine manufacturing capabilities

Building automotive body structure platforms is a significant capital investment for automotive manufacturers. Consequently automotive-body-structure-platform-sharing and standardization is the reason behind the high demand for modular assembly lines for body-in-white. Building body-in-white production lines with modular and reconfigurable design requires not only robotic programming,  system integration capabilities and experience, but also in-depth tooling and machine manufacturing experience and capabilities. Our in-house tooling and machine manufacturing facilities and design team gives us a great advantage over other system integrators with body-in-white robotic assembly line capabilities.

 

As a long-term Tier 1 supplier to both passengers and commercial vehicle body structure production lines, we’re experienced with many joining technologies for main frames, sub-frames and structural component assemblies, and the use of structural materials such as steel and aluminum alloys. Various joining methods have been deployed including laser welding.

Automotive Moving Parts Hemming System | Hemming Technology

Hemming quality affects the appearance and final quality of a vehicle, since it joins the inner and outer closure panels of trunk-lid, tailgates, hood, sun roof, fenders, doors and wheel arches and other moving add-on automotive parts that determine the overall look of the car. Because hemming quality is a key factor in applying the final touches to automotive moving parts, our robot programming capabilities, and multiple interchangeable tools for the roller heads, servo motor capability and hybrid hemming system enable us to excel among hemming system providers.

Hemming System Applicable Automotive Parts

Press Hemming System

These press hemming systems recycle press frames to switch among various upper-and-lower hemming dies that are exclusive to one panel sets. All hemming dies are designed and manufactured in-house, and a hydraulic source powers the press hemming system.

Press Hemming System with exclusive upper and lower dies, press frame recylcled

Robot Controlled Roller Hemming System

Robot controlled roller hemming system that uses industrial robots with roller-hemming heads is used extensively for rear doors, hoods, and trunks. Because hemming determines the final quality of a vehicle, and the appearance of its panels, hemming accuracy is crucial to provide the finishing touches to the automotive body.

Robot Controlled Roller Hemming System

Roller Hemming Quality Control Strategy

  • Strength in robot roller hemming systems comes from the programming capability to strictly control the hemming head’s angle and direction and the tooling design capability to change among a wide range of tools.
  • For hemming flexibility hemming roller heads can adjust up to 130˚.
  • Panels are hemmed in increments instead of hemming in one process. This enables operators to make minor changes in the hemming process when quality issues arise.
  • Constant hemming pressure is maintained using pneumatic pressure and monitoring the pressure with an embedded sensor and PC connection.
  • Hemming speed can go up to 250mm/s.
  • Hemming force can go up to 150 kgf.
  • Patented roller head technology uses three cylinders and one roller head for straight and smooth operations. This technology is most suitable for straight panels such as the automotive sunroof.

Servo Motor Hemming System

Servo motor hemming system implements roller hemming systems and hemming punching units for a demanding mass productions. our servo motor hemming system ensures efficient process time, and ensures that there is no quality dispersion resulting from the differences in robots’ operation skills. Our servo hemming system is widely used by global vehicle makers with a wide range of production requirements.

Among the advantages:

 

  • Hemming quality is maintained by controlling the hemming pressure force and pressing time.
  • Patented servo motor hemming technology operates pre-punch and main punch hemming in one step and shorten the hemming cycle time.
  • Minimal floor space is required for efficient overall line configuration
  • Hydraulics are eliminated to improve noise control and the operators’ work environment. And the running cost is lower.
  • Configuration mechanism is simplified
  • The top section of this hemming system is open for easier and safer maintenance and repair.
  • Hemming quality is strictly controlled using sequential operation of each hemming units, controlling pressing speed, power position and time. By using HMI in exert mode, we can set up the acceleration, deceleration, speed, position, time and torque for each job.
LPR Global Servo Motor Hemming System
LPR Global Servo Hemming Punch Unit Layout

Servo Motor Hemming Punch Unit Layout on Automotive Body-In-White Exterior Components

Pre-Welding Systems: Quality Checking Fixtures

 

Screw Body Technology

The accuracy of the degree of Body-In-White assembly and add-on parts (moving parts) has a direct impact on safety. We design checking fixture systems for Body-In-White and moving parts for  quality inspection before they are permanently assembled by  welding, sealing and hemming. Our checking fixtures use screw bodies to temporarily assembly and lock in the body-in-white for thorough and complete quality checking of gaps, panel holes and checking fixtures flush. Our capabilities in developing high precision manufacturing inspection jigs for automotive assembly component and screw bodies means that our expertise in the trial assembly of automotive Body-In-White and moving parts before mass production exposes problems early on. The implementation of checking fixtures leads to shorter production cycles for not only high quality automotive Body-In-White assembly, but also for new automotive models.

 

Raising the Jig Quality using Checking Fixtures

To increase the jig quality, we assembly each sub assembly parts to the new jig and compare the hole positions to quality check the jigs and ensure they match the sub assembly.

Body-in-white Checking Fixture

Body In White Checking Fixture

Door Checking Fixture

Door Checking Fixture

Trunk Checking Fixture - Checking Fixture for Moving Assembly

Trunk Checking Fixture

Automotive Body-In-White Assembly System Features

Geopallet – Transfers parts down the assembly line, drops off finished parts and transfers picked-and-placed new parts to minimize production cycle time

Automotive Body Assembly System- geopallet

Multi-jigs – The use of different jigs for each vehicle model allows several vehicles models to be assembled on a single line sharing the same layout, transfer system and robots. All tools are designed and manufactured in house with an optimized design to ensure the quickest changeover.

Body-in-white assembly system welding jig
Body-in-white assembly system loading jig

Automotive Body-In-White Welding Assembly Line Project Experience

pdf-iconBody-In-White Welding Assembly Project Reference (Includes Hemming System and BIW Checking Fixture)

Automotive Main Body Welding Assembly Line Project:

  • 4 vehicle models assembled on one shared assembly line with changeable tooling and geopallets.
  • A welding assembly line consisting of a wind mill unit that allows multiple models to be produced on one skid. It includes a  main buck system and a roof buck system and is driven by a servo motor.
  • 20 automotive body build line stations and 20 respot stations.
  • A cycle time of 55 seconds.
Automated Body-In-White-Welding Assembly System Layout

Automotive Body-In-White Welding Assembly Line Layout

Automotive Under Body and Side Body Assembly Line

  • 11 Stations with 7 linear cell stations
  • Vehicle type geo-pallet used for smooth operation
  • Linear motor system used
Automotive Under Body and Side Body Assembly Line Layout

Automotive Under Body and Side Body Assembly Line Layout

Automotive Door Assembly Line Project (Hemming)

  • Hybrid hemming system is used – hemming press and robot roller hemming
  • 4 Vehicle model doors are hemmed and assembled
Automotive Door Assembly Line Layout (Hemming)

Automotive Door Assembly Line – Hybrid Hemming System Layout

Automotive Body-In-White Main Assembly

  • Focused on assembly of 1 Vehicle model using slide gate buck and an under shuttle for transfer
  • Cycle time of 1800 seconds
Automotive Body-In-White Main Assembly System

Sub-frame and structural crossmember assembly

As a chassis component assembly and structural assembly provider we understand that preventing localized stress concentration is a key to reliable chassis quality. We have applied our knowledge and experience of precision tooling design and manufacturing accumulated over decades to our robotic chassis component assembly and structural crossmember assemble lines. Our chassis assembly lines consist of in-house designed jigs and fixtures to accurately position chassis components for welding. Our tooling design and manufacturing capabilities also minimize the issue of factory space constraints for chassis assembly lines. Our solid background as a fixture and tooling manufacturer for robotic assembly systems is one of the reasons why our clients come to us for robotic chassis assembly line solutions. Our modularized assembly systems ensure quick return on your assembly line investment by making the line as versatile as the clients’ needs.

Tooling Design and Manufacturing Capability for Body in White and Chassis

 

Body-In-White and Chassis Tooling Project Overview pdf-icon

Chassis Component Assembly Project Images

  1. Coupled Torsion Beam Axle Assembly Line (CTBA): CTBA is widely used as a chassis underbody package because of its light weight and compact size.
Coupled Torsion Beam Axle Welding Line Layout

Coupled Torsion Beam Axle Welding Line Layout

Assembled Coupled Torsion Beam Axle

Assembled Coupled Torsion Beam Axle

Couple Torsion Beam Axle Assembly Line

Couple Torsion Beam Axle Assembly Line

2. Front Crossmember Assembly Line

Front Crossmember Assembly Line Layout

Front Crossmember Assembly Line Layout

Front Crossmember Assembly

Front Crossmember Assembly

3. Rear Member Assembly Line Layout

Rear Member Assembly Line Layout
Rear Member Assembly

Rear Member Assembly

Copyright © 2018 LPR Global. All Rights Reserved. Automotive Body-In-White & Chassis Assembly System