长安PSA焊装过程质量控制CAPSA-Welding-Process-Quality-Control

1A4rb_standard–20100701–donotdeletethistextobject!长安PSA焊装过程质量控制CAPSAWeldingProcessQualityControl梁平LiangPing焊装项目主管WeldingProjectSupervisor研发中心车辆制造工艺部焊装R&D-VMED-Welding2A4rb_standard–20100701–donotdeletethistextobject!1.长安PSA焊装过程质量控制CAPSAWeldingProcessQualityControl离线抽检Offlinespot-check破坏性检查Destructiveinspection在线检测Onlinecheck不接受缺陷、不制造缺陷、不传递缺陷Notacceptdefect,Notmakedefect,Notpassdefect质量目标Qualitytarget23A4rb_standard–20100701–donotdeletethistextobject!2.在线检测Onlinecheck2.1质量门Qualitygate(PQG)2.2质量门检查内容PQGcheckitems2.3质量门图片展示PQGPictures2.4车身精度在线检测Framingbodygeometryonlinemeasuring2.5白车身间隙面差在线检测BIWgap&flushnessonlinemeasuring2.6在线检具测量Onlinecheckingfixture34A4rb_standard–20100701–donotdeletethistextobject!2.在线检测Onlinecheck2.1质量门Qualitygate(PQG)：为控制本工序质量问题流出而设定的质量检查工位Itisastationtocontrolqualityforcurrentprocessareaandpreventdefectfrompassingtonextprocessarea45A4rb_standard–20100701–donotdeletethistextobject!2.2质量门检查内容PQGcheckitems：一、二级外观面监控：100%检查Aspectmonitoring:100%check焊点监控：外观焊点100%检查，不允许外观严重扭曲变形、毛刺、焊渣、穿孔等焊接缺陷出现Weldingspotmonitoring:100%checkaspectweldingspots,notallowdeformation,burrs,weldingspatter,perforationdefects嵌入件监控：100%检查嵌入件有无漏装并进行画笔确认Insertpartmonitoring:100%checkinsertpartexistornotwithmarkingconfirmation.螺柱/螺母/螺钉/T型钉监控：使用胶锤敲击做100%强度检查，同时目视数量是否符合工艺文件要求Stud/nut/screw/T-studmonitoring:100%inspectionbyrubberhammer,checkthequantityalsoMIG/MAG焊监控：100%目视确认焊缝位置、外观是否符合标准要求MIG/MAGweldingmonitoring:100%checkthepositonandaspectconformityofweldingseam激光焊监控：100%检查焊缝质量及位置Laserweldingmonitoring:100%checklaserweldingseamqualityandposition52.在线检测Onlinecheck6A4rb_standard–20100701–donotdeletethistextobject!2.2质量门检查内容PQGcheckitems：激光钎焊监控：按照激光钎焊外观标准要求全检外观Laserbrazingmonitoring:100%checktheweldingseamaspectaccordingtorelatedstandard包边监控：对包边外观进行全检Hemmingmonitoring:100%checkhemmingaspect铆接监控：对外观进行全检，同时需要手工进行确认铆接是否牢固（手推铆接零件无松动）Clinchingmonitoring:100%checkaspectandclinchingstrengthbyhand(pushthepartandnotmove)拧紧扭矩监控：除翼子板外，使用扭矩扳手定扭，翼子板按照10%比例使用扭矩扳手定扭。此外亦需要监控螺栓数量及位置是否正确。Torquemonitoring:Exceptfenders,checkthetorquebytorquewrench,10%checkthetorqueforfenders.Besides,checkthequantityandpositionofscrew.其他动态监控项目：如临时增加需做特别监控的内容Otherdynamicmonitoringitems:suchastemporarymonitoringitemwithspecificpurpose62.在线检测Onlinecheck7A4rb_standard–20100701–donotdeletethistextobject!2.3质量门图片展示PQGPictures：门总成质量门DoorPQG侧围质量门BodysidePQG顶盖激光钎焊质量检查Rooflaserbrazingqualityinspection激光焊质量检查Laserweldingqualityinspection后地板质量门RearunitPQG72.在线检测Onlinecheck8A4rb_standard–20100701–donotdeletethistextobject!2.4车身精度在线检测Framingbodygeometryonlinemeasuring动态测量重复精度Dynamicmeasuringrepeatability：0.2mm,标准差Standarddeviationσ:0.0571mm态测量重复精度：•0.2mm,6sigma:0.3429mm测量报告Measuringreport机器人式柔性在线测量系统Robotflexibleonlinemeasuringsystem固定式在线测量系统Fixedonlinemeasuringsystem8测量位置超过75个Morethan75measuringpoints2.在线检测Onlinecheck9A4rb_standard–20100701–donotdeletethistextobject!2.5白车身间隙面差在线检测BIWgap&flushnessonlinemeasuring动态测量重复精度Dynamicmeasuringrepeatability：间隙Gap：0.2mm,标准差Standarddeviation:σ0.0571mm面差Flushness：0.2mm,标准差Standarddeviation:σ0.0571mm测量范围Measuringrange间隙Gap：1~20mm面差Flushness：-15~+15mm9固定式间隙面差在线测量系统Fixedgap&flushnessonlinemeasuringsystem测量位置40个左右40measuringpoints2.在线检测Onlinecheck10A4rb_standard–20100701–donotdeletethistextobject!2.5白车身间隙面差在线检测BIWgap&flushnessonlinemeasuring特点Features：节省人力Savemanpower更高的测量精度、测量重复性，有效避免手工测量误差Betteraccuracy,betterrepeatability,avoidmanualmistakes可以测量一些手工无法测量的数据，如左右侧的相对差值Addsomespecificchecksnotfeasiblebyhand(Right/leftsideconsistency)可以100%测量监控所有间隙面差控制点100%onlinemeasuringallgap&flushnesscontrolpoints白车身可以在移动中测量，不需要停下车辆Measurementintheflow,notnecessarytostopthevehicle平均一次完整的测量时间（测量+处理测量值+显示结果）：5秒钟Meancompletemeasurementtime(Grabbing+processingofmeasurements+displayofresults):5seconds10移动中测量Measurementintheflow测量分析Measuringanalysis测量报告Measuringreport2.在线检测Onlinecheck11A4rb_standard–20100701–donotdeletethistextobject!2.6在线检具测量Onlinecheckingfixture112.在线检测Onlinecheck12A4rb_standard–20100701–donotdeletethistextobject!3.1非破坏性质量检查Non-destructivequalityinspection3.2三坐标&PCF测量零件PartsmeasuredbyCMMandPCF3.3三坐标测量CMM3.4PCF（开闭件总成检具）测量PCF(checkingfixtureforclosureassemblyparts)measuring3.5白车身全尺寸Podium离线测量BIWoveralldimensionPodiumofflinemeasuring3.离线抽检Offlinespotcheck1213A4rb_standard–20100701–donotdeletethistextobject!3.1非破坏性质量检查Non-destructivequalityinspection分总成每天抽检3~4台车，车身总成每天抽检5台车3~4subassemblies&5framingbodiesperday3.离线抽检Offlinespotcheck非破坏性检查支架Non-destructivecheckingfixture非破坏性焊点质量检查Non-destructivespotweldingqualitycheck13冲铆连接质量检查Clinchingqualityinspection14A4rb_standard–20100701–donotdeletethistextobject!3.1非破坏性质量检查Non-destructivequalityinspection螺柱/螺母/螺钉/T型钉焊接质量检测Stud/nut/screw/T-studweldingqualityinspection涂胶直径、长度及位置监控Gluediameter,lengthandpositioncheck143.离线抽检Offlinespotcheck15A4rb_standard–20100701–donotdeletethistextobject!3.1非破坏性质量检查Non-destructivequalityinspection焊点质量超声波检测Weldingqualityultra-sonicinspection：按非破坏性检查频率对不可敲焊点进行检查；另外每月对全车所有焊点再进行一次全检。Accordingtonon-destructiveinspectionfrequency,inspectweldingspotswhichare