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轿车车身工艺制造技术计划完成时间：2009-6-15第一篇轿车车身制造焊接篇第二篇轿车车身制造尺寸篇第三篇轿车车身制造工业工程篇第一篇轿车车身制造焊接篇开篇第一章电阻工艺第一节点焊·······································一、点焊的特点································二、点焊的应用范围·····························三、点焊的要求································四、点焊质量的一般要求························五、点焊质量检查······························六、点焊的工艺参数····························七、电极要求··································第二节凸焊·······································一、凸焊的特点·································二、凸焊的应用范围·····························三、凸焊的要求································四、凸焊质量的一般要求························五、凸焊质量检查······························六、凸焊的工艺参数····························第二章电弧焊工艺··························第一节、电弧焊的特点······························第二节、电弧焊的应有范围··························第三节、电弧焊接技术······························第三章钎焊工艺································第一节、钎焊的特点·································第二节、钎焊的应用范围·····························第三节、钎焊参数···································第四章激光焊工艺······························第一节、激光焊的特点································第二节、激光焊的应用范围····························第三节、激光焊参数··································第五章焊接防错工艺····························第一节、焊点记数器··································第二篇轿车车身制造尺寸篇·············开篇：车身尺寸的重要性阐述···············第一章车身尺寸评价································第一节IQG评价·································第二节车身符合率评价···························第三节功能尺寸评价·····························第二章车身零件定位································第一节焊接夹具概述······························第二节焊接夹具的作用和分类······················一、夹具的分类·································二、夹具的作用·································第三节工件在焊接夹具中的定位····················一、自由度和六点定位原理·······················二、工件的定位································三、焊接夹具的过定位和欠定位··················四、焊接夹具定位方案设计方法···················第四节工件在焊接夹具中的夹紧····················一、夹紧力的方向·······························二、夹紧力的作用点·····························三、夹紧力的大小·······························四、夹紧件的功用和要求·························五、车身焊接夹具常用的夹紧方式·················六、夹紧机构的设计·····························第五节焊接夹具控制方式·························一、焊接夹具控制方式的分类·····················二、焊接夹具气动技术应用·······················三、电气控制焊接夹具的应用·····················第六节焊接夹具设计与制作·······················一、焊接夹具设计流程··························二、焊接夹具设计规范··························三、焊接夹具数模模拟··························四、其它······································第七节焊接夹具改造调整控制流程··················第八节焊接夹具保养的作用和方法··················第九节焊接夹具点检······························第十节焊接夹具维修·······························第十一节压合模、检具概述························第三章车身测量································第一节焊接夹具验证工作的目的····················第二节焊接夹具的检测方法························第三节焊接夹具的测量与验证方法··················第四章车身误差产生的原因·························第一节焊接夹具误差····························第二节工件误差································第三节装配误差································第四节其它误差································第五节焊接夹具定位误差计算公式················第五章车身测量数据分析和控制···········第六章车身尺寸防错·························第一节重复定位法防错·······················第二节干扰法防错····························第三节工序法防错····························第四节提示法防错····························第三篇轿车车身制造工业工程篇开篇提高过程质量，提高效率，降低成本第一章第二章第三章第四章第五章第二篇轿车车身制造尺寸篇开篇：车身尺寸的重要性阐述第一章车身尺寸评价第二章车身零件定位第一节焊接夹具概述从广义上来看，在工艺过程中的任何工序，用来快速、方便、安全、可靠的定位安装工件的装置，都可以称为夹具。轿车车身焊接加工过程中，用来固定被加工对象，使被加工对象在加工过程中有正确的位置，以接受施工或检测的装置，称为焊接夹具。在任何加工前必须将工件定位、夹紧。焊接夹具通常由定位元件（确定工件的加工尺寸）、夹紧元件、引导元件（装件引导元件和加工引导元件等）、连接元件（角座、规制板和连接块等）和焊接夹具本体（夹具基面）等组成。汽车的车身焊接已经普偏采用夹具进行定位和夹紧，同时让焊接夹具具有自动化、柔性化，自动化可以使被加工对象提高加工精度和保证产品的一致性并能够大幅度的提高生产效率和降低员工的劳动强度。柔性化可以实现一条生产线的夹具可以生产加工几中或多种规格的产品，提高了设备的利用率和降低了生产成本。这章我们主要讲解焊接夹具。第二节夹具的作用和分类一、夹具的分类（一）夹具按照应用的范围分类1、焊接夹具这类夹具主要任务是按照产品图纸和工艺指导书的要求，把焊件中的各零件或分总成的相互位置能准确的装配并采用焊接方法进行固定，即所谓的焊接夹具2、装配夹具这类夹具主要任务是按照产品图纸和工艺指导书的要求，把需装配在一起的各个零件或分总成的相互位置能准确的装配并采用螺栓连接经行固定，即所谓的装配夹具3、检验夹具在产品的焊接或装配工作完成后需对产品进行检验的夹具，即为夹具4、机床夹具是被加工零件在机床上加工时，用来装夹工件（和引导刀具）的一种工艺装备。二、夹具按照使用的动力源分类1、手动夹具通过人力来推动夹紧机构对工件进行夹紧的夹具。2、气动夹具利用压缩空气推动气缸工作，气缸推动夹紧机构对工件进行夹紧的夹具。3、电动夹具利用电机推动夹紧机构夹紧工件的夹具。4、电气夹具用电源控制气源，使气缸工作推动夹紧机构夹紧工件的夹具三、焊接焊接夹具的作用在汽车的总成的产品焊接和分总成的产品焊接中，为了保证产品的质量和劳动效率，在装配焊接生产过程中采用了夹具，它的主要作用如下：1、保证产品质量在装配过程中使被装配的零件或分总成件进入相互确定的位置，在焊接时控制焊接变形，最后达到焊接结构的尺寸要求，在装配定位焊时如果不用焊接夹具，用人工划线来装配焊接零件是很难保证产品尺寸的一致性的，还有工件在自由状态下焊接，由于焊接的热作用，焊接后工件一般都会产生变形。当装配焊接超出了产品设计图纸的要求时，将会影响到后面总成工序或产品使用性能，造成产品降级和报废。用夹具进行装配焊接，可以精确的对零件经行定位和牢固的夹紧，不仅可用保证装配零件的相对位置，而且在焊接过程中使零件的变形得到一定的限制。通常在焊接夹具上装配焊接可使结构达到IT10~IT11级精度。所以在焊接结构的生产中广泛采用夹具来保证和提高产品质量。2、提高劳动生产效率在装配焊接时，如果不采用焊接夹具，用手工来摆好工件的位置是十分的困难的，而在焊接过程中始终要扶住工件是十分疲劳的，如果采用焊接夹具则大大的简化到了装配工作，由夹具来保证零件的定位和夹紧，焊接时也不用扶住工件，降低了劳动强度，方便了操作，同时也减少了很多的辅助工作（如划线、对准、测量等）的时间，不同的焊接件，所用的辅助时间也不用。但是，正确的使用夹具一般都可以减少70%以上的辅助时间，大大的提高了生产效率。尤其是随着高效率的焊接方法的采用，必须相应的采用机械化和自动化程度较高的夹具来相匹配来获得更高的汽车生产效率。3、降低劳动强度凡是处于水平位置焊接时，焊接是最容易实施，在悬挂式电焊机经行电焊时，焊点成型好，工艺缺陷（半点、烧穿、毛刺等）少，对应处在竖直和倾斜位置进行焊接时，因操作不便，质量难以保证，而且焊接速度也比水平位置焊接低2倍，如果使用翻转夹具和旋转夹具就可以改变竖直的和倾斜的焊点位置，可以使焊钳处于水平位置经行操作，方便焊接，降低了焊接缺陷，保证了产品质量，提高了生产效率，同时也降低了劳动强度。第三节工件在焊接夹具中的定位一、自由度和六点定位原理任何工件（刚体）空间都有六个自由度，也就是工件在空间可X向、Y向、Z向、X轴旋转、Y轴旋转和Z轴旋转的六个自由度如（图2-1）（内容需增加）工件（刚体）在空间的定位也就是用夹具的定位元件对工件的六个自由度进行控制，可用合理的六个点来进行控制就称为六点定位原理,如