长安PSA焊装过程质量控制CAPSAWeldingProcessQualityControl

1过程质量控制WeldingProcessQuality

Control21.

焊装过程质量控制

CAPSA

Welding

Process

Quality

Control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,Notpass

defect质量目标Quality

target232.

在线检测Online

check3质量门Quality

gate(PQG)质量门检查内容PQG

check

items质量门图片展示PQG

Pictures车身精度在线检测

Framing

body

geometry

online

measuring白车身间隙面差在线检测

BIW

gap

&

flushness

online

measuring在线检具测量Online

checking

fixture42.

在线检测Online

check2.1

质量门Quality

gate(PQG)：为控制本工序质量问题流出而设定的质量检查工位Itisastationtocontrolqualityforcurrentprocessareaandpreventdefectfrom

passingtonextprocess

area452.2

质量门检查内容PQG

check

items：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,perforation

defects嵌入件监控：100%检查嵌入件有无漏装并进行画笔确认Insertpartmonitoring:100%checkinsertpartexistornotwithmarking

confirmation.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,checkthequantity

alsoMIG/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%checkthepositonandaspectconformityofwelding

seam激光焊监控：100%检查焊缝质量及位置Laserweldingmonitoring:100%checklaserweldingseamqualityand

position52.

在线检测Online

check2.2

质量门检查内容PQG

check

items：激光钎焊监控：按照激光钎焊外观标准要求全检外观Laserbrazingmonitoring:100%checktheweldingseamaspectaccordingtorelated

standard包边监控：对包边外观进行全检Hemmingmonitoring:100%checkhemming

aspect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(pushthepartandnot

move)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,checkthequantityandpositionof

screw.其他动态监控项目：如临时增加需做特别监控的内容6Otherdynamicmonitoringitems:suchastemporarymonitoringitemwithspecific

purpose62.

在线检测Online

check72.3质量门图片展示PQG

Pictures：门总成质量门Door

PQG侧围质量门Bodyside

PQG顶盖激光钎焊质量检查Rooflaserbrazingquality

inspection激光焊质量检查Laserweldingquality

inspection后地板质量门Rearunit

PQG72.

在线检测Online

check82.4

车身精度在线检测

Framing

body

geometry

online

measuring动态测量重复精度Dynamic

measuringrepeatability：<0.2mm,

标准差Standard

deviation

σ:<0.0571mm测量报告Measuring

report机器人式柔性在线测量系统Robotflexibleonlinemeasuring

system固定式在线测量系统Fixedonlinemeasuring

system8测量位置超过75个Morethan75measuring

points2.

在线检测Online

check92.5

白车身间隙面差在线检测

BIW

gap

&

flushness

online

measuring动态测量重复精度Dynamic

measuringrepeatability

：间隙Gap：<0.2mm,

标准差Standard

deviation:σ

<

0.0571mm面差Flushness：

<0.2mm,

标准差Standard

deviation:

σ

<0.0571mm测量范围Measuring

range间隙Gap： 1~20mm面差Flushness：

-15~+15mm9固定式间隙面差在线测量系统Fixedgap&flushnessonlinemeasuring

system测量位置40个左右40measuring

points2.

在线检测Online

check102.5

白车身间隙面差在线检测BIW

gap

&flushness

online

measuring特点Features：节省人力Se

manpower更高的测量精度、测量重复性，有效避免手工测量误差Betteraccuracy,betterrepeatability,oidmanual

mistakes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/leftside

consistency)可以100%测量监控所有间隙面差控制点100%onlinemeasuringallgap&flushnesscontrol

points白车身可以在某著名企业中测量，不需要停下车辆Measurementintheflow,notnecessarytostopthe

vehicle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Meanpletemeasurementtime(Grabbing+processingof

measurements+displayofresults):5

seconds10某著名企业中测量Measurement

in

the

flow测量分析Measuring

analysis测量报告Measuring

report2.

在线检测Online

check112.6

在线检具测量Online

checking

fixture2.

在线检测Online

check1112非破坏性质量检查Non-destructive

quality

inspection三坐标&PCF测量零件

Partsmeasured

by

CMM

and

PCF三坐标测量CMMPCF（开闭件总成检具

）测量

PCF(checking

fixture

for

closure

assembly

parts)

measuring白车身全尺寸Podium离线测量

BIW

overall

dimension

Podium

offline

measuring123.

离线抽检Offline

spot

check133.1

非破坏性质量检查Non-destructive

quality

inspection分总成每天抽检3~4台车，车身总成每天抽检5台车

3~4

subassemblies

&

5

framing

bodies

per

day3.

离线抽检Offline

spot

check非破坏性检查支架Non-destructive

checking

fixture非破坏性焊点质量检查Non-destructivespotweldingquality

check13冲铆连接质量检查Clinchingquality

inspection143.1

非破坏性质量检查Non-destructive

quality

inspection螺柱/螺母/螺钉/T型钉焊接质量检测

Stud/nut/screw/T-stud

welding

qualityinspection涂胶直径、长度及位置监控

Glue

diameter,

length

and

position

check143.

离线抽检Offline

spot

check153.1

非破坏性质量检查Non-destructive

quality

inspection焊点质量超声波检测Welding

quality

ultra-sonic

inspection：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,inspectweldingspotswhichareunabletobechecked

bymanualtool;besides,fullinspectionofallBIWweldingspotsper

month15焊点检查Welding

spotsinspection：利用发射一个极短的高频超音波透过焊点计算能量的飞行距离及衰减情况来评估焊接品质Launchaveryshorthighfrequencyultrasonictopenetrateweldingspotandthencalculatetheflightdistanceandattenuationofenergysoastoevaluateweld

quality3.

离线抽检Offline

spot

check16CMM侧围总成Bodyside后侧围内板Rearbodyside

inner激光在线测量Laser

onlinemeasuring机盖Hood尾门/行Tailgate/Trunk间隙面差在线测量Gap&flushnessonline

measuring前侧围内板Frontbodyside

innerCMM16CMM车身Framing

bodyCMM地板总成UnderbodyCMM仪表板DashboardCMM前地板Front

unitCMM后地板Rear

unitCMM前纵梁Frontside

membersCMM前门内板Frontdoor

innerCMM后门内板Reardoor

innerCMM前门总成Front

doorPCF后门总成Rear

doorPCFPCF翼子板FendersCMMPCF调整线MFLGauge3.2

三坐标&PCF测量零件

Partsmeasured

by

CMM

and

PCF3.

离线抽检Offline

spot

check173.2

三坐标&PCF测量零件

Partsmeasured

by

CMM

and

PCFCMMCMMCMMCMMCMMCMMCMMCMMCMMCMMPCFPCFPCFPCF3.

离线抽检Offline

spot

check17CMM18测量点超过5000个，合格率

>

95%Morethan5000measuringpoints,passrate>

95%3.

离线抽检Offline

spot

check183.3

三坐标测量CMMCMM每测4套

4

setsper

week

for

CMM193.4

PCF（开闭件总成检具

）测量

PCF(checking

fixture

for

closureassemblyparts)

measuring：每天抽检1台车

1

set/day门盖几何尺寸测量检具

Doors

&hood

&

trunk

geometry

checking

fixtures测量工具Tools面差测量

Flushness

measuring间隙测量Gap

measuring孔位偏差测量Positionof

holes门总成密封间隙测量Sealinggapof

doors包边厚度测量Hemming

thickness193.

离线抽检Offline

spot

check203.5

白车身全尺寸Podium离线测量

BIW

overall

dimension

Podium

offline

measuring每。监控内容不仅包括EDIXIA

在线监控的内容，还包括总装的部分装配尺寸Onetimeperweek.NotonlyincludeEDIXIAonlinemeasuringpoints,butalsoincludedimensionforsomeassemblyparts

mounting20前大灯与翼子板间隙面差测量Gap&flushnessbetweenheadlampand

fender机罩与前保险杠、翼子板的间隙面差测量Gap&flushnessbetween

frontbumperandhood&

fender尾灯及附属尾灯与侧围、行间隙面差测量Gap&flushnessbetweentaillampsandbodyside&

trunk测量位置超过160个Morethan160measuring

points3.

离线抽检Offline

spot

check门框密封间隙测量Sealinggapof

doors21焊接质量破坏性检查Welding

quality

destructive

inspection涂胶质量破坏性检查Gluing

quality

destructive

inspection激光钎焊焊缝金相分析Laser

brazing

seam

metallurgical

analysis214.破坏性检查Destructive

inspection224.1

焊接质量破坏性检查Welding

quality

destructive

inspection4.破坏性检查Destructive

inspection全车焊点合格率Pass

rate

>

99%22量产前Before

mass

production：试装期间总计破坏性检查约30台车用于监控及改善焊接质量About30BIWsfordestructiveinspection

inordertomonitorandimproveweldingqualitydur