长安PSA焊装过程质量控制CNEN-20150409

长安PSA焊装过程质量控制CAPSAWeldingProcessQualityControl1.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Qualitytarget22.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Itisastationtocontrolqualityforcurrentprocessareaandpreventdefectfrompassingtonextprocessarea32.2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,checkthequantityalsoMIG/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%checklaserweldingseamqualityandposition42.在线检测Onlinecheck2.2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(pushthepart

andnotmove)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%checkthetorque

forfenders.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:suchastemporarymonitoringitemwithspecificpurpose

52.在线检测Onlinecheck2.3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RearunitPQG62.在线检测Onlinecheck2.4车身几何尺寸精度在线检测Framingbodygeometryonlinemeasuring动态测量重复精度Dynamicmeasuringrepeatability：

0.2mm,6sigma:0.3429mm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Fixedonlinemeasuringsystem7测量位置超过80个，计算点超过200个Morethan80measuringpointsand200calculationpoints2.在线检测Onlinecheck2.5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,6sigma:0.3429mm

面差Flushness：

0.2mm,6sigma:0.3429mm测量范围Measuringrange

间隙Gap：1~20mm

面差Flushness：-15~+15mm8固定式间隙面差在线测量系统Fixedgap&flushnessonlinemeasuringsystem测量位置超过35个，计算点超过100个Morethan35measuringpointsand100calculationpoints2.在线检测Onlinecheck2.5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):5seconds9移动中测量Measurementintheflow测量分析Measuringanalysis测量报告Measuringreport2.在线检测Onlinecheck2.5白车身间隙面差在线检测BIWgap&flushnessonlinemeasuring测量绩效Performance10测量可靠性提升Measuringreliabilityimproving间隙面差在线测量一次通过率对标FTTbenchmarkforgap&flushnessonlinemeasuring2.在线检测Onlinecheck2.6在线检具测量Onlinecheckingfixture112.在线检测Onlinecheck3.1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-destructivespotweldingqualitycheck12冲铆连接质量检查Clinchingqualityinspection3.1非破坏性质量检查Non-destructivequalityinspection螺柱/螺母/螺钉/T型钉焊接接检测Stud/nut/screw/T-studweldingqualityinspection涂胶直径、长度及位置监控Gluediameter,lengthandpositioncheck133.离线抽检Offlinespotcheck3.1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,inspectweldingspotswhichareunabletobecheckedbymanualtool;besides,fullinspectionofallBIWweldingspotspermonth14焊点检查Weldingspotsinspection：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Launchaveryshorthighfrequencyultrasonictopenetrateweldingspotandthencalculatetheflightdistanceandattenuationofenergysoastoevaluateweldquality3.离线抽检Offlinespotcheck前纵梁Frontsidemembers前地板Frontunit后地板Rearunit地板总成Underbody仪表板DashboardCMM车身Framingbody侧围总成Bodyside前侧围内板Frontbodysideinner后侧围内板Rearbodysideinner激光在线测量Laseronlinemeasuring调整线MFL机盖Hood尾门/行李箱Tailgate/Trunk前门内板Frontdoorinner前门总成Frontdoor后门内板Reardoorinner后门总成Reardoor翼子板Fenders间隙面差在线测量Gap&flushnessonlinemeasuringCMMCMMCMMCMMCMMCMMCMMCMMCMMCMMPCFPCFPCFCMMPCFGauge3.2三坐标&PCF测量CMMandPCFmeasuringCMM每周各抽测4套4setsperweekforCMM153.离线抽检Offlinespotcheck3.2三坐标&PCF测量CMMandPCFmeasuringCMMCMMCMMCMMCMMCMMCMMCMMCMMCMMPCFPCFPCFPCF163.离线抽检OfflinespotcheckCMM3.3三坐标测量CMM17测量点超过5000个Morethan5000measuringpoints3.离线抽检Offlinespotcheck3.4PCF（开闭件总成检具）测量PCF(checkingfixtureforclosureassemblyparts)measuring：每天抽检1台车1set/day门盖几何尺寸测量检具Doors&hood&trunkgeometrycheckingfixtures测量工具Tools面差测量Flushnessmeasuring间隙测量Gapmeasuring孔位偏差测量Positionofholes门总成密封间隙测量Sealinggapofdoors包边厚度测量Hemmingthickness183.离线抽检Offlinespotcheck3.5白车身全尺寸Podium离线测量BIWoveralldimensionPodiumofflinemeasuring每周一次。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,butalsoinclude

dimensionforsomeassemblypartsmounting19前大灯与翼子板间隙面差测量Gap&flushnessbetweenheadlampandfender机罩与前保险杠、翼子板的间隙面差测量Gap&flushnessbetweenfrontbumperandhood&fender尾灯及附属尾灯与侧围、行李箱的间隙面差测量Gap&flushnessbetweentaillampsandbodyside&trunk测量位置超过160个，计算点超过250个Morethan160measuringpointsand250calculationpoints3.离线抽检Offlinespotcheck门框密封间隙测量Sealinggapofdoors4.1焊接质量破坏性检查Weldingqualitydestructiveinspection4.破坏性检查Destructiveinspection全车焊点合格率Passrate

>99%量产前Beforemassproduction：

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About30BIWsfordestructiveinspectioninordertomonitorandimprove

weldingqualityduringlaunchingphase.量产后Aftermassproduction：产量≤250台车/天:每2个月破检1台车

Volume

≤250Cars/day:1destructiv