Automobile Manufacturing Process and Future Trends
Automotive Manufacturing Process
The automotive industry encompasses the design, development, manufacture, assembly, marketing, and sale of automobiles. The construction of a vehicle involves several stages:
Drawing
Steel, delivered in rolls, cut sheets, or plates, is shaped to form the vehicle’s body: lateral parts, floors, wings, doors, etc.
- Developed Coil: Galvanized steel coils of different sizes and thicknesses are stored.
- Punching Plates: The ribbon is cut into metal plates for drawing.
- Drawing on the Plate: Each plate undergoes initial deformation in a double-acting press, followed by reset operations in single presses or transfer by suction.
Welding
The metal pieces are welded to form the “white box,” ready for painting. This stage is highly automated.
- Assembly of the Frame: Welding robots join the floors, front, and rear to the front unit, forming the base.
- Assembly of the Sides of the Box: Robots attach the sides of the box. Complementary subsets and surfaces are made by workers.
- Geometric Conformation: Geometric shaping holds parts in position during initial welding.
- Assembly of the Box: The frame box is welded and completed with the roof, fins, and closures (doors, hood, trunk lid) before inspection. Blank boxes are transported to the paint shop.
Painting
The blank box receives an anti-corrosive coating, a primer coat, and a lacquer layer for the final color.
- Classification of the Box: White boxes are sorted by color groups.
- Treatment of Banks: Boxes are cleaned, degreased, and dipped in baths for zinc phosphate coating, providing primary protection and better adhesion for subsequent layers. They are then rinsed and dried in an oven.
- Fitting Sealing Cords: Operators apply caulk to sheet metal joints to prevent water, odors, and dust from entering.
- Antigravilla: Anti-gravel is deposited by robots and operators to improve sealing and protect lower parts. Excess grain is manually removed after oven drying.
- Application of Primer: An automatic system deposits primer electrostatically. Primers come in three colors, depending on the final vehicle color.
- Application of Lacquer with Gun: The same electrostatic procedure is used for the base and varnish. Operators provide finishes. The body is painted and cleaned in the oven. Colored bases contribute to the final color and appearance.
- Polishing, Cleaning, and Control of Appearance: The box undergoes several oven steps, cleanings, and controls to detect and correct imperfections. A final visual check ensures a smooth paint finish.
Body Assembly
After removing closures, the painted box receives coverings, upholstery, circuits, electrical and mechanical elements, and glassware.
- Market Banks: The painted body is marked with a launch number. A vehicle allowance tile (FAV) indicates the parts to assemble.
- Removing the Doors: Doors are removed and prepared on a parallel line. Assembly begins with the electric beams.
- Control Panel Placement: The control panel, assembled on a parallel line, is attached with robotic assistance.
- Windshield Placement: Main glass areas are placed by direct bonding with robotic assistance.
- Final Assembly: Mechanical parts from specialized centers are integrated.
- Coating of the Box: The box is equipped with wheels, steering wheel, fenders, seats, etc.
- Installation of Doors: Prepared doors are integrated into the box at the end of the assembly line.
Control
Each vehicle undergoes a complete test suite to ensure safety and performance.
- Issue: Checked vehicles are loaded onto trailers or rail cars for distribution.
New Technologies
New automotive technologies benefit both the user and the environment. These include:
LPG: Liquefied Petroleum Gas (LPG), composed of propane and butane, offers low pollution and cost. Some regions restrict its use to taxis.
Direct Injection: Gasoline direct injection allows lean air/fuel mixtures for lower consumption. The engine adapts to driving conditions and minimizes particle accumulation.
Biodiesel: Biodiesel, derived from organic plants, emits less carbon monoxide, hydrocarbons, and particulate matter. It is biodegradable and can be mixed with diesel, though it currently has a higher cost.
Hybrid: A consolidated alternative combining a gasoline engine and an electric motor for reduced fuel consumption.
Natural Gas: Vehicles can run on gasoline or natural gas, offering extended range due to natural gas’s higher energy efficiency.
Fuel Cell Liquid Hydrogen: A promising alternative using electrochemical oxidation to generate electricity, eliminating battery duration issues.
Methanol Fuel Cell: A prototype electric motor powered by a fuel cell that produces hydrogen and electricity from methanol.
Trends
Early 21st-century cars face challenges: increasing occupant safety and reducing accident victims, and improving efficiency to reduce resource consumption and air pollution.
Safety mechanisms like ABS and airbags have been developed. Oil shortages and rising fuel prices have spurred the development of fuel-efficient technologies and alternative engines. Renewable fuels and hydrogen are being explored to reduce oil dependence.
Pollution
Burning fossil fuels is a major source of air pollutants. Vehicles emit pollutants that harm human, animal, and plant health and affect the atmosphere. Carbon dioxide and hydrocarbon emissions contribute to global warming. Due to oil depletion concerns, automotive companies are seeking alternative fuel solutions: biodiesel, liquid hydrogen, methanol, etc.