A total of about 400 robots turn the body shop into an impressive sight. However, despite the high degree of automation, human workers are essential here, in particular for quality controls, systems operation and several manual tasks. In the body shop we rely on harmonic interaction between expert human labor and state-of-the-art technology.
The production of the overlapping aluminum bonnet of the
Line production of the
In the line production area, the car bodies are taken through several measurement stations for quality assessment. Here, robots equipped with cameras measure the dimensions of the body to the smallest detail. The system reports any deviations directly to the system operator.
The complete underbody is transferred to the body assembly, where the body-in-white is put together. This includes the fitting of the interior and exterior quarter panels and the installation of the roof.
The first step here is the attachment of the interior quarter panels to the underbody by robots. However, the panels are not welded into place at this point, they are only mounted. Similarly, the roof bow, which is used to connect the interior quarter panels at the top, is loosely installed. In the next stage of the process, a so-called framer clamps over the complete body and precisely aligns the vehicle geometry. It is in this tensioned state that the interior quarter panels are welded to the body.
Once the interior quarter panels are installed, the exterior quarter panels are mounted onto the body in the same way and welded on by a second framer in their exact geometric positions. In this way, we can set the dimensions of the vehicle body and complete the base frame of the vehicle.
Roof laser station
Two different basic roof versions are delivered to the factory for the
In the line production area, the roof is welded to the body in a laser welding cabin. Here, a robot initially places the roof loosely onto the body. Then, a roof bell equipped with suction cups brings the roof into the correct position and puts it under tension. Robots then weld the roof to the side panels. To guarantee a smooth surface, the laser seams on the body are afterwards smoothed over with grinding disks.
This is the last station in the body assembly area. Here, the mounting for the pneumatic spring and the torque support for turbo engines are welded into place. To optimize workplace ergonomics for our colleagues, the car body is rotated by 90 degrees to avoid overhead work.
In the third section of the process, doors, bonnet and boot lid are added to the body-in-white. The overlapping bonnet of the
The fitting of the attachments takes place at two key stations: the best fit assembly and the attachments table. In the best fit assembly the first step is the automatic fitting of the front and rear doors and bonnet into place. The best fit process makes sure that each component is fitted in its ideal position. This position may vary from body to body by a few micrometers. First of all, the robots successively attach the rear doors, followed by the front doors and finally the bonnet.
Optimal fitting of the attachments therefore begins at the rear then moves on to the front. Prior to each step, camera systems precisely measure both the body and the part to be fitted.
At the attachments table, boot lid and fenders are fitted semi-automatically by workers. Now the body is complete.