Automotive Design Services

Range Rover Velar GT EMA L481: Optimizing Assembly with Automotive Design Services

Jaguar Land Rover (JLR) was looking to cue the assembly process for the Range Rover Velar GT EMA L481 model, concentrating on the production of critical body panels—wheelhouse rear quarter, Body Sides Inner (BSI), Body Sides Inner Reinforcement (BSIR), and Body Sides Outer (BSO). Ultimately, the prime goal was to optimize design and manufacturing processes in terms of efficiency, accuracy, and cycle time reduction across high-volume vehicle programs led by designer automotive teams.

In this project, the three main zones were classified as Z09, Z11, and Z12, each treating different parts of the body. BSI was produced in Z09, BSIR in Z11, and BSO in Z12.

The major challenge was to maximize precision in the processes changed for different variant parts and to ensure an efficient assembly process that included adhesive application, spot welding, Arplas welding, and stud welding.

The team encountered many challenges, particularly with Arplas welding and the loading process, which was still being done manually. Z12 really needed a smooth production flow that could accommodate component variants; for instance, the RH BSO had two component variants (with and without a charge port), while the LH BSO had one variant (with a charge port).

Process optimization: In Z09, the manual feeding of parts took place via LCAs (turntables), whereas the rest of the parts manipulation was performed by the robots kept within the defined area. The GEO area for a specific model was aligned to position the parts for continuous flow through a common area toward the EMS.

In Z11, the layout constraints of RH and LH assemblies were cleared by optimizing weld stations and combining multiple stations into one, thus significantly reducing cycle time.

In Z12, the operational task managed to cross variant complexities through the unbroken flow of production. The panels were de-racked from containers and handled through LCAs, where robots made the assembly work in defined zones.

The replacement of the tool changer with a new robot increased efficiency and decreased the cycle time for welding at Arplas.

Despite the complexities, the Range Rover Velar GT EMA L481 project was commissioned smoothly without any assembly issues. Through process optimizations and innovative solutions, the team managed to reduce cycle time and improve efficiency and production flow. This finally resulted in a highly efficient assembly system with considerable customer appreciation for its seamless execution.

Valmet Automotive S194: Enhancing Efficiency with Automotive Design Services

Valmet Automotive, one of the leading players in automotive manufacturing, started the S194 project with the aim of improving mechanical design and simulations of car panels. The areas of focus were Framing, C-D Pillar, Body Sides, and Body Side Subs, which made use of high-end welding technologies and very detailed engineering. The main objectives of the project were structural integrity, weight optimization, and durability, with the compliance of all applicable standards. Major hurdles were aligning properly during framing for maximum safety and aerodynamics, balancing welding techniques to ensure strength and reduction of weight, and integration of conflicting levels of panels for high production volume.

Framing car panel spot welding and CMT welding offered structural strength with little distortion. High-efficiency simulation tools have been used for optimizing the panel before production. C-D Pillar Car Panels needed CMT welding and riveting, providing extra strength and durability. The simulation models predicted stress distribution and optimized for joining concerning safety and manufacturability. On the Body Side Car Panel, CMT welding and riveting provided strength and flexibility. Precise robotic welding systems reduced defects and improved efficiency. The body side subs car panel was key in supporting the vehicle structure. It was decided to use MIG welding for its deep penetration and high-strength joints for crashworthiness and durability.

S194 accomplished the objective of improving durability through welding process optimization, enhancing production efficiency through material wastage reduction, and enabling high-precision assembly for superior vehicle functioning; yet this was accomplished with cost-effective production methods that do not compromise on quality. Using advanced mechanical design and simulation with Valmet Automotive now stands as the benchmark in the industry with the demonstration of precision engineering power.

This project displays how advancements in design, simulation, and welding techniques transform vehicle manufacturing. As technology moves forward, Valmet Automotive stays committed to engineering excellence in which each vehicle is built to a top standard of strength, safety, and performance.