Manufacturer of welding models for new energy vehicles

New Energy Vehicle White Body Welding Production Line Model Production Process (1:18 Scale)

Project Objectives

Accurately replicate the all-aluminium body welding production line, dynamically presenting laser welding, self-piercing riveting, and structural adhesive processes, with a reproduction accuracy of ≥90%.

I. Precision Casting of Industrial Skeleton

1. Steel Frame Main Structure

Main Beam Frame: 2mm cold-rolled steel plates are laser-cut, formed by a bending machine, and assembled using mortise-and-tenon joints, with critical joints reinforced by TIG welding

Ground Track System: Aluminum alloy base channels embedded with magnetic power supply copper plates, with AGV cart chassis integrated with miniature induction coils

Equipment Base: Solid aluminium ingots are machined into honeycomb lightweight structures using a five-axis machining centre, then sandblasted to create an industrial matte texture

2. Dynamic Mechanism Pre-installation

Robot base equipped with horizontal calibration bolt assemblies (accuracy ±0.05°)

Conveyor rollers incorporate miniature reduction motors, with brass rollers covered in anti-slip silicone rubber, operating noise ≤28 decibels

II. Core Equipment Refinement

1. Welding Robot Unit

Precision-engineered robotic arm: ① Anodised matte grey aluminium alloy joint cavities ② 0.3mm fibre optic cables routed internally within stainless steel telescopic arms ③ Welding gun head integrated with dual-colour LED module: orange-red light effect for the molten pool overlaid with yellow dots for weld spatter

Intelligent Fixture Restoration: → 3D scanning reconstructs real vehicle door surface data → Carbon fibre sheets are thermoformed, with micro-pressure sensors embedded at clamping points → Electromagnetic locking mechanism triggers a crisp ‘click’ sound effect

2. Process Effect Presentation

Laser spark dynamics: 0.1mm glass fibre threads dipped in fluorescent epoxy resin, curing to produce a starfire spatter effect

Invisible structural adhesive simulation: UV adhesive mixed with fluorescent powder injected into a dispensing gun, extruding a 0.2mm diameter adhesive line, emitting a continuous green light under UV light

III. Industrial scene artistic reinterpretation

1. Professional Coating System

Equipment Industrial Aesthetics:

Robot body coated with dark grey primer, bright orange safety markings applied via screen printing

Body zinc-coated steel panels coated with metallic primer, weld seams dry-brushed with lead grey to simulate thermal deformation

Use Trace Implantation: → Rubber particles are sprayed onto the surface of the tooling pedal, and the sole pattern is laser-engraved in reverse. → The welding gun electrode tip is coated with an iron powder adhesive mixture to recreate carbon deposits and coking layers.

2. Dynamic Scene Construction

Safety Protection System: Acrylic barriers are chemically etched with honeycomb reinforcements, and the emergency stop button triggers flashing red lights along the entire line.

Human-machine interaction details: HMI control screen with miniaturised printing of PLC interface, physical buttons linked to equipment start/stop

4. Millimetre-level quality mastery

1. Dynamic precision verification

Robotic arm repeatability test: Dial gauge measures trajectory deviation ≤0.3mm

Four-door two-cover assembly gap control: Feeler gauge inspection tolerance ±0.15mm

2. Process replication test

Riveting durability test: After 200 consecutive presses, the rivet coating shows no peeling or deformation

Adhesive line integrity inspection: UV lamp scans the body, fluorescent adhesive line breakage points ≤ 1 per metre

AGV tracking accuracy: Laser positioning calibration path deviation ≤ 0.4 mm

3. Creating a sense of flow on the production line

Magnetic suction-mounted tool rack with proportional socket wrenches

Fire extinguisher cabinet with a micro-water hose that can be extended by 50 mm

Epoxy resin mixed with engine oil for marking oil stains on the floor