Ergonomic Simulation and Optimization During the Body Assembly

Abstract

The ergonomic simulation is significantly important to reduce the cost and shorten the product development cycle in the vehicle development. In this paper, the technological design and simulation validation are performed with regard to assembly process of subframe subsystem and body structure on a particular vehicle. During the simulation, the problems are found as follows: (1) There is interference between dolly front pillar and spreader bottom when the subframe subsystem is transported; (2) The blind area happens to an operator at the static operating posture. The assembly operation needs to be accomplished by means of human body. Furthermore, the operator’s neck and arms are subject to fatigue. When cyclic load is applied, fatigue usually appears on the operator’s body. The analysis results indicate that interference can be avoided by optimizing the spreader structure and relative position or adjusting the dolly front pillar by nearby operator when the dolly goes through the spreader. By modifying the location of installation points, an easy assembly can be completely achieved, and fatigue can be substantially eliminated as well.

F2012-E12-041