In 1908, Henry Ford started making vehicles with the Model T. The Model T was developed over five years, relying on Ford’s initial Model A concept first produced in 1903. The mass manufacturing assembly line was introduced by its conception. Simply assembling replaceable sections is what inspired this groundbreaking notion. In the old days, the only way to get a buggy or coach was to have them hand-built by experienced artisans who seldom made more than one of anything. Ford’s unique design decreased the number of necessary components required and those of trained fitters who had historically comprised the backbone of the assembly process, providing Ford a considerable edge over his competing companies.
Image by JayMantri
The core notion of stationary employees placing parts on a car as it reaches their workspaces has not altered much over the decades, despite significant technological developments in automotive assembly procedures.
Raw Materials
Even though steel is what comprises most car components, materials based on petroleum (vinyl and plastics) have grown in importance when it comes to various automobile parts. There has been a decrease of 30% in weight by some versions, thanks to lightweight products generated from petroleum. Lightweight, more fuel-efficient cars will grow in popularity as fossil fuel prices increase.
Design
Launching a new automotive model typically takes between three and five years. Designers modify existing models to answer unmet public demands and tastes. However, car firms have successfully designed vehicles that meet the public’s preferences during the past five years. Developers use computer-aided engineering tools to create preliminary artistic renderings that assist them in envisioning the final appearance of the automobile.
Afterward, they create clay models, which style specialists then evaluate who know what the market is likely to favor based on this scenario. Aerodynamic experts also review airflow characteristics and crash test pilot projects. Tool developers can only create the necessary equipment to build the new model’s components once all other models have been examined and approved.
The Manufacturing Process
1. Components
When it comes to making a vehicle, the assembly plant is essentially the last step in manufacturing. The parts provided by over 4,000 external providers, including those owned by the corporation itself, are gathered together for installation. The chassis pieces are transported to one location, while the body components are hauled away to another.
2. Chassis
Manufacturers often build a conventional automobile or truck from the roots. The framework serves as a foundation for the remainder of the body and the starting point for all following parts. Conveyor clamps controlled by robot management software keep the frame in position as it goes down the manufacturing line. Afterward, the car’s structure travels to component assembly rooms, where workers fit in sequence the car’s braking system, wheel drums, steering box essentials, gearboxes, driveshafts, rear axles, gas tanks, and rear suspension.
3. Body
There are several boards and bracing that robots will bolt or weld into the floor pan – the most prominent body section. The car’s body is built as it passes down the production line while being clamped in position by fixtures. First, robotically detached right and left quarter panels from pre-staged cargo crates are positioned on the floor pan and soldered in place.
4. Paint
Before painting the vehicle, the body needs to undergo a thorough examination in white operation. Visual examiners thoroughly wash off the vehicle’s shell using towels drenched in hi-light oil in a highly illuminated, white chamber. This oil enables examiners to spot any flaws in the vehicle’s sheet metal. Repairs for dents, dings and other imperfections are done directly on the spot by professional body mechanics. After that, a cleaning workstation removes any remaining oil, dirt, or pollutants from the shell before it is sent back to the assembly line for final installation.
5. Mate
At this point in the process, conveyors of the body shell and chassis assembly come together. Robots automatically lift the shell from its attachments and place it above the vehicle’s frame when the chassis moves through the body conveyor. Workers underneath the conveyor and those on the first floor attach the vehicle’s body to the frame. After finishing the matching process, they send the car to get the final trim pieces, batteries, anti-freeze, wheels, and gasoline before they approve of driving it away from the assembly line.
Final Thoughts
Our highway networks have become overcrowded and out-of-date due to rising car ownership and a growing unwillingness to develop new roads. The problem can eventually be alleviated by modern technological innovations that allow automobiles to maneuver around traffic and even operate autonomously. As the years pass by, these advancements will eventually change the world’s transportation system.
