Recently, Dongfeng Citroen Versailles C5 X in the C-NCAP crash test, with its comprehensive strength in the three major safety areas of passive safety, active safety and pedestrian protection, at the same time obtained a comprehensive score of 90.6%, as well as C-NCAP "five-star" safety rating. What kind of manufacturing strength has made the Versailles C5 X achieve such results? Today, we visited the birthplace of Versailles - the Chengdu factory of the Shenlong Company, and witnessed how "Versailles" was refined.
The Chengdu plant of DPCA covers a total area of 2,484 mu, of which the construction area is 635,766 square meters, including the complete four major processes of automobile production, resin workshop and parts park. The planned annual production capacity reaches 240,000 vehicles, and after reaching the planned production capacity at this stage, a brand new car will walk off the production line every minute!
At present, the Chengdu plant is responsible for the production of Citroën brand Tianyi series, Versailles series, as well as Peugeot 4008, 5008 and other models, and the Versailles C5 X produced here is also exported to the European market to meet the needs of the local market.
Stamping line is the most critical part of vehicle manufacturing, Shenlong Chengdu factory has two fully enclosed, automatic high-speed stamping lines, the use of four-sequence production mode to achieve fully automated production of stamping, integrated stamping forming, stamping accuracy error is less than 0.01 mm.
Automatic high-speed mechanical stamping production line: the maximum beat can reach 15 times / min, the average of 12 times / min, to ensure production efficiency and meet high precision standards.
The mold adopts joint installation to achieve one mold eight-part manufacturing, 11% increase in the number of stamping times of single vehicles, 1.18% increase in material utilization, and automatic packing at the end of the line to improve efficiency.
Five-axis CNC milling machine and eight-level fitter: Five-axis CNC milling machine is used to process molds such as extremely precise body coverings to ensure the consistency and fineness of body parts.
For the complex shape of the outer plate, fender plate, side wall tail and other areas, the secondary stretch molding process is adopted, which perfectly presents the innovative shape of different models.
The welding workshop has a highly intelligent, high-beat, high-flexibility production process, and 491 robots have realized more than 5,000 solder joints in the whole vehicle, achieving 100% automated intelligent welding;
Laser online inspection ensures the quality of the body, and a large number of thermoformed steel, ultra-high-strength steel and laser welding technology are used to greatly improve the safety performance of the vehicle.
The automated welding production line has advanced visual guidance, non-contact dimensional measurement, high-speed laser welding, structural adhesive bonding and other processes and equipment, 100% automated welding.
The first hexahedral turntable in China: For the first time, 16 robots are integrated with a diameter of 10.5 meters super large hexahedral turntable, which can realize the automatic switching of 6 different models of products body side enclosure molding, and the model switching time only takes 6 seconds, which is the first in China and greatly improves production efficiency.
6000W high-power laser welding: welding speed up to 7 m / min, can meet the production beat of 60 units per hour, welding depth to width ratio, more firm, more beautiful.
Body-in-white geometric size online monitoring: the robot with laser measuring head, non-contact photography measurement of the body-in-white, fast measurement speed, high frequency, good timeliness, to prevent the outflow of unqualified products.
Versailles C5 X applies the new structural rubber process to the front and rear end of the floor and the overlapping area of the floor and the side wall, and the bonding range of the new structural rubber process of the whole vehicle is 17%, which is 6 percentage points higher than the previous model, and the bonding reliability, economy and environmental protection are further improved.
Panoramic sunroof and front and rear windshield robot automatic grasping gluing technology: after high temperature baking in the workshop, the bonding strength reaches 425 MPa, equivalent to more than 4 tons per square centimeter of force, higher than ordinary welding. Make the sunroof and body tightly sewn together, stronger and stronger.
The assembly workshop of the DPCA factory has achieved high quality of vehicle assembly through up to 95% intelligent assembly, automatic assembly of body chassis, monitoring and traceability management of key assembly parameters.
The assembly line has an S-shaped layout, using industry-leading logistics solutions such as aerial catenary chains, floor conveyor chains, and automated handling trolleys (i.e., AGV trolleys) to achieve accurate docking of parts logistics and assembly process stations, and the parts collection rate reaches 95%.
The body three-dimensional library technology, chassis and body automatic assembly technology, automatic servo tightening technology, etc. are used.
Versailles C5X not only integrates the technical essence of PSA Group, but also collects parts from many high-quality suppliers around the world, which can be said to be a "famous brand". Like shock absorbing rubber sleeves and paints from BASF in Germany, electronic shift mechanisms and safety curtains from ZF, Bosch 9.3ESP electronic stability system, millimeter wave radar and so on.
The entire process of key assembly parameters is monitored and traced. The key bolts and servo control box will keep the tightening data for backup for 10 years for later data investigation and analysis.
Each part is stamped with a digital code, which is used as a quality traceability, ensuring that every part has traces to follow and the quality is more reliable.
Every Versailles C5 X undergoes a rigorous quality inspection before leaving the factory. In China, the Versailles C5 X will have to carry out 1298 vehicle tests, while in France it will also carry out 606 tests to ensure that the global quality of the vehicle meets the best standards.
It needs to undergo 241 strict inspections before leaving the factory. On the basis of implementing more than 180 traditional tests for vehicle compliance such as internal and external appearance, rain, electrical functions, front beam functions, and turn hubs, the ADAS calibration bench and a new initial electrical inspection equipment have been newly upgraded.
After the new car test rolled off the production line, 100% of the vehicle participated in the multi-channel spectrum runway experiment, with a total length of 4.5 kilometers and 21 kinds of all-road condition road test tests.
Breaking test: After the welding process, the new car will regularly randomly select a frame for the inspection experiment to ensure the integrity of the product welding and the safety quality of the vehicle.
As the production site of Versailles C5 X, the Chengdu factory of Dongfeng Citroen not only allows us to witness the insistence on the quality of vehicle manufacturing, but also makes us feel the importance of Dongfeng Citroen to the domestic market. Versailles C5 X model is listed in the European market after being listed for the first six months in China, and during the visit, we also actually saw that Versailles sold domestically and Versailles for Europe are produced on the same production line, and truly achieve the unity of Chinese and European products in terms of quality and standards. Want to experience such a high-quality and first-of-its-kind model? Try the Versailles C5 X of Dongfeng Citroen!
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