How Do They Do That?
Car production has come a long way. With the exception of the Yugo, which ceased to exist as a brand in 2008, it’s been many decades since mass-market cars were put together by hand. Modern cars are built on a production line. The mental image of rugged mechanics expertly wielding welding equipment, and lovingly oiling and polishing each model is a dated one; except, perhaps, for the most expensive limited production, or custom made, cars.
There are two distinct processes for assembling cars. One process is aimed at unibody design cars, which are the most popular kind on the market today. The other process is aimed at body-on-frame vehicles such as trucks.
Unibody Car Production
In unibody car production, the first stage of production takes place in the body weld shop. Once the profile cutting is done, the major body panels are tack welded within a fixture. Next, the body is released from the framing fixture, and respot welds are applied. Most of these welds are done by a robot, rather than a human using welding equipment. In some cases, wire fed MIG welders are used by a human to reinforce the welds.
Next, the doors, trunk, and hood are put on, and the body is finished to make sure that it’s smooth, and that there are no defects. This is often done by a human, as it takes a lot of expertise to identify the potential defects.
Once the car has been carefully examined, it’s time for phosphate coating, and then painting. The car painting is a process in and of itself, with three coating stages (primer, topcoat, and clearcoat), and a baking stage after each one.
Once the car has been painted, it’s time to put the interior together. Of course, in a modern vehicle, there’s a lot of electronics to worry about, so once the interior is in place it’s time to sort out the engine, the wiring, and all of the accessories. This stage can be difficult and time consuming, and many custom car builders feel that sorting out the electronics is one of the hardest parts of putting together a car.
The final stage of assembly is connecting up all the wiring, installing the fuel and tank and radiator, and making sure that all of the fluids required for the car have been added.
Once all of that has been done, it’s time to test the car on a dynamometer. Every single aspect of the car must be tested, including acceleration, gear changing, and the brakes. If the car passes all of those tests, then it’s time to check the steering alignment. Only then is the car ready for sale.
A huge amount of the work that goes into making a car is automated these days, but that doesn’t mean that there’s no place for humans. There are still several stages in the production process that require the skills and knowledge that only a human possesses. You can automate profile cutting, but you can’t automate quality control!