防错技术作为企业质量管理体系中的一个非常重要的管理手段和组成部分，其在汽车制造行业中有着广泛的应用。随着工业4.0时代的到来和汽车电动化需求的增加，汽车生产线柔性化对防错技术提出了更高的要求，大部分的主机厂会采用混线生产，生产制造过程中的零件种类会成倍增加，尤其是紧固类零件增加最多，进而导致松装错漏问题出现频次增加，由此会带来更多的返修、报废等问题。S整车厂作为国内汽车行业先进汽车生产厂之一，其中的防错技术应用处于业界前沿。但是随着新能源时代的到来，生产线对于紧固件类防错手段已不能满足多元化紧固件装配的需求。因此，防错技术的应用升级对提升总装效率、工艺质量改进和成本优化起着至关重要的角色。本文以防错工艺为研究对象，系统梳理和分析了目前防错工艺在汽车总装及紧固类工艺中的应用与研究现状。通过对S整车厂紧固类工艺防错现状问题的分析，以及对紧固类防错工艺的优化设计，引入综合信息化防错系统，对生产痛点进行防错优化，实现了对紧固工艺的全面防错升级，取得了较为明显的成效。本论文研究的主要结论如下：（1）结合防错技术的基本概念、应用原理，介绍了S整车厂总装车间防错技术应用现状。主要有设计防错，制造工艺防错，设备防错、排序防错、视觉防错等防错措施。对目前S整车厂采取的各类防错技术进行研究和实例分析。（2）结合紧固件的基础知识，包括螺栓拧紧原理，拧紧工艺控制方法以及动力工具应用等，对S整车厂紧固类工艺防错现状进行分析，以侧安全气帘装配工艺为例，通过PFMEA分析识别出现有的防错体系中不能实现紧固顺序、安装位置和零件取用的防错自动识别等问题。（3）针对S整车厂紧固类工艺现有问题，引入智能拧紧系统，利用综合定位技术，HMI系统应用和建立数据库，对紧固类工艺进行防错优化，实现了对紧固顺序、安装位置，零件取用等防错控制。（4）利用智能拧紧系统，对某工段内9个试点工位进行防错工艺优化验证和跟踪。防错工艺实施后，该试点区域紧固类问题减少率平均达93%，验证了智能拧紧系统在紧固类工艺防错优化的有效性。关键词：防错技术，紧固类工艺，智能化防错系统
Error proofing technology, as a very important management tool and component in the enterprise quality management system, has a wide range of applications in the automotive manufacturing industry. With the arrival of the Industrial 4.0 era and the increasing demand for electric vehicles, the flexibility of automotive production lines has put forward higher requirements for error prevention technology. Most factories adopt mixed line production, and the types of parts in the production process will increase exponentially, especially for fastening parts, which leads to an increase in the frequency of loose installation, error, and leakage problems, resulting in more rework, scrap, and other problems. As one of the advanced automobile production factories in the domestic automotive industry, S Vehicle Factory is at the forefront of error prevention technology application in the industry. However, with the arrival of the new energy era, the production line‘s error prevention methods for fasteners can no longer meet the demand for diversified fastener assembly. Therefore, the application and upgrading of error prevention technology plays a crucial role in improving overall assembly efficiency, improving process quality, and optimizing costs.This article takes error prevention technology as the research object, systematically reviewing and analyzing the current application and research status of error prevention technology in automotive final assembly and fastening processes. By analyzing the current situation of error prevention in the fastening process of S vehicle factory and optimizing the design of the fastening process, a comprehensive information error prevention system was introduced to optimize the production pain points, achieving a comprehensive error prevention upgrade of the fastening process and achieving significant results. The main content of this article is as follows:(1) Introduced the basic concepts, application principles, and related technical measures of error prevention technology. Based on the current production status of the final assembly workshop of S vehicle factory, research and case analysis are conducted on various error prevention technologies currently adopted by S vehicle factory. This provides a theoretical basis for upgrading the error prevention technology of S factory.(2) Introduced the basic knowledge of fasteners, including bolt tightening principles, tightening process control methods, and power tool applications. Taking the assembly process of side safety air curtains as an example, PFMEA analysis is used to identify problems in some error prevention systems that cannot achieve tightening sequence, installation position, and component retrieval. By analyzing the current situation of error prevention in the fastening process of S vehicle factory, identify the problems that exist in the error prevention system that cannot achieve the tightening sequence, installation position, and parts retrieval.(3) In response to the existing problems in fastening processes, an intelligent tightening system is introduced, utilizing comprehensive positioning technology, HMI system application, and database establishment to optimize error prevention in fastening processes, achieving error prevention control over tightening sequence, installation position, and parts retrieval.(4) Utilized intelligent tightening system to optimize and tracked the error prevention process for a fixed workstation in a certain section. After the implementation of error prevention technology, the average reduction rate of problems at this workstation reached 93%, verifying the effectiveness of the intelligent tightening system in error prevention optimization of fastening processes.Keywords: error proofing technology, fastening process, intelligent error prevention system
