In the field of automobile manufacturing, which pursues extreme efficiency and perfect quality,
the traditional production model that relies on intensive manpower and fixed processes is encountering
serious challenges. Difficult to improve the production beat, complex process quality fluctuations, slow
response to customized demand, and rising labor costs, together constitute an invisible barrier that restricts
the development of the industry. How to break through these bottlenecks? Industrial automation technology
is becoming the core engine driving the innovation of automotive manufacturing industry with
unstoppable momentum.
How does automation technology profoundly change the four core
manufacturing processes?
Stamping: the fusion of high precision and high efficiency
In the large-scale high-speed stamping line, robotic arms have become the absolute main force. They accurately
complete the gripping, positioning and transmission of plates, and their speed and stability far exceed the limit of
manual labor. Together with the advanced optical inspection system, the surface quality and contour size of each
stamped body covering part have been scanned and analyzed intelligently at high speed before leaving the production
line. The automation technology here completely bids farewell to the sampling inspection mode relying on calipers
and visual inspection, and realizes 100% on-line full inspection, eliminating defects from the source into the
subsequent process.
Welding: Robots Build a Body of Steel
The body welding shop is the most intensive battlefield for automation technology. Hundreds of welding
robots form a highly coordinated “army”, which, based on precise three-dimensional programming, complete
the precise positioning and welding of thousands of welding points on the complex body structure. Laser
welding, spot welding, riveting and other processes are seamlessly integrated by the robots to ensure the
strength and consistency of each joint. The flexible welding production line is capable of quickly switching
fixtures and procedures, making it a reality to efficiently manufacture the bodies of different models on the
same production line.
Painting: Double Guarantee of Quality and Environmental Protection
Automation technology has revolutionized the painting process, which requires a high level of environmental
and quality requirements. The automated spraying robots are equipped with precision atomizers, which, through
preset paths and precise flow control, achieve highly uniform film thickness and significantly reduce the waste
of raw materials caused by overspray. The closed automated paint shop has precise environmental control, stable
temperature and humidity, and significantly reduces the impact of dust particles. Meanwhile, the exhaust gas
and waste water treatment system equipped with intelligent sensors operates automatically to ensure
environmental compliance.
Final Assembly: A Precision Symphony of Human-Machine Collaboration
In the final assembly segment, automation technology is not a complete replacement for labor, but rather
moves toward deep integration and collaboration. The automated transportation system (AGV/EMS) becomes
the flowing “blood vessel”, delivering parts and semi-finished products to each work station on time and precisely.
Collaborative robots (Cobots) work side-by-side with workers in positions that require high repetitive accuracy
or load-bearing operations (e.g., windshield gluing, tire tightening, precise seat placement). Intelligent assistance
systems provide real-time assembly guidelines and quality confirmation tips for workers through AR glasses or
displays, significantly reducing the risk of errors and omissions and improving overall efficiency.
Beyond Efficiency: The Deeper Transformation Brought by Automation
The value of industrial automation for automotive manufacturing goes far beyond efficiency improvement:
Quality leap: Stable execution of automated process parameters eliminates human fluctuations, and product
consistency reaches an unprecedented level. Real-time on-line automatic inspection system constructs a
tight “quality firewall”.
Flexible Manufacturing: Flexible automated production lines based on PLC, machine vision and MES systems can
respond quickly to market changes and achieve cost-effective production of multiple varieties, small batches and
even customized models on the same production line.
Data-driven decision-making: Automated equipment is a natural “data collection point”, and a huge amount of
production data (equipment status, process parameters, and quality information) converge into SCADA and MES
systems. Through big data analysis, plant managers are able to monitor production in real time, accurately trace
problems, predict equipment maintenance needs, and continuously optimize processes.
Safety and Sustainability: Automation technology takes on a large number of dangerous (e.g., welding sparks,
lifting heavy objects), heavy (e.g., long hours of repetitive motions), and harmful (e.g., exposure to chemicals) tasks,
significantly improving the working environment for workers. At the same time, optimized energy consumption and
resource utilization (e.g., precision gluing and painting) effectively reduces the carbon and environmental
footprint of the production process.
The Way Forward: Deepening Intelligence and Integration
The evolution of automation in the automotive industry is far from stopping. Digital twins are building virtual mirrors
of physical plants for simulation optimization and predictive maintenance. Artificial Intelligence (AI) and Machine
Learning (ML) are starting to analyze production data in-depth, enabling more accurate autonomous optimization of
process parameters, intelligent prediction of quality defects, and dynamic decision-making for production scheduling.
5G and the Industrial Internet of Things (IIoT) are paving the way for ultra-high-speed, low-latency interconnectivity
between devices, accelerating the convergence of the information flow and decision-making flow.
Industrial automation has long gone beyond the simple “machine for man” stage, it has become the core infrastructure
of automobile manufacturing to intelligent, flexible, green leap. Through the continuous deepening of automation
technology and integration of innovation, the automotive industry is not only able to cope with the current challenges,
but also shaping a more efficient, lean, intelligent and sustainable future manufacturing new paradigm. To embrace
automation is to embrace the future of automobile manufacturing.