So a car is manufactured, all phases

How a car made? Pictures processHow a car made? Pictures processHow a car made? Pictures processHow a car made? Pictures process

According to the information you have provided various car manufacturers, since the approval of the project is given the setting up of a new car until he steps on the street, they go from four to six years on average. If you want, look at it this way: recently, Mercedes Benz put on sale its new E-Class, one of the latest cars at dealerships. Well, it has simultaneously begun work on his replacement, expected to see the year 2023. And, of course, has prepared all the evolution that the current experience in their life cycle, as you can see is about seven years.

Yet few Car manufacturers declare a closed date when asked about the development cycle of a new model. In a way, there are reasons, it depends on what is meant by the new model. The car full, without mechanical? ¿Adding these, perhaps legacy of an earlier generation, still tinkering? Eye, for brands such as Mercedes have cited "jewels" in the style of the Class S, which changes once a decade. That is, for ten years its leaders evolve and develop meticulously the "know-how" needed to launch a vehicle that, like other flagships first level, when it comes becomes technological reference.

By the way, is priced considerably more time manufacturing unit requires a generalist car: a 20 hours since start welding and chassis frame until it emerges from the means of the assembly line.

How a car designed?

Seat explains it clearly: 1400 days, over a thousand sketches, 5,000 kilos clay Y 1,000 liters Of paint require fully define the design of a new car. And the best: it all starts with pencil and paper. The Spanish brand explains the process as follows:

1. Briefing. Drafting of guidelines they must meet the new car, a road map that marks the DNA model and will guide the process.

So a car is manufactured: design2. Booklets. Designers begin to draw the new car, from what they would do to an almost real picture of the new vehicle. In four years they produced over a thousand sketches.

3. sketches chosen virtually recreate volumizing future vehicle. The result officiates as technical document.

Four. model "clay". Clay maquette-size and four tons, more than double the production car. physically recreates the exterior design takes shape and as changes are introduced. In this process there is a craftsman work, Molder hand carving the piece.

5. "Frozen model". The final exterior design, approved by the company. Its appearance is quite real, although remain a model "clay". Throughout the process they reach about 5,000 kilos of clay used.

6. Colors. The Department of Color&Trim creates internal and external new car tones. She works in two years and gathers ideas and trends in the world of fashion, architecture and product design. 100 performed formulations and invest 1,000 liters of paint to finish a palette of 12 colors.

7. Seating. Developmental aspects of comfort and aesthetics are combined. Color&Trim intervenes here with a special sewing machine that prepares the patterns and combining materials and colors that best fit.

8. Interior design. Driver-oriented, now pivots around the screen, which has gained so much prominence is the first to be located; then comes the rest. Tastes and designs outside, all new model prevail aspects such as functionality and ergonomics for the new car especially useful and effective.

The preliminaries: chassis, aerodynamics ...

Once the design model has been approved, they will produce molds Y templates which will serve to produce their panels and parts. Overall, manufacturing of a car is divided into pressing stages, sheet, painting and assembly.

Chassis tuning: this car is manufacturedAs you can imagine, before reaching that point they have been invested thousands of engineering hours to trace the chassis... Already with the first real models are made tests aimed at define aerodynamics (at wind tunnel), The tightness and safety (shocks and impacts). Then come the test circuit and determine the road making dynamic point and the durability of the proposal. These will take place in such inhospitable places like the Arctic Circle, but also in hot desert environments, and even in some high altitude. Some others are made in a closed circuit.

Painting car

Painting a car is a delicate process, because any imperfections will be printed and return the unit to starting point. Hence this stage is carried out in a Aseptic nearly airtight environment, dust-free. It has scarcely human presence, and the workers who for some reason have access to cabins make sausages in special costumes, before crossing by air blowers that neutralize contaminant to the last speck.

from the bodyshop, the bodywork It is subjected to a intensive high-pressure washing and a sequence chemical treatments which determine a clean surface and uniform, fat free and of welding residues or projections workshops and press plate. The treatment also makes the body does not conduct electricity and resist corrosion. Then enters a electrocoat bath: Within a pool, the fully submerged body is subjected to electrical voltage and sheet, which acts as cathode, attracts paint particles disassociated. This first layer of paint prevents corrosion. Putties then every nook and sealing gasket to ensure tightness apply.

Finally applies the painting, first inside and then to outside the car (Also subjected to a varnishing process layer responsible brightness we see). The last step is a drying oven at 150 ° C for 15 minutes.

Begins manufacturing and assembling car

The start of production of a car itself takes place on the floor of the factory presses. There, large cattle arrive about 20 tons of a steel supplier (except the Hyundai group, which has its own steelworks). They spend a roller train that straightens to leave them flat. Then they routed to hydraulic presses as cutting each piece, sheet or plate.

Offcuts then pass the stamping stage where steel remains at room temperature and it is punched by a press that gives the final shape to the piece, with corresponding profiles, silhouette and holes for screws: roof, door, fin, frames, hood ...

The presses SEAT's Martorell exert a force equivalent to the weight of 500 cars and repeat the maneuver 6.4 million times per year. Yes, the procedure fully automatic, is supervised by a demanding quality control. This can be automated, but also made by operators. Typically one sampling every few pieces of the line is extracted to check meticulously that meets expected parameters.

He assembly and the welding (Average about 3,000 points, plus strings attached laser) is the next step. It shapes the body in a process commanded by the robotics (About 95 percent of operations). Starts on the floor, added the wheel, the dashboard screen that supports the subfloor front and rear, sides and finally the roof, one of the pieces that give a more robust vehicle. That done, doors, hood and flaps are added. Robots with laser scanner examined by whole body to verify that allowances and tolerances between parts are correct.

So a car is manufactured: assemblyCar mount, piece by piece like puzzles

When the car is already painted, access the final production phase in the assembly shop, where each unit receives all its internal accessories, motor .... First the gates are removed for easy access and installation of internal elements. Here dominates man's hand with the help of machines that facilitate moving heavy parts such as the dashboard (usually comes in one piece from supplier, wiring, inclusive), the wheels ... Before mounting the headliner and other trim is inserted and fixed wiring and the relevant pipes. Finally seats (turn and as the engine and transmission, preassembled in other workshop effect) and mirrors are mounted. When mechanical reaches the body, exhaust, transmission, rear axle or steering column already positions. The power train is lifted by a machine to effect, but the assembly and tightening all borne by operators. Finally, the front (the mask, with grille, bumpers and headlights) and the doors is added, before incorporating the fluid (fuel, coolant, wipers, brake fluid and address ...).

Each car is then subjected to a comprehensive quality test to test that everything is going as it should. Also on a test, which verifies the delivery of adequate power. Then the car is first started and goes outside, where the technicians undergo demanding driving tests on taxiways different surfaces: smooth asphalt, rough, cobblestones, bumps ... brakes and direction are also verified, and tested for the presence or absence of background noise. The car will still be subjected to a pressure washer in a tunnel that ensures proper sealing.

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