Motorcycle assembly line: intelligent manufacturing journey from parts to complete vehicles

The core production links of the motorcycle assembly line

Motorcycle manufacturing is a complex process with multiple processes coordinated. A standard assembly line usually contains 12 key workstations, each of which is seamlessly connected. These links are both independent and interrelated, and jointly determine product quality and production efficiency.

1. Basic construction stage

• Frame pretreatment and installation: As the “skeleton” of the motorcycle, the frame is the installation basis of all parts. Fixed on the conveying line through positioning clamps, providing accurate benchmarks for subsequent assembly. Some automated production lines have adopted visual recognition technology to ensure that frame installation errors are controlled within 0.5mm.
• Engine integration: As the “heart” of motorcycles, the installation accuracy of the engine directly affects the performance of the whole vehicle.In a dedicated workstation, the robotic arm will accurately connect the engine to the frame, and the torque wrench will complete bolt tightening according to preset parameters to ensure that the connection strength meets safety standards.

2. System assembly stage

• Chassis and transmission system assembly: covers the installation of key components such as suspension, wheels, and brakes. On the flexible production line, the equipment can automatically adapt to the chassis parameters of different models, and cross-model production switching can be achieved through modular design.
• Electrical system laying: The installation of electrical components such as instrument panels, batteries, and wiring harnesses must strictly follow circuit design specifications, and at the same time, real-time power-on tests must be carried out to ensure that electrical equipment such as lights and speakers work normally.

3.Finished product forming stage

• Fluid filling and sealing testing: Accurately inject engine lubricating oil, brake fluid and other fluids to avoid performance problems caused by excessive or insufficient amounts. Airtightness testing is then carried out to ensure that there are no hidden dangers.
• Exterior parts and coating process: Exterior parts such as body shells and seats are installed with robotic arms or manual assistance, and then enter the coating workshop for painting.
• Full-process inspection and debugging: including 12 basic tests such as dynamic performance test, brake performance test, and light calibration. AI vision inspection system has been introduced into some high-end production lines,which can complete appearance defect identification within 30 seconds, and the product qualification rate has been increased to 99%.