CompositesWorld
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NOVEMBER 2016 30 CompositesWorld PLANT TOUR "We use roughly 150m of glue per 7 Series BIW," says Roth. ere are drums of adhesive from Sika AG (Baar, Switzerland) and also MMD machines at each production cell. "We have used SIKA and bonding for metal parts for years," says Roth, "but the adhesive we use for the CFRP stations is a specialty adhesive for CFRP-to-sheet-metal bonding." e tunnel is then mated to the steel components of this subassembly. Rivets are applied to affix the CFRP and steel pieces together until the epoxy hardens five hours later, when the BIW goes into the paint oven. e tunnel production cell produces 17 units per hour. When asked about issues encountered while developing the various press cells, Roth responds, "e challenge was how to qualify personnel to repair and maintain these new machines for joining multiple materials. So, we pulled our best mainte- nance personnel and placed them within the process development group so that they would understand the technology behind these machines and processes." ese personnel then became specialists for the new joining equipment. "It is key that they were involved from the begin- ning," Roth adds. Building the Carbon Core Other cells that join CFRP and metal parts include those for sills, B- and C-pillars and roof rail assemblies. Most of the completed subassemblies that contain CFRP are used to form the BIW's mid-section. e C pillar reinforcement and upper trunk cover are on the rear section (Fig. 8, p. 29). e front section is all metal. Once a subassembly is completed, it is loaded by elevator onto an overhead conveyor that transports it to the BIW assembly line. Assembly of the BIW begins with key steel and aluminum chassis pieces joined and welded atop a moving sled. e BIW then progresses through subsequent stations where additional subassemblies are lowered, robotically placed, fastened and/or welded until the Carbon Core is complete (Fig. 9, p. 29). Final assembly line Completed BIWs are painted before proceeding through Hall 52, which produces 5, 6 and 7 Series vehicles. An adjacent Hall 50 produces BMW 3,4 and 5 Series cars. A car rolls off the line every 83 seconds in Hall 52, and every 58 seconds in Hall 50. Each hall contains 350-400 stations on three levels: Pre-assembly modules are on the ground floor (level 0) and transported up to level 2, where vehicle assembly is completed and then back down to level 1 for the finishing line. "All of our cars are built to order, so this presents a challenge," notes CW's guide Read this article online | short.compositesworld.com/BMW7Series The 7 Series is breaking ground in top-line vehicle luxury. See CW's online Side Story titled "BMW 7-Series: New definition of luxury" | short.compositesworld.com/7SeriesLux Read more in "Wet compression molding" online | short.compositesworld.com/wetcomp Working with Composites One is a unique partnership with our PEOPLE . From regional customer service reps and technical sales teams, to local support teams at over 35 distribution centers in the U.S. and throughout Canada, we'll make sure you find what you need, and receive it when you need it. As your partner, we'll give you access to emerging market expertise and process application know-how, and do what it takes to help grow your business. We'll also provide you with the unmatched service and support you should expect from North America's leading composites distributor. That's the power of Partnership. The Power of One – Composites One. 800.621.8003 | www.compositesone.com | www.b2bcomposites.com People | Product | Process | Performance "At Composites One, we make it our business to know your business." Gary Yoder, Driver, Goshen, IN Visit the all-new compositesone.com.