Intelligent Flexible Assembly Line for Low-Speed Electric Vehicles (LSEV) – Enhanced Technical Layout

1. Scenario-Based Production Layout

Rather than relying on cumbersome large robotic arms, our system adopts a cost-effective “Overhead Flexible Conveying + Ground Ergonomic Manual Assembly” model (as shown in the picture), specifically designed for the “multi-model, small-batch, high-mix” characteristics of micro-mobility production lines.

The entire line uses an overhead Power-and-Free conveyor as its backbone, connecting vehicle bodies at various assembly stages. The ground level is organized around the main line with pre-assembly stations, main-line fitting zones, and final inspection areas. This layout preserves the flexibility of manual operations while utilizing vertical space to avoid floor congestion, perfectly suiting the diverse configurations of modern LSEVs.

2. Detailed Core Technologies

Overhead Power-and-Free Conveying System

• Customized Hanging Fixtures: Tailored to the compact nature of micro-cars, we utilize multi-point white wide-strap hangers (visible supporting the light-green body in the image). This design distributes weight evenly, preventing deformation of thin-walled stampings during transport while avoiding pressure damage to the paint.
• Full Process Protection: Bodies are transferred via the overhead system post-painting without ever touching the ground. This utilizes the factory’s vertical clearance, completely isolating the product from floor debris and preventing secondary contamination of the chassis and finish.

Ground Human-Machine Collaborative Workstations

• Stand-up Operation Design: As depicted in the assembly scene, the ground line does not rely on fully automated machinery but provides workers with stable platforms. The line height is calibrated to suit Asian ergonomics, complemented by blue multi-functional material trolleys on casters (seen on the left). This allows workers to perform “fetch-assemble-return” tasks seamlessly without excessive bending or stretching.
• Pneumatic Assistance & Cable Management: For heavier tasks like wheel mounting, pneumatic balancers or assist arms can be mounted directly to the overhead fixtures or columns, significantly reducing physical strain. Furthermore, the overhead cable bundles (green and white cables in the image) are neatly housed in durable drag chains, ensuring a clean 5S-compliant shop floor and eliminating tripping hazards.

Modular Powertrain Mating Process

To reduce bottlenecks during assembly, the line incorporates an offline sub-assembly station. The powertrain (motor, controller, battery pack) is pre-assembled on a dedicated jig and then lowered onto the main line body using a specialized lift. This modular approach shortens the critical path cycle time on the main line.

Intelligent Control & IT Integration

The entire line is centrally controlled by a PLC system with variable frequency drives, allowing flexible adjustment of the production takt time (from 3 to 8 minutes per unit). Furthermore, the control cabinet reserves standard communication ports (MES/ERP ready) and supports barcode scanner integration for real-time data upload and quality traceability.