The Minivan / Passenger Van assembly line consists of a floor conveyor system and a workstation operation system. The line body runs through the assembly workshop. Vehicles are arranged on the conveyor line, and workers complete assembly tasks at each station on both sides of and inside the vehicles.
The floor conveyor system of the Minivan / Passenger Van assembly line adopts a slat chain conveyor line. The slat chain is formed by connecting multiple metal plates with hinges, creating a continuous annular conveying surface. The slat chain is installed in a ground trench, with its upper surface flush with the ground. The driving device is located at one end of the slat chain, consisting of a motor, a reducer, and a sprocket, driving the slat chain to run at a set speed. The tensioning device is located at the other end to adjust the slack of the slat chain. Minivans and passenger vans have a large overall weight; therefore, the plate thickness and drive power of the slat chain are designed according to the weight of the fully loaded vehicle. The chain and plates are made of steel. The vehicle tires rest directly on the surface of the slat chain, and no dedicated fixtures are set on the slat chain. The position is maintained by the friction between the tires and the slat chain surface. The running speed of the slat chain is set according to the production cycle time, and the dwell time at each station is fixed. The distance between stations is determined by the vehicle length and assembly content, and a safe distance is maintained between adjacent vehicles.
The assembly process of the Minivan / Passenger Van assembly line is divided into multiple sections. The front section handles body loading and interior assembly. The body shell is transported from the painting workshop to the entrance of the final assembly workshop via a power and free conveyor or skid conveyor system, and is transferred to the slat chain by a lift or transfer device at the transfer station. In the interior section, workers install the instrument panel, steering wheel, seats, headliner, side trim panels, carpet, and wiring harness inside the vehicle. Minivans and passenger vans have a large interior space, requiring workers to enter the cabin for operations. Some parts are heavy, so assist manipulators or lifting platforms are configured at stations for handling. The wiring harness is routed along the body cavity and floor grooves, and connectors are plugged into corresponding sockets for instruments, lights, air conditioning, and body control modules.
The middle section performs chassis and powertrain assembly. Workers install the engine, gearbox, drive shaft, rear axle, suspension, fuel tank, exhaust pipe, and brake lines under the vehicle body. The engine of a minivan or passenger van is mostly arranged at the front of the vehicle or under the front seats. The powertrain is delivered to the assembly station by an independent conveyor line and docked with the body via an assist manipulator. Electric tightening tools are used for chassis bolt fastening, and torque values are specified by process documents. Data from key connection points is uploaded to the production traceability system. After chassis assembly is completed, a sealing test is performed on the braking system, including air inflation and pressure holding tests of the brake lines.
The rear section of the Minivan / Passenger Van assembly line carries out the assembly of exterior parts and final inspection. Workers install bumpers, lights, rearview mirrors, wipers, grilles, and decorative strips on the exterior of the body. Door glass and seals are installed in the interior or final section. The sliding side door — a signature feature of minivans — is assembled at a dedicated station, including the debugging of guide rails, rollers, and locks. Tires and wheels are installed at independent stations, where workers use special tools to mount tires and perform dynamic balancing. The final section handles fluid filling, including engine oil, gearbox oil, brake fluid, coolant, and washer fluid. The filling volume is controlled by a quantitative filling machine, and data is recorded at the station terminal.
The final section conducts vehicle commissioning and testing. Workers perform functional tests on the complete vehicle at the end of the slat chain to check engine starting, lights, air conditioning, window lifting, sliding door opening/closing, and braking performance. The inspection stations include four-wheel alignment, headlight adjustment, brake performance testing, and exhaust gas detection. Some workshops are equipped with chassis dynamometers; vehicles drive onto the roller test bench at the end of the slat chain for road test simulation. After passing the tests, the vehicle leaves the line and enters the waiting area or parking lot.
An auxiliary operation system is installed above the line body of the Minivan / Passenger Van assembly line. Suspension rails are mounted on the workshop ceiling, equipped with pulleys and balancers for hanging pneumatic and electric tools. Air pipes and cables are connected to the tools via spiral tubes or slide rails. Some workshops have lighting bridge frames above the conveyor line, with fixtures arranged along the conveying direction to meet assembly illumination requirements. The steel structure of the workshop ceiling suspends air ducts and cable trays to provide compressed air and power to each station.
The station layout is arranged according to the assembly sequence. Each station is equipped with tool racks, parts boxes, and work instructions. The work instructions display assembly steps and inspection points in graphic form. Material racks are placed beside the stations to store parts and fasteners required for the station. Due to the large size of minivan parts, the layer spacing and load-bearing capacity of the material racks are correspondingly increased. Yellow safety lines are marked on the station floor to divide the work area and passageways. Station screens are installed at key stations, displaying production cycle time, quality prompts, and call information.
The control system of the Minivan / Passenger Van assembly line consists of a PLC and a touch screen. The PLC controls the start, stop, running speed, and positioning accuracy of the slat chain. The touch screen is installed in the central control cabinet or beside the line body, allowing operators to set parameters and view status through the interface. Multiple emergency stop buttons are set on the conveyor line, distributed on both sides of the stations and at the central control position. When the emergency stop is triggered, the slat chain stops running, and it restarts after the fault is eliminated and reset. The line body is equipped with audible and visual alarms to indicate equipment abnormalities or shift change information.
The cycle time of the Minivan / Passenger Van assembly line is determined according to the production capacity plan, ranging from several minutes to over ten minutes. The line length is calculated based on the number of stations, station spacing, and workshop dimensions. The width of the slat chain is determined according to the vehicle track to ensure that both front and rear wheels fall within the effective width of the slat chain. The drive power is calculated based on the weight of a single vehicle and the number of vehicles online simultaneously.
This assembly line is used to produce minivans and passenger vans. The vehicles are characterized by an enclosed cabin, multi-row seat layout, and sliding side door design, suitable for passenger transport and light cargo scenarios. By adjusting slat chain parameters and station operation content, the Minivan / Passenger Van assembly line can be compatible with models of different wheelbases and body heights. The slat chain conveying method is widely used in this product line, where vehicle tires rest directly on the slat chain surface and are driven by the chain to pass through each assembly station in sequence. All systems operate in coordination through a control program, forming a complete Minivan / Passenger Van assembly line for mass production.
Technical Parameter Supplement Table for the Minivan / Passenger Van Assembly Line
| System Category | Key Parameter Item | Typical Technical Indicators/Description |
|---|---|---|
| Floor Conveyor System (Heavy-duty Slat Chain/Roller Bed) | Conveying Medium | Uses high-strength steel heavy-duty slat chains or metal roller beds with surface hardening to adapt to the chassis and full load weight of minivans and passenger vans. |
| Running Speed | Usually variable frequency adjustable within 0.1 ~ 2 m/min, meeting the low-speed and stable conveying requirements of heavy vehicles. | |
| Load Capacity | Single station load capacity usually 2,000kg ~ 10,000kg and above, designed according to the maximum load of the whole vehicle and fixtures. | |
| Station Spacing | Standard range 6,000mm ~ 14,000mm, providing sufficient space for the assembly of large vehicle bodies, interiors, chassis, and powertrains. | |
| Auxiliary Supply System | Air Supply Pressure | Main workshop pipeline supply with quick couplings at stations, standard pressure 0.6 ~ 0.8 MPa. |
| Power Supply Configuration | 220V/380V multi-specification universal sockets and data interfaces configured for each station to support heavy-duty electric tools and testing equipment. | |
| Tool Distribution | Equipped with pneumatic balancers and heavy-duty torque wrench systems to support high-precision fastening of large components such as engines and transmissions. | |
| Overall Production Line Indicators | Production Cycle Time | Mainstream range 5 ~ 30 minutes/vehicle, adapting to the mass production of multi-variant minivans and passenger vans. |
| Positioning Accuracy | Station stopping accuracy usually required ≤ ±2mm to ensure precise docking of the chassis assembly and body. | |
| Key Process Equipment | Chassis Marriage | Utilizes AGVs (Automated Guided Vehicles) or heavy-duty lifting machines for the in-air assembly of powertrains and bodies, featuring high positioning accuracy to meet the long wheelbase requirements of minivans and passenger vans. |