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Improved Fit and Finish
New process from Johnson Controls ensures that luxury autos are truly works of art
For customers who purchase an upper segment car, the choice is about more than just transportation—it’s about a driving and lifestyle experience. And that means an uncompromising attention to detail, not only in performance but in fit and finish as well. Because design elements affect that fit and finish, it can be difficult to strike a balance between aesthetics and manufacturing realities.
Take, for example, something as seemingly simple as a two-toned door panel. Getting that accomplished means manufacturing two separate parts, then applying to one another. More often than not, two pieces means a difficult match—gaps and seams could show through after the final assembly. Not exactly a luxury experience for the end consumer.
For the first time, this process is being used for the new BMW 5 Series. Johnson Controls developed the process by working closely with automobile manufacturer BMW during the redesign of this new model.
To this end, machinery and tool advances ensure the color demarcation lines stay within the exacting tolerances at all times. Image-processing sensors are also employed in the automated process, monitoring the positioning and application of the two-color foils. If the foils move out of alignment, the sensor notifies the machinery to make adjustments so the color demarcation stays within tolerances.
Furthermore, Johnson Controls also uses twin tools to increase production efficiency for BMW. They allow two door panels to be applied at one time, cutting down on manufacturing time. Subsequent pre-assembly of the door pocket, airbag, loud-speaker grille, trim strips and armrests, all with different surfaces, plus numerous optional extras are also tasks completed by Johnson Controls. This means the plant has to have the logistical and technical capability to accommodate more than 100,000 possible variations per door panel.
Take, for example, something as seemingly simple as a two-toned door panel. Getting that accomplished means manufacturing two separate parts, then applying to one another. More often than not, two pieces means a difficult match—gaps and seams could show through after the final assembly. Not exactly a luxury experience for the end consumer.
Twice as Nice
But now, Johnson Controls has developed a process that applies a two-color foil to one single-component door panel, allowing for unprecedented fit and finish. Because only one panel needs to be secured instead of two, there are no gaps or crevices—just a smooth, seamless finish. Best of all, the new process allows for effective production processes, a shorter assembly schedule and a higher quality finish.For the first time, this process is being used for the new BMW 5 Series. Johnson Controls developed the process by working closely with automobile manufacturer BMW during the redesign of this new model.
No Distortion
One of the challenges of developing the process involved the color demarcation line in the one-piece door panel. Anyone who has ever tried to wrap an asymmetric object with striped gift wrap paper in such a way that the lines are absolutely parallel, even along the edges, can probably imagine the kind of challenges engineers faced. Because the foil is stretched over the substrate to create two tones in one piece, there was a potential for the demarcation to be distorted.To this end, machinery and tool advances ensure the color demarcation lines stay within the exacting tolerances at all times. Image-processing sensors are also employed in the automated process, monitoring the positioning and application of the two-color foils. If the foils move out of alignment, the sensor notifies the machinery to make adjustments so the color demarcation stays within tolerances.
Furthermore, Johnson Controls also uses twin tools to increase production efficiency for BMW. They allow two door panels to be applied at one time, cutting down on manufacturing time. Subsequent pre-assembly of the door pocket, airbag, loud-speaker grille, trim strips and armrests, all with different surfaces, plus numerous optional extras are also tasks completed by Johnson Controls. This means the plant has to have the logistical and technical capability to accommodate more than 100,000 possible variations per door panel.
