Research On Ergonomics Simulation Of Car Body Welding Plant Based On EM-Engineer

Operators-machines-condition system is considered as a unified whole in ergonomics, so that the equipment and condition that adapt for human are created and the operators-machines-condition system is corresponded, so as to ensure a safe, healthy, high-effective, and comfortable working status. With the development of society and science, more and more people begin to realize the importance of work safety and life quality, and application of ergonomics has also become increasingly convenient and accurate. This paper applies the simulation technology and theory in ergonomics. The situation of car body welding workshops in a motor company is evaluated. Typical ergonomics problems in the situation are analyzed and improvements for these problems are carried out. Through the contrast and analysis between old and new project, the improvement effect is obvious.First and foremost, this paper analyzes and summarizes the computer-aided ergonomics (CAE), ergonomics and welding workstation modeling and simulation technology. The eM-Engineer software is introduced to build a 3D virtual model for welding workstation and simulate the operations of workers.Second, the following ergonomics problems are analyzed and improved one by one based on computer simulation and theory in ergonomics. (1) A car door plate shelf whose structure is improved is designed. It makes the operations of getting plates comfortable and reduces workers' labor intensity. The number of actions and the time are reduced by half, too. (2) A hanger is introduced to solve the problem of manual material handling and reduce workers' workload. (3) A ladder structure material box without walls is designed. The materials are arranged by layers in this box. So the workers can easily get the materials without searching and bending. (4) A horn-type sleeve for hammer and a bracket for grinding wheel are added in the workstations so that the worker gets the tools without searching and bending. (5) An industrial blower is added in the workstation so that the worker can hold it and clear the welding slag scattered on the door plate. Thus, the actions of shaking off slag by hands can be avoided. (6) A sliding-type hanging chain for welding gun is introduced to simplify the redundant motions of rotating gun and shorten the operating time.Finally, with the help of ergonomics analysis tool of eM-Engineer software, this paper discusses the factors that affect the workload. A method for evaluating workloads of workers in different types of work is introduced by applying the fuzzy analytic hierarchy process (FAHP). The evaluation results are approving widely. Then, a method to maintain the optimal workload is introduced based on the evaluation results and experience.