Lower parts first, from the inside to the outside, light parts to heavy parts. These are the rough rules that guide the assembly sequence.
While the classic construction method used by established vehicle manufacturers usually involves filling a dip-painted body with components, the multi-part frame structure of the TWIKE 5 allows the body to be built up in layers. The layered construction (lower parts first) on a height-adjustable work platform enables a time-saving and ergonomic work process.
The pre-assembly of sub-assemblies provides the opportunity to carry out small-scale work processes close to the body and to sort these assemblies, taking into account accessibility during final assembly (from the inside to the outside). An overhead crane on a trolley aligned with the position of the work platform helps the worker to bring the subassemblies into the desired position precisely and without damaging the body.
After the third stage of final assembly, over 50% of all vehicle components will have been joined, providing a solid basis for the bodywork, which takes less than eight hours.
This short assembly time is ambitious for a small series, but in our estimation and in comparison with experience from the assembly of the TWIKE 3, it is possible.
One challenge to be mastered remains the optimization of all upstream assembly processes while simultaneously meeting all quality requirements.
