A COMPREHENSIVE DIGITAL TWIN FOR BEV MANUFACTURING: TIME ANALYSIS AND ERGONOMICAL ASSESSMENT

The topic of the thesis is to study the manual assembly of the high-tension cable on the underbody of a battery electric vehicle. A cardinal part of this work is the integration of two software programs to enhance the simulation and create the digital twins of the working station. This work exploited the software tools provided by FleXstructures to simulate in the most realistic way the industrial case study assigned by Stellantis The main research questions are related to two different comparisons, related to “time spent”: •??The comparison of the results obtained and the results with an analysis conducted by the Mirafiori plant •??The comparison with the results obtained with the simulation carried out with this thesis and the results obtained with a previous simulation with a different geometry. Another important topic of this work will be the highlighting of all potential ergonomic issues. In order to do this, the project has been broken down in three main parts: •??Construction of the analysis ambient •??Simulation of the assembly •??Analysis of results The thesis will break down in four chapters. The first chapter will be dedicated to the introduction, where the background of the work will be provided and how these models can be integrated into the industrial environment. The second chapter will present the case study and its development, in terms of creation and simulation of the work environment. The third chapter focuses on the analysis of the results obtained, comparing them with company benchmarks. The fourth chapter will carry out a comparative study between this case and a previous one, involving a non-rotated vehicle. In the fifth chapter, the research will be concluded, with a summary of the whole activity