Chrysler Simulates Hybrid Production Process To Work Out The Bugs

Chrysler has announced that it has begun production of its Dodge Durango and Chrysler Aspen hybrid electric vehicle at the company's Newark Assembly Plant. While preparing to begin production, the company created a computer simulation of the assembly processes to spot problems and trouble points while the plant was still being prepared.

The first pilot vehicles were put together on the plant's assembly line and the assembly processes were analyzed to help identify what the company calls "anomalies." The production of hybrid vehicles is different and required modifications to the powertrain assembly process, and specialized assistive machinery to help with the installation of the vehicles' 300-lb battery packs.

Analysis concentrated specifically on the hybrid component production processes. In addition to the battery installation, Chrysler reviewed assembly processes that involved the vehicles' transmission and torque inverter, the electric air conditioning and hydroelectric power steering, among others. According to Chrysler, the vehicles are the first two-mode full hybrid systems available.

The vehicles can operate on electric-only power, engine-only power or a combination of electric- and engine power when operated at low speeds with light loads. At highway speeds, the vehicle uses full power from the engine when the vehicle is passing, towing or climbing. Most hybrid vehicles have no towing capacity.

The Newark Assembly plant covers 3.4 million square feet and employs about 1,000 workers represented by UAW Locals 1183 and 1212, which assisted in producing the simulation. The Newark Assembly Plant was originally constructed in 1951 as a tank plant and was converted to automobile production in 1957.

Source: Chrysler, LLC