Recently, polar star 1 (Polestar 1) the world’s first order user’s merchandise model is constantly slowly from the production line of the Polarstar Chengdu production base, marking the high-performance electric hybrid GT coupe is about to be officially delivered to the user. Built by the internationally renowned architecture and design company Snøhetta, this global production site was launched in August this year, opening the world’s first mass production of orders.
Polar star 1 (Polestar 1) off the production line
This month, polar star Chengdu production base ushered in another milestone. Located in the polar star Chengdu production base in the test track officially opened, the factory self-built test track will greatly contribute to the full-featured vehicle detection, further ensure product quality, while reducing the previous for vehicle testing between the test site between the transport.
Exclusive test track put into use
Polar Star Chengdu production base is one of the few in China to produce million-dollar price-level luxury models, and exported to mature markets in Europe and the United States, the automobile manufacturing base, which can not be separated from its stringent quality standards and quality control system.
Supplier quality testing
Polar star uses a global lying, unified component procurement and strict quality control of all raw materials from suppliers, with 25 measurement metrics to regulate requirements. From the early on-site assessment, the trial production phase of quality control, as well as the formal post-production supplier delivery quality of the whole process management monitoring, these means are to ensure that the incoming materials meet the polar star quality standards.
Akebono brake system in installation
Precision build carbon fiber body
Polar star uses CFRP carbon fiber-reinforced composites from Italy, all components are strictly cleaned and finely polished before starting bonding, and adequate surface treatment is maintained to ensure structural integrity to ensure bonding strength.
Carbon fiber body structure bonding
The carbon fiber molding chamber, which is responsible for the bonding process of the body structure, is built with a high degree of cleanliness standard, and its indoor temperature is strictly controlled at 23 degrees Celsius (23 x 2), the humidity is maintained at 60% (less than 60%), the pressure difference between indoor and outdoor is maintained at 5pa, and the operator must wear dust clothing, gloves and masks, Ensure that no more than 29,300 dust particles larger than 5 microns per square meter of air in the room, high cleanliness workshop to meet ISO 14644-1 level 8 standard. Operators need to be trained and certified by European Adhesive Bonder European bonding operators to deliver the best quality with their craftsmanship. The cutting-edge SCA two-component dispensing device can achieve a dispensing ratio error of no more than 5%, with ABB’s high-precision robotic arm for high-fit and high-precision carbon fiber bonding.
After the body is bonded, while the vehicle front cover, rear tail box cover and the door mount on both sides are installed, the white body will be very precise stitching adjustment on the adjustment line to ensure that each stitching is uniform, with an error of no more than 0.8 mm.
Carbon fiber body panel stitching adjustment
Carbon fiber finish quality
The carbon fiber body requires different paint ingresss than conventional steel bodies, is more complex and takes longer.
In order to obtain the correct color and surface effect, all carbon fiber bodies and non-carbon fiber body components (mirrors, front and rear bumpers, fuel tanks and detector covers, etc.) will be sprayed at the Chengdu production site to ensure a high degree of color uniformity.
Carbon fiber body spray
Polar 1 uses expensive low-temperature paint, which is slow lying by pure manual spraying. Sharp-eyed and skilled spraying technicians can ensure that the paint surface does not appear any defects, Polar Star 1 has 4 different layers of coating, in the paint workshop each polar star 1 needs to go through about 20 hours to complete the overall coating of the body, each layer of paint finish before and after repeated grinding, to ensure the smoothness of the surface and coating adhesion. At the same time, before each step of the process completes into the next step, will go through the quality inspector’s testing, to eliminate any non-conformance process into the next step.
Body paint polishing
Eco-friendly coatings and sealants
Polar stars follow high environmental standards. During the manufacturing process, Polar star conducts comprehensive testing of raw materials, components, assembly systems, and the entire vehicle to ensure air quality in the vehicle from the source. For example, for the adhesive for carbon fiber material bonding, Polar 1 uses carbon fiber adhesive from Dow, in ultra-high strength of carbon fiber components and components, the toughness of the adhesive can bring a certain absorption effect on the body structure, while more odor-free volatile, safe and environmentally friendly.
ABB mechanical glue arm with Dow carbon fiber environmental adhesive
In the choice of coatings and sealants, Polar star 1 abandoned the traditional asphalt damping gaskets, using SSD water-soluble spray-resistant materials, it has no volatile toxic substances, nor does it produce odor. Equally safe and environmentally friendly are NVH anti-stone paint and body self-adhesive. The anti-stone paint sprayed in the chassis area can effectively reduce the noise during driving and play a protective effect on the chassis (water resistance, corrosion, impact resistance, etc.). The unique self-drying glue used in the gap between the sealed steel floor and the body on the carbon fiber ensures a complete seamless connection between carbon fiber and steel, further enhancing the sealing effect while avoiding friction and resonance between two completely different properties.
Although these materials and processes are relatively expensive, but for the user’s health has made a guarantee, its benzene, toluene, xylene, styrene, acetaldehyde, acrylaldehyde and other harmful emissions of nearly zero, formaldehyde content to meet the minimum standards at the same level.
Exclusive test track High-level NVH performance and dynamic full-featured testing
In the Polar Star Chengdu production base, self-built an exclusive test track, not all vehicle manufacturers have the conditions to build their own test track. With 2.5 km of paved loops and 0.8 km of special road surface, the quality department’s engineers will use the runway to conduct a full range of dynamic vehicle testing to ensure that all functions of each Polar Star 1 are functioning properly.
Exclusive test track top view
In the high-speed loop, the quality department’s engineers will test the smoothness of the vehicle in different drive modes, the operation of the in-vehicle electronic system, radar calibration testing and lighting functions, acceleration performance, braking performance, turning radius and various controls.
High-speed ring test track
On special roads comprising upand, Belgian roads, undulating roads, cobblestone roads, step roads, deceleration belts, cellar covers, slats, rope roads, horn road, straight-line twisting roads, engineers will challenge vehicles through these simulated road conditions to detect and eliminate vehicle resonance and noise to the maximum extent possible. Ensure that every new car delivered to the user has a high level of NVH performance.
Straight-line twisting section of the runway of the special road interview car
At the end of the dynamic test, Polar Star 1 will also undergo a rain shower test that simulates heavy rain extreme weather to ensure that the vehicle is waterproof and closed. Each Polar Star 1 that passes these tests will eventually be subject to final review on the customer recognition line.
Consumer Perspective Review
The task of the Consumer Perspective Review is carried out by polar star review teams, all of which must be trained for up to 2 years and certified professionally from their headquarters in Gothenburg, Sweden. The judges will sample vehicles from qualified products every week, and each vehicle will be reviewed in a rigorous manner from the eyes of the consumer of luxury cars, with more than 100 static items reviewed through different sensory testing methods, and detailed close-up inspection of the upcoming new car. Each vehicle that is reviewed will face a full day of sensory testing from the judging panel, and any subtle flaws will be left in the dark.
Consumer Perspective Review