Automotive Carbon Steel Stud Automatic Projection Welding Equipment Workstation

Customer background and pain points

Shenyang LJ Company introduced a new model of Red Flag, and welded a total of 39 M6*20 bolts on the new stamping parts. The melting depth is required to be greater than 0.2mm and the screws cannot be damaged. The original welding equipment has the following problems:

1. the welding quality can not be guaranteed: the old equipment is power frequency welding equipment, manual holding welding, the fastness of the workpiece is not within the safety value;

1.1 welding melting depth can not reach: the melting depth of the workpiece after welding can not meet the requirements;

1.2 welding splash, burr: the old equipment welding spark, burr, shape damage is serious, need manual wiping, scrap rate is high.

1.3 the equipment investment is large, need to purchase foreign equipment: welding bolts, red flag audit requirements must achieve automatic welding, and do full closed-loop control, parameter records can be traced back, domestic manufacturers can not meet this requirement;

1.4 the workpiece size is large: this product workpiece is the front fence under the Hongqi HS5 center control; The workpiece size is 1900*800*0.8, the size is large, the plate thickness is 0.8, and manual hand-held welding is easy to cause industrial accidents

2. customers have high requirements for equipment

Based on the product characteristics and past experience, the customer discussed with our sales engineers and put forward the following requirements for the new customized equipment:

2.1. Meet the welding depth requirement of 0.2mm;

2.2. The position of the product after welding is relatively high;

2.3. Device beat: 8S/ time

2.4. Solve the problem of workpiece fixation and operation safety, use the manipulator to grasp and increase the anti-splash function;

2.5. Yield problem, increase the quality management system on the original equipment to ensure that the welding yield can reach 99.99%.

3. according to customer needs, develop and customize automatic bolt medium frequency welding station

According to the requirements of customers, the company’s R & D department, welding process department and sales Department jointly held a new project research and development meeting to discuss the process, fixture, structure, positioning mode, configuration, list key risk points, and make solutions one by one, and determine the basic direction and technical details as follows:

3.1 equipment selection: First of all, due to the customer’s process requirements, welding technicians and R & D engineers together to determine the selection of heavy fuselage medium frequency inverter DC welding machine model: ADB-180.

3.2 the advantages of the overall equipment:

1) High yield, saving process: The welding power supply uses energy storage welding power supply, short discharge time, fast climbing speed, DC output, to ensure that the depth of melting can reach 0.2mm, no deformation, damage or welding slag after welding thread, no need to do back teeth treatment, the yield can reach 99.99% or more;

2) There is an automatic alarm device for missing welding and wrong welding, which calculates the number of nuts of welding parts. If missing welding or wrong welding occurs, the equipment will automatically alarm;

3) High equipment stability: the core components are imported configuration, the use of Siemens PLC integration of our self-developed control system, network bus control, fault self-diagnosis, to ensure the reliability and stability of the equipment, the whole welding process can be traced, and can be MES system docking;

4) To solve the problem of difficult stripping after welding: our equipment adopts automatic stripping structure, and the workpiece can be automatically removed after welding, to solve the problem of difficult welding stripping;

5) Quality self-check function to ensure quality: increase the quality control system to ensure the welding quality of products and improve welding efficiency;

6) With post-welding thread chip blowing function: according to the workpiece and welding requirements, the electrode and positioning fixture with chip blowing function are made;

Agera fully discussed the above technical plan and details with the customer, and the two sides signed the “Technical Agreement” after reaching an agreement, which is used as the standard of equipment research and development, design, manufacturing and acceptance, and reached an order agreement with Shenyang LJ Company on August 13, 2022.

4. rapid design, on time delivery, professional after-sales, customer praise!

After determining the equipment technical agreement and signing the contract, the delivery time of 50 days is indeed very tight. The project manager of Agera held the production project start-up meeting at the first time to determine the mechanical design, electrical design, mechanical processing, purchased parts, assembly, joint adjustment time node and the customer’s pre-acceptance, rectification, general inspection and delivery time. And through the ERP system orderly arrange the work order of each department, supervise and follow up the work process of each department.

After 50 days, Shenyang LJ customized automatic bolt medium frequency welding station

Finally completed, our professional technical service personnel in the customer site after 10 days of installation and commissioning and technical, operation, training, equipment has been normally put into production and all reached the customer’s acceptance standards. Customers are satisfied with the actual production and welding effect of the automatic bolt intermediate frequency welding station, which helps them improve production efficiency, solve the problem of yield, and save labor.

5. To meet your customized requirements is Agera’s growth mission!

The customer is our mentor. What material do you need to weld? What welding process do you need? What welding requirements? Need fully automatic, semi-automatic, or assembly line? Please feel free to propose, Agera can “develop and customize” for you.

Title: Hot forming steel + bolt projection welding machine – Galvanized plate + bolt projection welding machine success case – Suzhou Agera

Key words: bolt automatic projection welding station, galvanized bolt projection welding machine

Description: bolt energy storage convex welding machine is a double head welding machine developed by Suzhou Agera according to customer requirements, the equipment has the functions of blowing, slag removal, detection, automatic alarm of missing welding and wrong welding. Good appearance after welding.