Copper bar brazing detection integrated welding machine

1. Customer background and pain points

Wenzhou FD is because it took over the OEM project of new energy vehicles, which was developed by Bosch in India and manufactured by FD; and the production requirements are high, the inspection standards are high, the life cycle is long, and the number of platform parts is extremely large:

1. High precision requirements and large monthly supply: the old equipment is purely handmade, the precision cannot beat the long production cycle, and the quality cannot be controlled;

2. The welding position of the brazing piece is high: the position degree of the brazing piece after welding is ±0.1, the difficulty of manual inspection is high, and the inspection quality cannot be guaranteed;

3. Strict requirements for post-welding overflow: After brazing the copper bar, it is necessary to ensure overflow on both sides, and there must be no weld scars and weld bumps on the overflow.

4. The equipment has high precision and a high degree of automation: Bosch requires fully automatic welding and cutting, and no personnel can participate in production and testing;

5. All key data shall be kept for more than 2 years: Since the product produced is the motor part of the new energy vehicle, which involves customs inspection parts, it is necessary to ensure that the welding process is monitored throughout the welding process and the key data shall be preserved;

     The above five problems caused headaches for customers, and they have been looking for solutions.

2. Customers have high requirements for equipment

     According to the product characteristics and past experience, the customer and our sales engineer put forward the following requirements for the new customized equipment after discussion:

1. Meet the welding cycle requirements of 15S one piece;

2. The position of the brazing piece after welding meets the requirements of the drawing;

3. Adjust the welding process and accurately control the heat required for welding;

4. The movement of the manipulator and the servo motor is used to ensure the accuracy, and the CCD detection is used to ensure the inspection of the finished product after welding;

5. Independently develop the MES data system, and save the key welding time, welding pressure, welding displacement and welding temperature to the database.

According to customer requirements, conventional resistance welding machines and design ideas cannot be realized at all, what should I do?

3. According to the needs of customers, research and develop a custom copper bar brazing detection integrated welding machine

According to various requirements put forward by customers, the company’s R&D department, welding technology department, and sales department jointly held a new project research and development meeting to discuss technology, fixtures, structures, positioning methods, and configurations, list key risk points, and make one by one. For the solution, the basic direction and technical details are determined as follows:

1. Equipment type selection: First, due to the customer’s process requirements, the welding technologist and the R&D engineer will discuss and determine the model of the intermediate frequency inverter DC welding machine with a heavy-duty fuselage: ADB-260.

2. Advantages of the overall equipment:

1) High yield and beat saving: the welding power source adopts inverter DC welding power source, which has short discharge time, fast climbing speed and DC output, ensuring the overflow of both sides after welding;

2) Automatic loading and unloading, automatic welding, the equipment adopts manual pendulum loading, and 5 plates of material can be placed at a time, which can meet the equipment production of 2H, reduce labor costs, and can ensure the consistency of products;

3) High equipment stability: The core components are imported configurations, Siemens PLC is used to integrate the control system independently developed by our company, the network bus control, and fault self-diagnosis ensure the reliability and stability of the equipment, and the whole welding process can be traced. In case of missing welding or wrong welding, the equipment will automatically alarm and save the SMES system;

4) With CCD self-inspection function to ensure quality: add CCD photo inspection system to ensure the welding quality of the product. When NG products appear, it will be automatically eliminated without stopping the machine to improve welding efficiency;

5) The overall sealing of the equipment: the overall safety protection of the equipment is equipped with a water-cooled smoking device to meet the use of dust-free workshops;

Anjia fully discussed the above technical solutions and details with the customer, and signed the “Technical Agreement” after the two parties reached an agreement, as the standard for equipment R&D, design, manufacturing, and acceptance, and reached an order agreement with Wenzhou FD Company on October 31, 2022 .

4. Rapid design, on-time delivery, and professional after-sales service have won praise from customers!

After confirming the equipment technical agreement and signing the contract, the 90-day delivery period for such fully automatic newly developed welding equipment is indeed very tight. Anjia’s project manager immediately held a production project kick-off meeting to determine the mechanical design, electrical design, and mechanical processing. , Outsourced parts, assembly, joint debugging time node and customer’s pre-acceptance, rectification, general inspection and delivery time, and orderly dispatch work orders of each department through the ERP system, and supervise and follow up the work progress of each department.

In the past 90 days, the automatic brazing equipment for copper bars customized by Wenzhou FD has finally been completed. Our professional technical service personnel have undergone 10 days of installation, commissioning, technology, operation, and training at the customer site. The equipment has been put into production normally and has all reached customer acceptance criteria. Customers are very satisfied with the actual production and welding effect of the copper bar automatic brazing equipment, which has helped them improve production efficiency, solve the problem of yield rate, save labor, and ensure product consistency and stability, which has been well received by them!

5. Meeting your customization requirements is Anjia’s growth mission!

    Customers are our mentors, 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 ask, Anjia can “develop and customize” for you.