New Energy Automobile Copper Braided Wire Square Forming Automatic Welding Machine

TK Company was established in China in 1998. It is one of the industrial enterprises in the United States and is engaged in automotive connection, high-voltage electrical appliances, electrical and other industries. TK Company is well-known for its innovative and cutting-edge products and system solutions, and is also one of the world’s largest automotive technology suppliers. In March 2023, TK Company required Suzhou Agera to develop an all-in-one copper braided wire forming and shearing machine according to the requirements. The equipment adopts an automatic wire pulling mechanism and an automatic cutting module, which can meet the 12S rhythm, add a quality management system, and CCD photography and inspection functions. , a welding machine that can ensure welding quality. The following is the scene when customers found us:

1. Customer background and pain points

TK took over the product of the German luxury brand AD project, which requires high precision, high production requirements, high inspection standards, large quantities, fast pace, and less manual participation:

1.1 High accuracy requirements: The development of new products requires industry-leading dimensional accuracy, and TK does not have equipment samples on site.

1.2 High production requirements: the product is required not to be deformed, the cutting surface cannot have R and C angles, and the size of the two-stage square forming is required to be 0.5mm.

1.3 Fast pace and high degree of automation: TK requires fully automatic welding and blanking, minimizing human participation and achieving fool-like operation;

1.4 All key data need to be saved: Since the products produced are accessories for new energy vehicles and involve customs inspection parts, the entire welding process must be monitored and key data must be saved;

    The above four problems give customers a headache and they are always looking for solutions.

2. Customers have high requirements for equipment

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

2.1 Meet the welding rhythm requirement of 12S piece;

2.2 Meet the drawing requirements after pressing and forming;

2.3 Automatic square pressing and automatic cutting after manual feeding;

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

According to customer requirements, conventional resistance welding machines and design ideas simply cannot be achieved. What should I do?

3. According to customer needs, develop customized copper braided wire forming and cutting all-in-one machine

According to various requirements put forward by 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 method, and configuration, list the key risk points, and make decisions one by one. The solution, the basic direction and technical details are determined as follows:

3.1 Equipment selection: First of all, due to the customer’s process requirements, the welding technician and the R&D engineer discussed together to determine the model of the medium-frequency inverter DC welding machine with a heavy-duty body: ADB-920.

3.2 Advantages of the overall equipment:

3.2.1 High yield rate, saving beats: The welding power source adopts inverter DC welding power source, which has short discharge time, fast climbing speed and DC output to ensure the thickness after pressing;

3.2.2 Automatic welding, high efficiency and fast speed: the equipment uses manual loading of coil materials, and automatic square cutting can ensure the consistency of the product;

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

3.2.4 Overall sealing of the equipment: The entire equipment is protected for safety and equipped with internal and external water cooling systems to meet the requirements of dust-free workshops;

Agera fully discussed the above technical plan and details with the customer. After the two parties reached an agreement, they signed a “Technical Agreement” as the standard for equipment development, design, manufacturing, and acceptance. Agera reached an order agreement with TK Company on March 30, 2023.

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

After confirming the equipment technology agreement and signing the contract, the 100-day delivery time for the fully automatic newly developed welding equipment was indeed very tight. Agera’s project manager immediately held a production project kick-off meeting and determined the mechanical design, electrical design, and mechanical processing. , outsourced parts, assembly, joint debugging time points and pre-acceptance, rectification, general inspection and delivery time when customers come to the factory, and arrange work orders for each department in an orderly manner through the ERP system, supervise and follow up the work progress of each department.

100 days have passed, and TK’s customized copper braided wire forming and cutting all-in-one machine has finally been completed. After 30 days of installation, debugging, technology, operation, and training by our professional technical service personnel at the customer’s site, the equipment has been put into production normally and is fully operational. Reached customer acceptance criteria. Customers are very satisfied with the actual production and welding results of the copper braided wire forming and shearing all-in-one machine. It has helped them improve production efficiency, solve yield problems, save labor, and ensure product consistency and stability, which has been well received by them!