Robot Nut Projection Welding Workstation

1. Customer background and pain points

      Changzhou BR Company is an auto parts manufacturer. It mainly supports SAIC, Volkswagen and other OEMs. It mainly produces small sheet metal parts. There is a bracket projection welding ready for mass production. Because it is a platform part, the quantity is not large. During the early production Have the following questions:

1. The labor intensity of personnel is high. In order to meet the needs of production capacity, personnel work continuously throughout the shift, and the loss of personnel is serious;

2. Insufficient welding or reverse welding occurs at the welding site, and quality accidents occur that the main engine factory cannot load;

3. There are standard parts of nuts of various specifications on site, which is very prone to mixed materials, resulting in mixed welding of nuts;

4. The artificial production efficiency is too low, and the personnel need to continuously pour materials, and the personnel training period is long;

5. The main engine factory needs the product to have data traceability function, and the on-site stand-alone machine cannot be connected to the factory’s MES system;

The customer is very distressed by the above 4 points, and has not been able to find a solution.

2. Customers have high requirements for equipment

    After encountering problems in the early stage of production, Changzhou BR Company found us to assist in the development and solution in June 2022 through the introduction of the OEM, discussed with our project engineer, and proposed to customize special equipment with the following requirements:

1. The automatic projection welding workstation is adopted, and the receiving robot realizes the pick-up and unloading;

2. Equipped with a nut detector to prevent mistakes in nut welding and count automatically;

3. Adopt automatic nut conveyor, automatic screening and conveying;

4. Adopt the form of palletizing and refill once in about half an hour;

5. The new projection welding equipment has the ports and data collection required by intelligent factories.

   According to the requirements put forward by the customer, the existing equipment cannot be realized at all, what should I do?

3. According to customer needs, research and develop robot nut projection welding workstation

     According to the 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 the process, structure, power feeding method, detection and control method, list key risk points, and do one by one After the solution, the basic direction and technical details are determined as follows:

1. Process confirmation: Anjia’s welding technologist made a simple fixture for proofing at the fastest speed, and used our existing projection welding machine for proofing and testing. After the tests of both parties, it met the technical requirements of BR Company and determined the welding parameters. Final selection of intermediate frequency inverter DC power supply;

2. Welding scheme: R&D engineers and welding technologists communicated together and determined the final robot nut projection welding scheme according to customer requirements, which consists of intermediate frequency inverter DC projection welding machine, robot, gripper, automatic feeding table, and nut conveyor. , Nut detector and upper computer and other institutions;

3. Advantages of the whole station equipment solution:

1) The four-axis robot is used to replace manual work, and the gripper is used to automatically pick and place the workpiece, and the working state can achieve the effect of unmanned black light;

2) Equipped with a nut detector, which is used for leak prevention and error prevention of nuts, and conducts penetration detection after welding to ensure that an alarm can be issued to stop the machine if there is an abnormality, so that unqualified products will not flow out and quality accidents will be avoided;

3) Equipped with a nut conveyor, which is screened by a vibrating plate and delivered by a conveying gun to ensure that the product will not be mixed;

4) Equipped with an automatic palletizing and loading table, the left and right multi-stations are used to simultaneously load the material, and ordinary workers can replenish the material once an hour;

5) Adopt the host computer quality management system to automatically transmit the welding parameters and corresponding inspection data of the product to the host computer system, and have the data and ports required by the EMS system of the intelligent chemical factory;

4. Delivery time: 50 working days.

An Jia discussed the above technical plan and details with BR Company in detail, and finally the two parties reached an agreement and signed the “Technical Agreement”, which was used as the standard for equipment R&D, design, manufacturing and acceptance, and signed an equipment order contract with BS Company in July 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, Anjia’s project manager held the production project start-up meeting immediately, and determined the time nodes of mechanical design, electrical design, machining, purchased parts, assembly, joint debugging and customer’s pre-acceptance at the factory , rectification, general inspection and delivery time, and through the ERP system orderly dispatch work orders of each department, supervise and follow up the work progress of each department.

Time passed quickly, and 50 working days passed quickly. BR Company’s customized robot nut projection welding workstation was completed after the aging test. After a week of installation and commissioning and technical, operation and maintenance training at the customer site by our professional after-sales engineers , the equipment has been put into production normally and all have reached the customer’s acceptance criteria. BR company is very satisfied with the actual production and welding effect of the robot nut projection welding workstation, which helped them solve the problem of welding efficiency, improve product quality, save labor costs and promote the implementation of intelligent chemical factories, and gave us Anjia great recognition And praise!

5. It is Anjia’s growth mission to meet your customization requirements!

    Customers are our mentors, what material do you need to weld? What welding process is required? What welding requirements? Need fully automatic, semi-automatic, or assembly line? Please feel free to ask, Anjia can “develop and customize” for you.