The automatic spot welding production line for the air conditioner base plate mounting ears is a fully automatic spot welding production line for welding air conditioner floor plates and mounting ears tailored by Suzhou Anjia for customers. Only 2 people need to be online, reducing 12 manual workers, and helping customers basically realize artificial intelligence.
I. Customer background and pain points
KK company is engaged in the manufacture of white goods, and is a local benchmark manufacturer. Long-term and beautiful household appliances such as Gree, Haier and other leading manufacturers supply manufacturing and processing parts. For the welding of the mounting ears of the bottom plate of the existing air conditioner, the welding of the existing equipment encountered the following problems:
1. The welding efficiency is particularly low : each workpiece has 4 welding positions, and it is difficult to locate manually. The relative position of each point is required to be no more than 1mm, and the assembly is difficult.
2. Welding stability : The workpiece itself is galvanized, and the stability of welding has been improved by another grade. Workers need to spend time to ensure the consistency of welding, which affects the welding cycle.
3. The appearance of the fastness is not up to standard : After the welding of the workpiece is completed, it needs to be installed and fixed externally. The entire bearing weight must be ensured by the welding position. There are certain requirements for the welding fastness. The quality of manual welding is unstable and there are often false welding phenomena , Fastness cannot be guaranteed.
For the above three problems, customers have been having a headache and cannot find a solution.
Second, customers have high requirements for equipment
KK found us online on August 1, 2019, discussed with our sales engineers and wanted to customize the welding machine with the following requirements:
1. The welding efficiency is required to be increased by 100% on the original basis;
2. The appearance qualification rate should be increased by 70% on the original basis;
3. Solve the problem of welding instability;
4. Originally required 14 people for operation, and now needs to be reduced to 4 people;
According to the requirements of customers, the existing standard spot welding machine cannot be realized at all, what should I do?
3. Develop customized automatic spot welding production line for mounting ears of air conditioner external machine baseplates according to customer needs
According to the customer's requirements, 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, feeding method, and configuration, list key risk points, and make one by one The solution, the basic direction and technical details are determined as follows:
1. According to the above requirements, we basically determined the plan, the entire line automatically loading and unloading, to achieve the entire line of robot operation, automatic welding, the entire line only requires 4 people to operate online, basically realized artificial intelligence, and made the following process sequence :
2. Workpiece proofing test : Anjia Welding Technician made a simple fixture for proofing at the fastest speed. We used our existing intermediate frequency welding machine for proofing test. After 5 days of back-and-forth test and drawing test by both parties, it was basically determined. Welding parameters
3. Welder power source selection : R & D engineers and welding technologists communicated together and calculated the selection power according to customer requirements. Finally, it was confirmed as ADB-160 * 2 intermediate frequency power supply;
4, the stability of the welding line : our company uses all the core components "into the product configuration";
5. Advantages of automatic welding line :
1) Fully automatic welding, reducing labor and ensuring welding stability : This welding line is used for automatic welding of air conditioner bottom plates and mounting ears. It uses an automatic conveying mechanism and is configured to use IF power sources to weld both sides of the brackets at the same time. The air conditioner floor uses robots. Automatically pick up from the loading bin, and then transfer it to the welding station. The mounting ears on both sides are automatically pushed to the station using a vibrating disk, and then welding is started. After the welding is completed, the workpiece is transferred to the unloading station and picked up by the robot. To the unloading bin, no human intervention is needed in the middle, which reduces welding instability caused by human factors, ensures welding quality, reduces labor, and realizes the original need of 14 people for welding. Now only 2 people are required for the whole process, which reduces 12 manual labor.
； 2) Process innovation, fastness and appearance, and energy saving : According to the welding characteristics of galvanized sheet, Anjia process engineers passed various tests and finally changed the original welding process. We adopted the new special process of galvanized sheet. We chose intermediate frequency Inverter power supply, short discharge time, fast climbing speed, and DC output make the production more stable and fast. At the same time, it guarantees the fastness and appearance of the welded product. The pass rate reaches 99.99% and energy saving is more than 30%. ;
3) High welding efficiency : The entire welding process is split using an assembly line method. The final positioning of a workpiece is 6 seconds, and the efficiency is increased by 200%.
6. Delivery time: 60 working days.
Anjia discussed the above technical solutions and details with KK. After the two parties reached an agreement, they signed a "Technical Agreement" as the standard for equipment R & D, design, manufacturing, and acceptance, because our thoughtfulness touched the customer. On December 12, an order agreement was reached with KK.
Fourth, fast design, on-time delivery, professional after-sales, and get praise from customers!
After confirming the equipment technical agreement and signing the contract, Anjia's project manager held the production project launch meeting as soon as possible, and confirmed the mechanical design, electrical design, machining, outsourced parts, assembly, joint adjustment time nodes and customers to come to the factory for pre-acceptance. , Rectification, general inspection and delivery time, and orderly issue work orders of each department through the ERP system, supervise and follow up the work process of each department.
After 60 working days in a flash, the KK custom-made air conditioner external machine base plate automatic spot welding automatic spot welding production line was completed after aging test. After our professional after-sales engineer passed the 7-day installation and commissioning and technical, operation and maintenance training at the customer site, The equipment has been put into production normally and all reached the customer's acceptance standards.
KK is very satisfied with the production and welding results of the automatic spot welding production line for the mounting ears of the air conditioner's bottom plate, helping them solve the welding quality problem, improve the welding efficiency, save labor, and give us full affirmation and praise!
Fifth, meeting your customization requirements is the growth mission of Anjia!
The customer is our mentor. What material do you need to weld? What welding process do you need? What welding requirements? Need full-automatic, semi-automatic, or assembly line? ”。 Despite your suggestion, Anjia can develop and customize for you.
Reprinted please indicate the source: Anjia spot welding machine 92shizhi.com ( spot welding machine manufacturer )