Automotive motor commutator automatic welding production line is an automatic spot welding production line customized by Suzhou Anjia to weld the carbon brush line and pin resistance of automotive motor commutator according to customer requirements. The welding line is assembled, welded and inspected with high efficiency , High yield, good solder joint consistency.
I. Customer background and pain points
BZ Group Corporation is the world's leading automotive electronics manufacturer and a leading automotive electronics company, supplying the world's major automotive plants. Now it is necessary to use a full-automatic automotive motor commutator automatic welding production line. The original welding equipment has the following problems:
1. Many product specifications, easy to mix: the original welding machine was used to hold the operation, it is easy to mix;
2. The yield is too low: it is easy to be partial, missed, over-welded when welding. The consistency of the workpiece after welding is too poor, and there are many customer complaints;
3. The intelligent flow operation is not realized, the production efficiency is low, and the staff complains a lot: there are many types of workpieces, and the welding tools need to be changed every time the product is changed. Low production efficiency;
The above three problems, customers have a headache, always looking for solutions.
Second, customers have high requirements for equipment
According to product characteristics and past experience, after discussing with our sales engineers, we put forward the following requirements for new customized equipment:
1. Based on the analysis of the welding process and the beat of the product, the overall workstation method using a four-station turntable plus vision with a robot arm is given;
2. Products of different specifications can be produced on one welding production line, only need to change the tooling, the time of changing the tooling is less than ten minutes;
3. Pipeline beat: 8S / pcs;
4. Solve the problems of workpiece placement, difficulty in taking materials after welding, and poor welding consistency;
5. The finished product rate needs to reach 99.99%.
6. Production capacity increased from 1100 pieces per shift to 5600 pieces per shift;
According to customer requirements, conventional welding machines and design ideas cannot be realized at all, what should I do?
3. Develop customized welding motor assembly line for automotive motor commutator 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, positioning method, assembly method, loading and unloading method, and configuration, and list the key risks. Points, and made solutions one by one, and determined the basic direction and technical details as follows:
1.According to the above requirements, we basically determined the plan. The entire line assembly welding inspection automatic flow operation, the three stations are transported by the feeding mechanism to the manual position, 4-5 people assembly, manual feeding to the conveyor belt, manual picking, Manually weld the carbon brush line, put it back on the conveyor belt, transfer it to the automatic welding station, automatically identify the tack welding (capacitor / resistance wire pin), intelligently inspect and control the quality, automatically cut the material, manually visually detect and install the plate. And made the following process sequence:
； 2. Equipment selection and fixture customization : According to the workpieces and dimensions provided by the customer, our welding technologists and R & D engineers discuss together and optimize the selected models based on the original BZ for different product components and welding requirements: ADB-75 also customizes different welding positioning fixtures according to each product design, and both adopt single-head single power supply, and single-head single power supply can realize simultaneous welding on both sides, ensuring the flatness and fastness of the product after welding, and ensuring the quality of welding. To improve welding efficiency ;
3. Advantages of welding line :
； 1) Energy saving and high yield : Welding power supply uses IF inverter power supply, short discharge time, fast climbing speed, DC output, to ensure the flatness and fastness of the product after welding, to ensure the quality of welding. Work at the same time at the same time, which saves the floor space of the equipment and greatly improves the equipment utilization rate ;
2) Solve the problem of difficult workpiece loading and reduce labor costs : labor only needs to place the track on a specific fixture to automatically position, weld, and move the welding head. 。 The labor intensity is reduced, and only one person needs to feed the carbon wiring .
； 3) Equipment stability : The equipment uses all imported core components, and the equipment welding power source uses our company's developed precision power supply in conjunction with Siemens PLC and the control system independently developed by our company. Network bus control and fault self-diagnosis ensure the reliability of the equipment. And stability, the whole welding process can be traced, and can be docked with ERP system ;
； 4) Solve the problem of difficult stripping after welding is completed : Our station adopts an automatic stripping structure. After welding is completed, the workpiece automatically falls on the assembly line. Manually, only the workpiece after welding is taken on the track to solve the problem of product welding. Unexpected problems
； 5) Welding quality is guaranteed : the equipment is highly intelligent, it can automatically identify the missing workpiece station, automatically identify the height after welding, welding quality is qualified and all parameters can be exported, can automatically detect the wrong equipment and automatically connect with the waste system, In contrast, it is guaranteed that no outflow of waste material will occur, and the finished product rate is above 99.99% ;
。 6) Optimization of production line layout, efficiency and energy saving : because of our company's consideration of the overall cycle requirements and product characteristics, the wiring harness is soft and assembled by manual loading. The position of the pin is fixed by automatic positioning and identification welding, and the welding quality is intelligently controlled. Automation, the production capacity has been increased from 1100 pieces per shift to 5600 pieces per shift, and the line rate reaches 7S / PCS .
Anjia fully discussed the above technical solutions, details and BZ. After the two parties reached an agreement, they signed the "Technical Agreement" as the standard for equipment R & D, design, manufacturing, and acceptance, because our professional technology and meticulous service moved customers, and An order agreement was reached with BZ on January 19, 2019.
Fourth, fast design, on-time delivery, professional after-sales, and get praise from customers!
After confirming the equipment technology agreement and signing the contract, the 60-day delivery period was indeed very tight. Anjia's project manager immediately held the production project launch meeting and determined the mechanical design, electrical design, mechanical processing, outsourced parts, assembly, and assembly. Time nodes and customers come to the factory to pre-accept, rectify, general inspection and delivery time, and orderly issue work orders for each department through the ERP system, and supervise and follow up the work process of each department.
After 60 days in a flash, the automatic welding line of the BZ custom-made BZ auto motor commutator has finally been completed. Our professional after-sales service has undergone 20 days of installation and commissioning and technical, operation and maintenance training at the customer site. The equipment has been put into production and All met the customer's acceptance criteria.
BZ Company is very satisfied with the actual production and welding results of the automatic welding line of automotive motor commutators, helping them improve production efficiency, solve the problem of yield, save labor, and lay the foundation for customers to build "unmanned" factories. Got their praise!
Fifth, meet 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? ”。 Please do not hesitate to mention that Anjia can " research and develop " for you.
Reprinted please indicate the source: Anjia spot welding machine 92shizhi.com ( spot welding machine manufacturer )