Car seat slide rail bracket automatic hot riveting welding line is customized by Suzhou Anjia to weld car seat bow and swivel bracket. The entire line is automatically loaded and unloaded, robotic arm operation, automatic identification and positioning, automatic welding, intelligent control. For quality inspection, the entire line only needs one person to operate online, which basically realizes artificial intelligence. It has the characteristics of high efficiency, high yield, and solving the problems of workers' difficulty in loading and unloading.
I. Customer background and pain points
ADT Group is the world's leading manufacturer of automotive seats and a leading company in the automotive seat industry, supplying major auto manufacturers in the world. At present, it is necessary to use a fully automatic auto seat riveting welding line for car seat bow and rotating bracket. The original equipment has the following problems:
1. Welding products have many specifications and long changeover time : the original double-head hot riveting equipment was used. It was difficult to change the product type and replace the electrode. The tooling replacement time was too long.
2. Low yield rate : due to the manual placement during welding, the consistency of the product after hot riveting is not good, there are many post-weld deformations, etc., and the quality problems of leaked products are even more serious;
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. According to the product quality, the welding process and the analysis of the beat are given in an assembly line, without increasing the heat.
Under the premise of the riveting welding machine, the efficiency of the welding equipment is maximized, and the yield of the equipment is improved to prevent leakage of leaked products;
2. Products of different specifications can be produced on one welding line without changing tooling;
3. Pipeline beat: 12S / pcs;
4. Solve the problems of high labor intensity and poor welding consistency;
5. The finished product rate must reach 99%;
6. The production capacity has been increased from 1200 pieces per shift to 2600 pieces per shift.
According to customer requirements, conventional projection welding machines and design ideas cannot be realized at all, what should I do?
Third, according to customer needs, research and develop custom slide rail bracket hot riveting welding line
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, automatic loading and unloading of the entire line, robotic arm operation, automatic identification and positioning, automatic welding, intelligent control and quality inspection. The entire line only requires one person to operate online, and artificial intelligence has basically been realized. 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 ADT for different product components and welding requirements: ADB-160 also customizes different welding positioning fixtures according to each product design, and uses a single-head Dr. welding power source, which can realize the production of different products in-line, and solves the problem of poor product compatibility.
2. The advantages of hot riveting welding line:
，因自动上料自动焊接，自动下料，大大提高生产效率，产能由原来每班的1200件提升到目前的每班2600件，节拍11S/pcs； 1) High yield : Welding power supply uses IF inverter power supply, short discharge time, fast climbing speed, and DC output. Due to the double-headed single power supply, the power can be discharged at the same time, which ensures that the product is flat and not deformed after welding. Degree, to ensure welding quality, the finished product rate is above 99.99% . Due to automatic loading and automatic welding, automatic cutting, which greatly improves production efficiency. The production capacity has been increased from 1200 pieces per shift to 2600 pieces per shift at present, with a beat of 11S / pcs. ;
2), to solve the problem of workpiece loading, the staff only needs to put the workpiece in the guide rail : the guide pad bracket is automatically screened by the automatic material selection and selection system, conveyed by the robotic arm to the station to be welded, and the guide rail is manually placed on the assembly line. Precisely placed on the jig for hot riveting. After hot riveting, the automatic discharge is left in the material box. The labor intensity is reduced, and only one worker needs to complete one assembly line.
3) Equipment stability : The equipment adopts all imported core components. The equipment welding power source adopts the Dr. brand with Advantech industrial computer and the control system independently developed by our company. Network bus control and fault self-diagnosis ensure the reliability and reliability of the equipment. Stability, the whole welding process can be traced, and can be docked with ERP system;
； 4) Solve the problem of difficult discharging and many people complaining after the welding is completed : our hot riveting line adopts the feeding structure and automatic mold changing structure. After the welding is completed, the workpiece automatically falls to the material frame, and the worker only needs to place the workpiece on the assembly line. Yes, there is no need to unload the material, and the problem of high labor intensity and complaints is solved ;
5) Improved production efficiency and guaranteed welding quality : The equipment is highly intelligent, and can automatically identify whether the hot riveting is at a reasonable height, whether the guide rails and brackets are in place, whether the welding quality is qualified, and all parameters can be exported, and the wrong equipment can be reversely detected. Automatic alarm and docking with the waste system to ensure that no outflow of waste will occur;
Anjia fully discussed the above technical solutions, details and ADT. After the two parties reached an agreement, they signed the "Technical Agreement" as the standard for equipment R & D, design, manufacturing, and acceptance. Our professional technology and meticulous service moved customers and An order agreement was reached with ADT on April 17, 2018.
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 90-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, 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.
90 days later, the ADT custom-made auto seat riveting line for car seat slide brackets has been successfully completed. Our professional after-sales service has been installed and commissioned at the customer's site for 7 days, as well as technical, operation, and maintenance training. The equipment has been put into operation normally. Production and all reached the customer's acceptance standards.
ADT is very satisfied with the actual production and welding effect of the automatic hot riveting line of the car seat slide rail bracket, which has helped them improve production efficiency, solve the problem of yield, save labor, and lay a "unmanned" factory for customers Basic, 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 submit, Suzhou Anjia can " research and develop " for you.
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