The special projection welding machine for seat side plate is an automatic special projection welding machine tailored by Suzhou Anjia according to customer requirements, according to the material and process requirements of the welding product. It has the characteristics of no need to return teeth after welding, strength can be pulled through the base material, high efficiency, strong equipment compatibility and so on. The scene when the customer found us was:
I. Customer background and pain points
Ningbo SL Auto Parts Co., Ltd. is a joint-stock enterprise manufacturing auto parts. Its main products are car seat systems, automotive interior and exterior trim parts, automotive engine peripherals, and automotive molds. The connection of these automotive metal parts requires spot welding and projection. weld. The main supporting customers of the seat system SL are GM, Volkswagen, Ford and Changan. In particular, through cooperation with Brose, the seat has become SL's flagship product in recent years. The seat is a safety component and the parts are mostly fine-brushed components. The materials are mostly high-strength steels, so the welding requirements are quite high. The main plant will list the side plate welding as the main process during the review. The seat parts supplied before SL are mostly stamped parts. Assembly, therefore, a complete set of special equipment for side plate projection welding is urgently needed to solve the current problems. The problems encountered are:
• The OEM stated that the welding of the side plates was Applas welding, and no one at SL knew this process;
• SL has been tested many times on the original welding machine in Ningbo factory, and the strength cannot meet the customer's requirements;
• Tested on a third-party welding machine. After the strength reaches the standard, there is too much extrudate and the appearance cannot meet the standard;
• Submit small batches after manual TIG welding, the amount of deformation after welding is too large, and the inspection tool cannot pass;
• Welding efficiency is low, and the single-machine CT after the initial test cannot meet the annual capacity requirements;
• High security requirements, safety regulations are the first audit item when the OEM audits, the original equipment and third-party equipment cannot provide the security guarantee to meet their customers;
• According to the production capacity of the main engine factory, at least four welding lines are required, but the power space of the factory is already limited, and it is necessary to consider that it cannot be overloaded after full production in the future;
Second, customers have high requirements for equipment
Ningbo SL put forward the following requirements for the new customized equipment after discussing with our sales engineers based on the customer suggestions and test cases:
1. Satisfy the requirements of Aplas welding, and recommend a reasonable model;
2. After welding, the strength meets the requirements of the drawing, and the ribs can be pulled through the base metal;
3. The surface of the side plate is flat after welding, and no grinding is required after welding;
4. There is no need to return teeth after welding the side plates, and the screw teeth of the small bracket cannot be damaged and extruded;
5. Each dimension of the side plate must meet the requirements of the drawing after welding, and go through the full inspection;
6. Simultaneously meet the interchange of three different specifications products;
7. Need to increase welding efficiency by 50% to reach 13 seconds / piece;
8. The whole machine meets the safety requirements of German-funded OEMs;
9. The energy consumption of the whole machine is controlled at 60% of the field equipment, and it has the function of time-sharing control to meet the power load of the factory when the four complete lines are put into production in the future;
According to the requirements of customers, ordinary standard spot welding machines cannot be realized at all, what should I do?
3. According to customer needs, research and development of customized seat side panel projection welding machine
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. The model is recommended to be accurate : This product meets the characteristics of narrow ribs of Aplas welding. It needs to be welded with hard specifications. A capacitor energy storage welding machine is the best solution. The power is selected as ADR-30000 energy storage convex. welder;
； 2. Guarantee welding strength : Passed the verification in our company's capacitor energy storage welding machine, it fully meets the welding strength requirements of the side plate ribs, and can be pulled through the base material ;
，同时降低了电极的消耗； 3. No need to polish, the product is beautiful : the largest electrode contact surface is simulated by 3D, the largest possible increase in conductive area in a limited space, to achieve the input of current and heat dissipation, to meet the beautiful surface of the product, no need to polish , At the same time, the consumption of the electrode is reduced;
； 4. No need to return teeth after welding : Through the strong standard process, the production of extrudates can be reduced under the premise of ensuring the strength. At the same time, the lower electrode is compressed with air. Passing of teeth improves welding quality ;
； 5. Dimensional guarantee : through 3D design software analysis and simulation, to ensure all the basic requirements of the workpiece, matching the size of the drawing to meet the tolerance range of the product, can pass the inspection tool smoothly, and ensure that the size of the welded product reaches the requirements of the drawing ;
； 6. Good interchangeability of fixtures : realize the interchange of different side plate fixtures, fast replacement through positioning pins and clamping mechanism on the fixture bottom plate, fast replacement through gas-water fast-connecting joints, and sensor lines and control lines using aviation The plug-in form is fast and real-time, so that the fixture can be quickly switched in 1 minute and 30 seconds ;
； 7. Improve efficiency : adopt double-station, left-right translation, reduce the number of clamping times, increase the utilization of welding machine, improve welding efficiency, and control the beat within 13 seconds ;
8. Safety requirements : use two-hand pressing system, grating and aluminum alloy fence to protect the operator; increase the displacement sensor of the welding machine to detect the workpiece in place and detect the penetration depth after welding; welding machine configuration phase loss and network pressure detection, welding machine is equipped with air pressure switch Testing and water pressure testing to ensure that the equipment starts to work under normal conditions; the welding machine is equipped with transformer over-temperature detection and current over-limit detection to ensure the safe and stable output of the equipment;
； 9. Energy saving and cost reduction: The capacitor energy storage power supply has the lowest power demand in the existing spot welding equipment. We use a new technology, namely constant current charging, to reduce the peak current and control the energy consumption to the minimum while ensuring the charging speed; and Set up time-sharing control ports to ensure that the demand for power will not increase when more production lines are invested in the future; the overall energy saving is more than 60% ;
Anjia fully discussed the above technical solutions, details and SL. After the two sides reached an agreement, they signed a "Technical Agreement" as the standard for equipment R & D, design, manufacturing, and acceptance, because our comprehensive consideration and help customers solve problems, and in 2019 An order agreement was reached with SL on June 1.
7, the overall process diagram of the project:
(Overall process diagram)
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 30 working days in a flash, the SL customized seat side panel automatic special projection welding machine was finally completed after aging test. Our professional after-sales service has been installed and commissioned and technical, operation and maintenance training at the customer site for 2 days. Equipment Has been put into production normally and all meet the customer's acceptance standards. SL Company is very satisfied with the actual production and welding effect of the automatic special projection welding machine for seat side panels, helping them meet product strength requirements, improve welding quality, improve production efficiency, and save 60% of energy, which has been highly recognized and praised by them. !!
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.
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