Suzhou YM Group Corporation is the world's leading manufacturer of door products and industry leader. Its products cover industrial and household uses. Now it is necessary to use a fully automatic steel door frame spot welding assembly line. The original welding equipment has the following problems:
1. Welding products have many specifications and poor compatibility : the welding line cannot be compatible with the welding of door frames of various specifications;
2. Low yield : the original spot welding machine is an AC machine, and single-head welding, welding is uneven, needs to be polished, manual waste, product quality cannot be guaranteed after welding, and the yield is low;
3. The intelligent flow operation is not realized, the production efficiency is low, and the staff complains a lot : because of manual arc welding, which is also used for the frame pull plate, the efficiency is low, and the environmental pollution is serious. Heavy, carrying load operation, complaining a lot, and low efficiency;
The customers of the above three issues are very distressed and have not been able to find a solution.
According to product characteristics and past experience, after discussing with our sales engineers, the following requirements for the new customized equipment are put forward:
1. The entire line of equipment is customized to realize the product welding assembly line operation. Nine sets of equipment are required for one line, and only an operator at the welding place is required. The workpieces are transported to the various stations by the assembly line.
2, 8 products need to be completed on a welding line, of which there are nearly 30 welding parts;
3. Pipeline beat: 60S / pcs;
4.Solve the problem of sanding of the frame pull plate, welding flatness and welding strength of other products;
5.The yield must be 99.99%;
6.Production efficiency needs to be increased by 30% on the original basis.
According to the requirements of customers, according to the conventional projection welding machine and design ideas can not be achieved at all, what should I do?
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 of welding automatic flow operation, and made the following process sequence:
，可实现两边同时焊接， 保证了产品的焊后的平整及牢度，保证焊接品质，并减少了打磨工序; 2. Equipment selection and fixture customization : According to the workpieces and dimensions provided by the customer, our welding technicians and R & D engineers discuss together and select different models based on the original HM for different product components and welding requirements. : ADB-160, ADB-320, at the same time, different welding positioning fixtures are customized according to the design of each product, and both heads and dual power sources are used to achieve simultaneous welding on both sides, ensuring the flatness and fastness of the product after welding, and ensuring welding Quality and reduced grinding process;
3. Advantages of automatic welding line :
1) High yield : Welding power supply uses IF inverter power supply, short discharge time, fast climbing speed, and DC output. Single-sided and double-headed welding is achieved due to the double-headed and double-powered supply, which ensures the flatness and fastness of the product after welding. Guarantee welding quality and reduce grinding process, the finished product rate is over 99.99%;
2) Solve the waste of equipment and use one machine for multiple purposes : Because the welding machine has added a servo control system, it can accurately control the welding of multiple specifications of products. At the same time, the welding fixture is designed with different tooling fixtures according to different specifications of the product to ensure that the machine is multi-purpose and saves The use of equipment is wasted, and the problem of having to use multiple pipelines is solved;
3) Equipment stability : The equipment uses all imported core components for configuration, and uses our own independently developed control system, network bus control and fault self-diagnosis to ensure the reliability and stability of the equipment;
4) Solve the welding problem of frame drawing plate : We have implemented the projection welding process of frame drawing plate, which reduces the grinding time after welding and improves production efficiency;
5) The intelligent control of the assembly line reduces the operating requirements of employees: the assembly line has the function of self-testing whether the product requires welding, and it automatically flows to the next station without welding, realizing intelligent control, and automatically scanning code to identify the welding station and welding The parameters are convenient for controlling the quality of welding products, realizing intelligent operation, reducing the operating requirements of employees , and eliminating the need for professional welders, ordinary workers can operate, reducing personnel costs;
6) Improved production efficiency : As the equipment realizes automatic assembly line operation, reducing the work intensity of personnel, the entire line has improved welding efficiency by 40% on the original standard machine operation , and the assembly line has achieved 57S / pcs cycle. See the detailed operation arrangement of the following pipeline: