Automatic Projection Welding Machine for Dishwasher Bracket

一、Customer Background and Pain Points

YJ Group Company specializes in injection molding. In order to better meet customer needs, customers need to complete welding and injection molding together, and directly deliver samples of finished products. Many product varieties require multi-station welding, and require multiple points for one-time welding. The post-welding position, deformation and precision are controlled within 0.2 . Traditional welding equipment has the following problems:

1、Low welding efficiency: The old production process has been using power frequency AC welding, and the welding efficiency is low;

2、Poor welding appearance: Due to the AC, the current output is unstable, and there is a zero-crossing effect, and the welding appearance and quality cannot be guaranteed;

3、The customer is not familiar with the resistance welding process; due to long-term engagement in the injection molding industry, the customer is not familiar with the resistance welding process , and the quality requirements after welding are so high.

4、Poor precision and low yield: When welding the bracket, the requirements of multiple solder joints cannot be met at one time, and multiple clamping and welding are required, resulting in the appearance and position not meeting the final customer’s needs. The customer has inspected many resistance welding manufacturers in Hebei, Suzhou, Shanghai, Zhejiang, Guangzhou and other places, hoping to get a proper solution. In the end, the customer chose Anjia to jointly develop the solution.

The above four problems, the customer is very headache, has been looking for a solution.

二、Customers have high requirements for equipment

    According to the product characteristics and past experience, the customer and our sales engineer put forward the following requirements for the new customized equipment after discussion:

1. Pull-off force requirements after welding;
2. Meet the assembly precision requirements after welding;
3. Can not be blackened after welding, and the bonding gap is ≤0.2mm ;
4. The equipment requires multi-point welding to be completed at one time; 

5. To meet the safety requirements, start with both hands, and add safety doors, safety gratings, and fixtures for easy replacement;

6. For the problem of yield rate, add a quality management system to the original equipment to ensure that the welding yield rate can reach 99.99% .

According to customer requirements, conventional projection welding machines and design ideas cannot be realized at all, what should I do?

Make pictures yourself ;

3. According to customer needs, develop a customized automatic projection welding machine for dishwasher brackets

According to various requirements put forward by customers, the company’s R&D department, welding technology department, and sales department jointly held a new project research and development meeting to discuss technology, fixtures, structures, positioning methods, configurations, list key risk points, and make one by one. For the solution, the basic direction and technical details are determined as follows:

1. Equipment type selection: First, due to the customer’s process requirements, the welding technologist and the R&D engineer will discuss and determine the model of the intermediate frequency inverter DC welding machine with a heavy-duty body: AD B - 180*2 .

2. Advantages of the overall equipment:

1) High yield rate: Bosch Rexroth welding power source is adopted, with fast discharge, high climbing speed, and DC output to ensure welding quality. The good product rate is over 99.99%;

2) Intelligent alarm device: automatic monitoring of missing welding and wrong welding, counting the number of nuts, and automatic alarm for abnormalities;

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4) Diversified tooling and fixture replacement: We introduce the tooling identification function to ensure the stability of welding quality according to the diverse needs of customers. The design of the tooling fixture is flexible, the replacement is simple and convenient, the operation time is saved, the work efficiency is greatly improved, and the safety of the operator during the replacement process is guaranteed.

5) Fully guarantee the operation safety: the equipment is equipped with a two-hand start device, and the equipment can only be started when both hands press the start button at the same time, effectively preventing potential safety hazards caused by misoperation. At the same time, the equipment is equipped with a safety door and a safety grating. Once someone approaches or enters the dangerous area, the equipment will stop running immediately, ensuring the safety of the operator and the working environment in all aspects .

6) Stable and reliable: adopt imported core components, such as Siemens, etc., combined with our company’s self-developed PLC control system, network bus control, fault self-diagnosis, to ensure equipment stability, to achieve full welding traceability and docking with the MES system;

Anjia fully discussed the above technical solutions and details with the customer, and after the two parties reached an agreement, they signed the “Technical Agreement” as the standard for equipment R&D, design, manufacturing, and acceptance, and reached an order agreement with Mercury on June 13, 2021 .

4. Rapid design, on-time delivery, and professional after-sales service have won praise from customers!

After confirming the equipment technology agreement and signing the contract, the 60- day delivery period was indeed very tight. The project manager of Anjia immediately held a production project kick-off meeting, and determined the mechanical design, electrical design, mechanical processing, purchased parts, assembly, and joint production. Adjust the time node and the customer’s pre-acceptance, rectification, general inspection and delivery time, and orderly dispatch work orders of each department through the ERP system, and supervise and follow up the work progress of each department.

In the past 70 days, the automatic projection welding machine for the dishwasher bracket customized by the customer was finally completed. The customer came to our company for proofing and learning. After 5 days of installation, commissioning, technology, operation and training, the equipment has reached the customer’s acceptance standard. Successful acceptance. The customer is very satisfied with the actual production and welding effect of the automatic projection welding machine for the dishwasher bracket . It has helped them improve production efficiency, solve the problem of yield rate, and save labor, which has been well received by them!

5. Meeting your customization requirements is Anjia’s growth mission!

   Customers are our mentors, what material do you need to weld? What welding process do you need? What welding requirements? Need fully automatic, semi-automatic, or assembly line? Please feel free to ask, Anjia can “develop and customize” for you.

Title: Successful Case of Automatic Projection Welding Machine for Dishwasher Bracket -Suzhou Anjia

Key words: window swing bracket welding machine, double-headed window swing bracket welder, automobile window swing bracket welder;

Description: The intermediate frequency DC double-head ring convex welding machine is a double-head nut welding machine developed by Suzhou Anjia according to customer requirements . The equipment has the function of detection, automatic alarm for missing welding and wrong welding . Safety protection; the product does not turn black after welding .