Automobile Shock Absorber Automatic Spot Welder And Projection Welding Machine

1. Customer background and pain points

     T Company is a world-renowned auto parts manufacturer. It provides shock absorbers and exhaust system products to major global auto brands. It provides supporting products and services to major global auto manufacturers. It is also a major force in Volkswagen, General Motors and new energy vehicle manufacturing. The main supporting supplier of the company currently has a new electronically controlled shock absorber ready for mass production. There are the following problems in the early production:

1.1 The on-site equipment structure is unreasonable, inconvenient to operate and affects safety. There are many complaints from the on-site use and maintenance departments;

1.2 The welding yield rate is not up to standard, and customers complain about welding slag and weak welding;

1.3 There are many products covered, and the tooling switching and debugging cycle is too long;

1.4 To add product codes and batch codes, the data needs to be uploaded to the factory’s MES system;

2. Customers have high requirements for equipment

   After Company T encountered problems in its early production, it was introduced by the main engine manufacturer and found us in October 2022 to assist with development and solutions. We discussed with our project engineers and proposed customizing special equipment with the following requirements:

2.1 Optimize equipment structure and increase safety protection;

2.2 Adopt new welding system and confirm new welding process;

2.3 The tooling adopts the form of quick change, and is equipped with a heavy-duty plug to automatically switch the gas and electric parts;

2.4 Add a code scanner for product codes and batch codes, and synchronously transmit the associated welding data to the factory MES system.

 According to the customer’s requirements, the existing equipment cannot be realized at all. What should we do?

3. According to customer needs, develop special projection welding machines for shock absorbers

    According to various requirements put forward by customers, the company’s R&D Department, Welding Process Department, and Sales Department jointly held a new project R&D meeting to discuss the process, structure, feed method, detection and control method, list the key risk points, and implement them one by one. The solution was worked out and the basic direction and technical details were determined as follows:

3.1 Process confirmation: Agera welding technicians made a simple fixture for proofing as quickly as possible, and used our existing projection welding machine for proofing and testing. After testing by both parties, the technical requirements of Company T were met, and the welding parameters were determined. Special projection welding machine for final selection of shock absorbers;

3.2 Welding plan: R&D engineers and welding technicians communicated together and determined the final special projection welding machine plan based on customer requirements, which consisted of a new medium-frequency inverter DC power supply, pressurizing mechanism, quick-change tooling, automatic lift doors, gratings, and sweepers. Composed of encoder and other institutions;

3.3 Advantages of the whole station equipment solution:

3.3.1 Adopting a vertical structure, the welding machine is equipped with a protective frame, and the defective product box is placed at the bottom to ensure the safety of the equipment and the processing of defective products and facilitate operation, and has been well received by the equipment and production departments;

3.3.2 Using Agera’s latest medium-frequency DC power supply, the three-stage current can be controlled separately, and the output pressure curve can be controlled to ensure that the shock absorber projection welding strength is guaranteed and there is no welding slag;

3.3.3 The tooling adopts a quick-change form to achieve floating control of the tooling, and will be equipped with a heavy-duty plug to automatically switch the gas and electric parts. The number of different bumps can automatically match the welding specifications;

3.3.4 Add a code scanning gun for product codes and batch codes, manually scan batches, and automatically scan product codes, and synchronously transmit the associated welding data to the factory MES system.

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

After confirming the equipment technical agreement and signing the contract, Agera’s project manager immediately held a production project kick-off meeting and determined the time nodes for mechanical design, electrical design, machining, outsourced parts, assembly, joint debugging and customer pre-acceptance at the factory. , rectification, general inspection and delivery time, and orderly dispatch work orders to each department through the ERP system, supervise and follow up the work progress of each department.

Time passed very quickly, 50 working days passed quickly. Company T’s customized shock absorber projection welding machine was completed after aging tests. After a week of installation, debugging, technology, operation and maintenance by our professional after-sales engineers at the customer’s site After training, the equipment has been put into production normally and all met the customer’s acceptance standards. Company T is very satisfied with the actual production and welding results of the shock absorber projection welding machine. It has helped them solve the welding efficiency problem, improved product quality, saved labor costs and promoted the implementation of smart factories, giving us Agera great benefits. Recognition and praise!