1.Preamble：
With the requirements for lightweight and safety of the car body, an integrally formed door knocker was born. The integrally formed door knocker consists of AB pillars, thresholds, top frames, etc., which are integrally hot stamped after laser tailor welding; The strength has been increased from 900Mpa to 1500Mpa, and 20% of the weight of the door knocker has been reduced; because of these advantages, the one-piece door knocker is becoming more and more popular in mainstream car companies. The nuts on the door knocker mostly use the projection welding process. The original AB pillar projection welding is manual. + Form welding of tooling, due to the large shape and heavy weight of the door knocker, the automatic projection welding method must be adopted in consideration of safety and quality factors.
2.Process analysis:
The one-piece door knocker adopts hot stamping process, the strength before welding is about 1500 Mpa, and has aluminum-silicon coating, so its projection welding process is similar to single AB column projection welding, and hard specification welding is required, that is, short time, high current, Due to the high pressure, capacitor energy storage projection welding machines are often used for equipment selection; due to the use of automatic projection welding, it is necessary to consider adding a floating mechanism while ensuring accurate positioning of the work piece to adapt to the incomplete fit between the product and the electrode to ensure welding quality.
3.Case：
One-piece door knocker for a car model, material thickness 1.6MM, surface aluminum-silicon coating, need to weld 4 M8 flange nuts + 1 M8 square nut; found us by friends, we use automatic feeding, automatic projection welding, automatic unloading material.
3.1 Scheme layout:
Through CCD photo identification, the robot grabs the material from the material truck, and then shifts to the double-head welding machine, and the nut is sent out by the nut conveyor, automatically shifted and welded, and then transported by the robot to the unloading station for automatic spot welding.
3.2 Description of the successful solution
A. Loading station: Take pictures from the material cart through the CCD, control the coordinate accuracy to ±0.5mm, position through the pin, and then clamp the work piece to take it out;
B.Welding station: Due to the large size of the door knocker and the matching of two kinds of nuts, Agera customized an ultra-high double-head energy storage welding machine with a working height of 1.8MM and two conveyors to meet the transportation and welding of flange nuts and square nuts;
C.Data collection and traceability: collect welding parameters such as welding current, pressure, displacement, etc., and can expand laser marking to trace the production data of the product, and connect with the factory’s MES to achieve closed-loop management.
3.3 Testing and Verification: Welding test through the universal testing machine to test the ejection force, through the torque meter to test the torque, both reach the standard of the main engine factory and more than 1.5 times; through the small batch test of the position of the nut and verify the consistency of the welding, all meet the design requirements.
4.Conclusion:
The robotic automatic projection welding of the one-piece door knocker meets the needs of production capacity, quality and safety. There is still room for improvement in the form of workstations in the future. For example, in the form of feeding, the current method is feeding cart + CCD. The feeding cart can only hold about 20 pieces, and frequent replacement of feeding carts is required. CCD adopts 3D vision and the cost is high. Subsequent pass and forming The connection of cutting stations will greatly improve the transfer efficiency of work pieces and reduce costs.
Label: Introduction of Welding Process for Fully Automatic Projection Welding Workstation for Integral Door Ring-Suzhou Agera
Description: The fully automatic projection welding workstation for one-piece door ring is identified by CCD photos. The robot grabs the material from the material truck and then shifts to the double-head welding machine. The nuts are sent out by the nut conveyor, automatically shifted and welded, and then transported by the robot Automatic spot welding at the material station.
Key words: one-piece door ring automatic projection welding workstation, automobile door ring automatic nut welding workstation, welding process
Post time: Feb-16-2023