Welding Workstation for Flange Bolts of Automobile Galvanized Sheet

一、Customer Background and Pain Points

Shenyang L D Company is because of the introduction of new BMW models, welding M8 flange nuts on the new stamping parts , requiring the fusion depth to be greater than 0.2mm and not to damage the thread. The original welding equipment has the following problems:

1、The welding quality cannot be guaranteed: the old equipment is power frequency welding equipment, and the fastness of the workpiece after welding is not within the safe value;

2、Welding fusion depth cannot reach: after welding, the workpiece fusion depth cannot meet the requirements;

3、Large welding spatter, many burrs, and serious thread damage; old equipment has large sparks, many burrs, and serious thread damage during welding, requiring manual resetting, and the scrap rate is high.

4、The early samples could not meet the requirements : when welding nuts, BMW required that automatic welding must be realized during the audit, and full-closed-loop control should be done, and the parameter records can be traced back. Many manufacturers were found to make samples and could not meet the requirements;

The above four problems have caused headaches for customers, and they have been looking for solutions.

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. Satisfy the welding penetration depth requirement of 0.2mm;
2. There is no deformation, damage or welding slag on the thread after welding, so there is no need to do back-to-back treatment;

3. Equipment beat: 7 S/time

4. Solve the problem of workpiece fixation and operation safety, use manipulator to grab and add anti-splash function;

5. 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?

3. According to customer needs, research and develop customized automobile galvanized sheet flange bolt projection welding workstation

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. Advantages of the overall equipment:

1) Yield improvement: energy storage welding power supply is adopted, with fast discharge and high climbing speed, ensuring that the nut melting depth reaches 0.2mm, and the thread after welding has no deformation, damage or welding slag. %above;

2) Intelligent alarm device: Equipped with an automatic alarm device for missing or wrong welding, which can count the number of nuts in real time. Once a missing or wrong welding occurs, the equipment will automatically alarm;

3) Stability guarantee: the core components adopt imported configuration , combined with the self-developed PLC control system, network bus control, fault self-diagnosis, to ensure the reliability and stability of the equipment, and realize the traceability of the whole welding process and the docking of the MES system;

4 Intelligent stripping design and quality self-inspection function: the equipment is equipped with an intelligent automatic stripping structure, and the workpiece can be easily separated from the tooling after welding, which solves the problem of welding stripping. At the same time, add a quality control system to ensure product welding quality, improve welding efficiency, and keep your welding process in the best state.

5) Thread chip blowing function after welding: according to workpiece and welding requirements, equipped with electrodes and positioning fixtures with chip blowing function;

6) Intelligent identification design: realize the identification of left and right tooling, automatic parameter switching, and support multiple operating states at the same time, improving production flexibility.

reached an agreement with Shenyang LJ Company on August 13, 2022. Order agreement.

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 delivery time of 50 days was indeed very tight. The project manager of Anjia held the production project kick-off meeting as soon as possible, and determined the mechanical design, electrical design, mechanical processing, purchased parts, assembly, joint 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 50 days, Shenyang LJ ‘s custom-made automobile galvanized sheet flange bolt projection welding workstation has finally been completed. Our professional technical service personnel have undergone 10 days of installation, commissioning, technology, operation and training at the customer site, and the equipment has been completed . It has been put into production normally and has all met the customer’s acceptance criteria. The customer is very satisfied with the actual production and welding effect of the flange bolt projection welding workstation for automobile galvanized sheet . 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 galvanized sheet flange nut projection welding machine-Suzhou Anjia

Key words: hot forming steel nut spot welding machine, galvanized sheet flange nut projection welding machine

Description: Flange nut double-head energy storage welding machine is a double-head nut welding machine developed by Suzhou Anjia according to customer requirements . The equipment has the functions of air blowing, slag removal, and detection. It has automatic alarm for missing welding and wrong welding . The nut is not used after welding. back teeth .