Auto door panel welding equipment

Requirements:

Welding the upper and lower body, the panel, the map bag, the anti-collision block five parts, total of 35 welding points.

1.Welding method: Hot riveting welding
through electric heating.

2.Every welding points’ temperature can be independently
controlled by PLC

3.Welding strength : Up to standard
strength after welding, no drawing, no damage on the surface.

4.Transmission of the equipment uses
pneumatic drive system.

5.Can use one machine frame with few
fixtures to complete the welding work, It depend on your requirement and output
requirement. Each fixture can be matched one trolley.

6.The Equipment operation using standing
operation, the equipment is designed ergonomic. The operating height from the
ground is 0.7–0.8m, it’s convenient for operator loading and unloading
materials, and by operating the button to complete the automatic welding.

7.Overall equipment life guarantee more
than 700,000 die.

8, The device is reserved infrared scanner
install interface.

Design Concept

1.The electrical and pneumatic connect of the equipment uses heavy duty
connector and quickly plug. It’s convenient to cut mold,electrical and
pneumatic parts of the machine quickly when changing the fixture.

2.With a separate control box, gas, electric control
cabinet handled separately.

4.The device is equipped with air-cooling
system to ensure quick cooling of the workpiece during welding, improve welding
speed, weld single piece is about 40-60 seconds time / piece (including manual
handling time).

5.PLC control system, welding parameter
adjustment completed in the man-machine interface (touch screen) .

6. PLC set is controlled by muti-unit
parameter program, can save different welding parameters of different welding
workpieces.So it needn’t re-adjust the welding parameters after changing
fixture.

7.Dual start button with safety grating double
protection to ensure operator safety.

8.Operating mode: Adopt standing operation, put in and out the
workpiece by worker, weld by equipment automatically.

10.Equipped
with safety grating in front of the machine near operation door, equipped with
door grating in the rear of the machine.

11.Change
the fixture on the opposite of the machine( If customer wants the right
change,we can design)

Equipment Frame

⊙ Machine frame dimension:∽（L）3500×（W）1200×（H）2600(MM)

⊙ Trolley dimension:∽（L）1200×（W）1000×（H）900(MM)

⊙ The
frame use high-quality steel welding structure,the outer plate is shaped by CNC
sheeting machine, the surface of the cover board is painted.

⊙ The
color can be choosed by customer.

⊙ Machine
is designed according to Ergonomics Principle, and has necessary safety signs.

⊙The
machine is equipped with dedicated ring to up and down.

⊙ The
machine is equipped with safety grating, all the doors are equipped, to ensure
the machine can’t work when the doors aren’t closed.

⊙ The
machine is equipped with adjustable feet and fork hole, can be adjusted in
100mm limits.

⊙ The
worktable of the front is higher than 1850mm from the ground.

⊙ The
machine can weld the size :1100*600mm of left/right automotive door.

⊙ The
machine is equipped with dedicated trolley to change the fixtures.

The fixture movable structure
and lifting structure

⊙The machine fixture movable
structure use 4 posts linear bearing and guide pillar structure, to hold the
fixture do up and down movement. Movable structure use pneumatic system.

⊙ Fixture change lifting
structure uses guide pillar and guide bush structure, movable structure use
pneumatic system.

⊙ Fixture is processed by CNC,
to ensure the precision of machine parts.

Hot riveting fixture

⊙ Hot riveting fixture and
equipment fixture movable structure uses screws to fix.

⊙ Welding point uses single
independent temperature control mode, every hot riveting point can control
temperature independently.

⊙ Every hot riveting point can be adjusted independently
in horizontal and vertical direction, horizontal adjust distance is 3mm ,
vertical adjust distance is 20mm.

⊙ Hot riveting fixture is equipped with prepressing
device, to ensure the fitness of the workpieces,no gap. Each 2 points is
equipped with prepressing head which are sinews material, to protect the
workpieces from scratching.

⊙ The machine is equipped with
cooling system, to ensure after melting, cooling quickly ,welding point smooth.

⊙ The cooling pipe can be
removed structure, blowing time can be controlled.

⊙ The fixture is equipped with 1 independent trolley. Between the
trolley and machine ,there is quick guide structure.

⊙ The hot riveting post uses
copper, hot riveting point material use stainless steel , use CNC to shape.

4、Model Membrane

⊙ Model membrane is equipped with sensor. Every welding part is
equipped with sensor to keep the workpiece from missing.

5、Driving system

⊙ Moving structure adopt
cylinder drive.

⊙ Mould safety locker structure
adopts cylinder drive.

⊙ Changing mould marbles lifting
structure adopts cylinder drive.

⊙Adopt PLC controller, All the
parameters can be adjusted on the screen panel.

6、Hot riveting system

⊙Equipment welding points quantity
depends on the the customer’s products and requirements.

7、Safety device

The machine has double
protective function, to ensure the workers safe.

⊙ Use double
buttons to start, one emergency stop button.

⊙ The machine operating place is
equipped with one set safety raster, other places design outer cover plates.
One machine is equipped with 2 set switches.

8、Controlling system

⊙ The machine
adopts PLC controlling system, All the
parameters can be adjusted on the screen panel.

⊙ The machine
is equipped with electrical/pneumatic controlling cabinet separately.

⊙Electrical
parts use SIEMENS and same level electrical components.

⊙ Pneumatic
parts use FESTO/SMC and same level components.

9、PLC function
and screen panel show

⊙ Welding
units option

⊙ Manual/Automatic
switch adjustment

Manual status—Each driving
parts, time can be independently adjusted.

Automatic status—The machine
automatically finish all the process.

⊙ Temperature
false display function.

⊙ Safety
protection false display function.

⊙ Multiple
sets of welding parameters function

⊙ Temperature
adjustment

⊙ Welding
counter

⊙ Can use
password to protect, in case non-professional workers operate.

The machine operation method and
fixture changing method

⊙Operator put the workpiece to
the mold membrane, sensor check the workpieces position, if ok ,the status lamp
on.(about 5 seconds)

⊙ Press the starting button, hot
riveting mold down quickly, almost close to hot riveting pillar , fixture
stops, meanwhile the pre-pressure device automatically press the
workpieces.(about 15 seconds)

⊙ When the hot riveting pillar
soft, hot riveting mold continue to press down , to make the hot riveting
pillar shaped.(about 20 seconds)

⊙ After hot riveting,blow air to
cool the workpieces, fix and shape it.(about 10 seconds)

⊙ Hot riveting mold back,
operator put out the workpieces (about 5 seconds)

⊙ Operator continues to put
workpieces in sequence.

⊙ Weld the whole workpiece needs
about 40-60 seconds.(include put in and out time)

Fixture changing method

⊙ Operator adjust the machine to
fixture changing mode, mold changing light indicator on. Put the upper and
lower fixture together by manual button.

⊙ Push the trolley to fixture
changing place (There is position device between trolley and machine)

⊙ Loosen the locked screws, open
the marble lifting button, lift the fixture.

⊙ Push the fixture into the
trolley, move the trolley to appointed position.

⊙ Push the another hot riveting
fixture into fixture changing position of the machine.

⊙ Push the fixture to the
welding place.

⊙ Open the marble lifting
button, put the fixture down to the machine plate, lock the screws.

⊙ Down the fixture to the
fixture base, lock the fixture screws.

⊙ Inserts all the electrical and
pneumatic connector, pull the fixture.

⊙ Adjust the machine to the
welding status, select the welding unit,open heating button, when the hot
riveting temperature up to the needed temp, status light on, it can be welded
then.

⊙ All the fixture change needed time less than 10 minutes.

Machine components and brands

1、Electrical components

NO.	Components name	Components brand
1	PLC	SIEMENS
2	Screen Panel	SIEMENS
3	Electrical parts	SIEMENS、Delta
4	Safety raster	Sensorc

2、Driving parts

NO.	Components name	Components brand
1	Cylinder	FESTO、SMC
2	Valve	FESTO、SMC
3	Pressure regulator	FESTO、SMC
4	Filter	FESTO、SMC
5	Pneumatic control parts	FESTO、SMC

3、Transmission parts

NO.	Components name	Components brand
1	linear bearing	ABBA
2	Bearing steel rod	ABBA
3	Cylinder	FESTO、SMC

October 23, 2020