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In January 2017, Tung Hi-Tech undertook the “turnkey project” of the 9BUX&9BYC top cover laser brazing project of the GMK Incheon plant in South Korea. According to the customer's preliminary plan, according to the traditional roof laser brazing process (single spot, hot-dip galvanizing welding speed <3.0m/min), it is necessary to build a double station to meet the production needs of 4 models +60JPH. The same high-tech recommends the world's latest "diode three-spot" laser brazing process, hot-dip galvanized material welding speed ≥4.5m/min, automation efficiency increased by more than 50%, such a workstation can meet the production needs of 4 models +60JPH, In the end, this solution was approved by the customer and successfully implemented, which not only saved the budget of a workstation, but also greatly reduced the site area.
該項(xiàng)目利用原有生產(chǎn)線預(yù)留工位進(jìn)行改造，新建的車頂激光站采用上下兩層鋼結(jié)構(gòu)布局方式，占地面積6x12x8.5米，一層為輸送滾床、龍門架及左右各1臺(tái)激光釬焊機(jī)器人，二層鋼平臺(tái)上布局2臺(tái)車頂抓搬運(yùn)機(jī)器人及4套夾具庫(kù)位，可實(shí)現(xiàn)混線無(wú)縫切換車型車頂夾具。
? 單工位60JPH+4車型柔性生產(chǎn)，節(jié)拍CT=52s；
? 該工位目前規(guī)劃2+2車型，2臺(tái)焊接機(jī)器人+2臺(tái)夾具搬運(yùn)機(jī)器人；
? 采用“三光斑”焊接工藝,實(shí)現(xiàn)高速、高品質(zhì)激光釬焊焊接；
? 采用了在線質(zhì)量監(jiān)控系統(tǒng)，對(duì)焊縫表面質(zhì)量實(shí)時(shí)自動(dòng)檢測(cè)；
? 工位采用同高科技自主研發(fā)的雙層鋁合金的防護(hù)系統(tǒng)，并通過(guò)德國(guó)TUV安全檢測(cè)及認(rèn)證；
項(xiàng)目采用全世界最新“二極管三光斑”激光釬焊工藝，將LaserLine二極管激光器發(fā)射的一束激光束通過(guò)帶有OR三光斑模塊的激光鏡組，分解為三個(gè)焦斑。
三光斑工藝圖
其中焊接方向前的兩個(gè)小光斑分布在焊絲左右側(cè)，焊接過(guò)程中對(duì)車頂及側(cè)圍表面的鍍鋅層進(jìn)行清潔，隨后主光斑將焊絲融化并連接車頂和側(cè)圍板件，這樣就解決了鍍鋅板焊接過(guò)程中鋅蒸汽對(duì)焊接質(zhì)量造成的焊接缺陷，從而最終能夠有效提高焊接速度和焊接質(zhì)量。
焊接后焊縫兩側(cè)的黑線特征
