Another breakthrough in robotics applications! STEP spot welding solution for automobiles.
2023-11-10
Spot welding is a welding process in which columnar electrodes are used to create weld spots between the contact surfaces of two overlapping workpieces. During spot welding, pressure is first applied to bring the workpieces into tight contact; then, an electric current is passed through, causing the contact areas to melt under the effect of resistive heating. After cooling, weld spots are formed. Spot welding is primarily used for joining stamped parts made of thin sheets with thicknesses of 4 mm or less, and it is particularly well-suited for welding automobile bodies and carriages as well as aircraft fuselages.
To improve the efficiency and processing quality of spot welding, STEP, leveraging robotic welding technology, has launched a comprehensive robotic spot-welding solution tailored for the automotive industry. It enables the rapid and consistent production of high-quality spot welds, making it an ideal choice for high-volume manufacturing environments.
STEP spot welding solution for automobiles debuts at the 2023 Industrial Fair.
Typical Pain Points in Spot Welding for Automobiles
In a typical spot-welding operation, the robot positions the welding electrode onto the workpiece and applies pressure. Then, the power supply delivers a high-current, low-voltage electrical pulse, generating heat that instantly melts and fuses the workpieces together. During the welding process, which takes place on the order of milliseconds, the high current raises the temperature to around 2,500 to 3,000 degrees Fahrenheit before the joint rapidly cools and solidifies.
During the welding process, the system can control process parameters via robots, thereby delivering exceptional precision and repeatability and ensuring consistent welding quality throughout the entire production line.
However, precisely controlling welding parameters—such as current, welding time, and electrode pressure—is not easy. If these parameters are not properly controlled, it could lead to poor weld quality, for example, weak weld seams, excessive indentation, or burn-through. Moreover, the contact area at the weld point is limited, which can pose a challenge when welding complex structures.
STEP Automotive Welding Solutions
01 Scheme Composition
Robotic Spot Welding System: Composed of the STEP SR220/2700 robot, Leoni cable harness, Orona resistance spot welding power supply, X-type resistance spot welding torch, and electrode grinding equipment.
02 Program Features
High-precision control:
√ Brand-new series-connected high-load platform, featuring a modular design, high rigidity, and high precision, equipped with dedicated spot-welding mounting interfaces.
√ Precise pressure calibration;
√ Supports functional algorithms such as electrode cap wear compensation and welding plier deflection compensation, enabling high-precision and high-quality welding control.
Easy to operate ：
√ Develop a dedicated resistance spot welding process package that simplifies user operations, boasts powerful functionality, supports multiple communication protocols such as PN and EIP, and is compatible with servo welding guns from various brands.
√ One-click alignment of coordinate systems, monitoring, manual operation, device configuration, welder configuration, and torch configuration—all via a dedicated interface.
High security:
√ Real-time monitoring of the servo welding clamp motor torque and electrode wear compensation status, with strict control over welding process parameters.
Scalability:
√ Flexible servo configuration supports adaptation to three devices and six welding torches; supports quick torch replacement.
√ Compatible with servo welding guns and pneumatic welding guns, supporting bus communications such as EIP, PN, and ECAT.
Currently, automotive welding automation equipment is moving toward... Large-scale, large-sized, high-efficiency, high-precision Moving forward, STEP will continue to leverage its technological strengths in the robotics field and inject new momentum into the automotive manufacturing industry.
Contact Us
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market@stepelectric.com
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No. 1560, Siyi Road, Jiading District, Shanghai Municipality