Automobile Shock Absorber Assembly Line
1). Struck Welding and Assembly Semi-Auto Line
A). Welding Assembly Unit 1, including the following equipment and robotic arm
Item
|
Quality
|
Tube Auto Feeder
|
1
|
90° Turn Table
|
1
|
Hydraulic Press for Bracket Assembly
|
1
|
CO2 Spot Welding Machine (Single Torch)
|
1
|
Hydraulic Bottom Cap Assembly Press
|
1
|
End Cap Auto Feeder (Vibration Plate)
|
1
|
Load/Unload Robotic Arm (2 Workstation)
|
1
|
4 Workstation (Single Line into Dual Line)
|
1
|
End Cap Welding Machine
|
2
|
180° Turn Table
|
1
|
Upper Bracket Welding Machine
|
2
|
Conveyor
|
1
|
Load/Unload Robotic Arm (4 Workstation)
|
1
|
B). Welding & Assembly Unit 2, including the following equipment and robotic arms
Item |
Quantity |
Spring Plate Spot Welding
|
1
|
Spring Plate and Bracket Welding
|
1
|
Descaling Machine (Automatic)
|
1
|
Automatic Unload Robotic Arm for Spring Plate
|
1
|
C). Fully automatic welding slag grinding, cooling, shaping, punching, unloading and more, including the following equipment and robotic arms
Conveyor
|
1
|
Descaling Machine (Automatic)
|
1
|
Workpiece Cooling System
|
1
|
Bracket Opening Inspection Before Shaping
|
1
|
Unload Robotic Arm for Unqualified Products
|
1
|
Conveying System
|
1
|
Bracket Shaping Machine
|
1
|
Dual Directional Punch Press for Bracket
|
1
|
Load and Unload Robotic Arm to Punch Press
|
1
|
Conveyor System
|
1
|
D). Robot Welding Workstation:
Item
|
Quantity
|
Robotic Welding Machine with stabilized bar
|
2
|
Conveyor System
|
1
|
E). Projection welding for signal brackets and after-welding cleaning after leakage test
Item
|
Quantity
|
Projection Welding for A, B lugs
|
2
|
Conveyor System
|
1
|
Dual workstation leakage test machine (liquid type)
|
1
|
Inspection Table
|
1
|
2). Shock absorber Welding and Assembly Auto Line
Rear shock absorber production procedures include: tube loading, end cap loading, end cap assembly press, end cap seam welding, lifting ring loading, lifting ring projection welding, End cap MIG welding, auto unloading, leakage test and more
Item |
Quantity
|
Servo beam transportation system
|
1
|
Robotic arm up & down moving system
|
1
|
Robotic Claw |
5
|
Tube loading machine
|
1
|
End cap loading robotic arm |
1
|
End cap assembly press
|
1
|
End cap seam welding machine
|
1
|
Lifting ring loading robotic arm
|
1
|
Lifting ring projection welding machine
|
1
|
End cap MIG welding machine
|
1
|
Leakage testing machine
|
1
|
3). Shock absorber Welding and Assembly Machines
3.1)Projection Welding
3.1.1)Projection Welding for Support & Lower Fixation
Specifications
- Capacity: 2 tons Cylinder
- Vertical Stroke: 160 mm
- Throat Depth: 350 mm
- Welding Spots: 12 projection
- Power: 300 KVA
- MIYACHI welding control
- Prismatic system to guarantee the upper head movement and alignment during processing
- Welding quality control with RED box.
3.1.2)Projection welding for piston rod, lifting rings, rustproof cover and more
Specifications
- Capacity: 2 tons with tandem cylinder
- Vertical Stroke: 120 mm
- Throat Depth: 350 mm
- Daylight: 300 mm
- Power: 200 KVA
- MIYACHI welding control
- Welding parameters preset
- Prismatic system to guarantee the upper head movement and alignment during processing (up and down movement)
- Welding quality control with RED box.
3.1.3)Projection welding for Fuel Tank Supporting Brackets
Specifications
- Capacity: 2 tons with Tandem Cylinder
- Vertical Stroke: 120 mm
- Power: 200 KVA
- MIYACHI welding control
- Welding parameters preset
- Prismatic system to guarantee the upper head movement and alignment during processing (up and down movement)
- Welding quality control with RED box.
3.1.4)Horizontal Projection Welding for Piston Rods
Specifications
- Capacity: 1.5 tons Cylinder
- Horizontal Stroke: 120 mm
- Power: 200 KVA
- MIYACHI welding control
- Welding parameters preset
- Prismatic system to guarantee the upper head movement and alignment during processing (up and down movement)
- Welding quality control with RED box
3.2)Spot welding
3.2.1)Spot welding and testing force for piston rod, spacing ring
Specifications
- Capacity:600Kg Cylinder
- Vertical Stroke: 100 mm
- Power: 100 KVA
- MIYACHI welding control
- Welding parameters preset
- Welding quality control with RED box
3.2.2)4-Spot Welding for Piston Rod, Spacing Ring
Specifications
- Capacity:600Kg Cylinder
- Vertical Stroke: 100 mm
- Power: 2X100 KVA
- MIYACHI welding control
- Welding parameters preset
- After spot welding, test the force of ring
- Welding quality control with RED box
3.3)Seam Welding
3.3.1)Seam Welding for Upper Weld
Specifications
- Rated Capacity: 200 KVA
- Electrode Force: 3900 KN
- Shock Absorber Diameter: 30—80 mm
- Shock Absorber Length: 100—500 mm
- Vertical Clamping Force: 6000 KN
- MIYACHI welding control
- Seam electrode head with Ag (99.99%) contactors
- Welding quality control with RED box
3.3.2)Semi Auto Upper Seam Welding Machine
Specifications
- Rated Capacity: 200 KVA
- Electrode Force: 3900 KN
- Shock Absorber Diameter: 30—80 mm
- Shock Absorber Length: 100—500 mm
- Vertical Clamping Force: 6000 KN
- Six index table with loading and unloading position
- MIYACHI Welding Control
- Electrode head with Ag (99.99%) contactors
- Welding quality control with RED box
3.3.3)Semi Auto Lower Seam Welding Machine
Specifications
- Rated Capacity: 200 KVA
- Electrode Force: 3900 KN
- Shock Absorber Diameter: 30—80 mm
- Shock Absorber Length: 100—500 mm
- Vertical Clamping Force: 6000 KN
- Six index table with loading and unloading position
- MIYACHI welding control
- Electrode head with Ag (99.99%) contactors
- Welding quality control with RED box
3.4)MAG Welding
3.4.1)Two Torches MAG Welding Machine
Specifications
- Gas: -Mix of gas to arc weld process: 83% Ar and 17% CO2
- Wire: - Wire diameter: 1,0 or 1,2 mm
- Wire feeder and Welding Power – Panasonic or Lincoln
- Torch: - Quantity: 2
Adjustment of the Torches: adjustment in three axis (x, y and z)
Welding torch –Panasonic/ BINZEL
- Torch Support
Strong, durable and precise structure
Easy positioning system adjustment of the torches
- Gear Box
Protected spherical roller for sliding movement
Proportional valve to control tooling table movement
- Program
Counter parts program;
Counter parts program
Program to alert the operator for torch cleaning and changing
Red Switch program to alert any welding anomaly, alarm
Tooling: - Tooling will be provided by the Supplier
Provide 2 large, lateral windows and doors for easy operator access
3.4.2)Single Torch MAG Welding Machine
3.5)Spin Closer
3.5.1)Gas filling and Spin Closer for struck
Up head adjustment
|
300mm
|
Force of closing forming max.
|
12000Lbs
|
Speed of upper shaft
|
180rpm
|
Load and unload
|
Manual
|
Total power
|
15KW
|
Overall dimensions of machine
|
1800x110x2300mm
|
Weight of machine
|
3600Kg
|
PLC
|
SIEMENS
|
Gas filling and orbital spin close at same time
The lower base up speed is servo valve controlled
Closing load, revolution and gas force can be controlled and displayed on screen
3.5.2)Spin Closer for Rear Shock Absorber
Up head adjustment
|
80 mm
|
Max. Force of closing forming
|
6000 Lbs.
|
Speed of upper shaft
|
500 rpm
|
Total power
|
15 KW
|
Diameter |
40-60mm
|
Thickness
|
2mm
|
Length
|
300-940mm
|
Cycle time
|
7 Second
|
Overall dimensions of machine
|
1500x130x2300 mm
|
Weight of machine
|
2600 Kg
|
3.6)Hydraulic Press
3.7)Automatic Multi-Head Drilling Machine
Total stroke
|
80 mm
|
Cutting stroke
|
0-30 mm
|
Spinning speed
|
2600 rpm@ 50Hz
|
Total power
|
3.3 KW
|
Max. drilling hole dia. (Steel)
|
3.5 mm
|
Max. bit quantity
|
8
|
Cycle time
|
3 Second
|
Loading and Unloading |
Automatic
|
Overall dimensions of machine
|
2510*2050*2300
|
Weight of machine
|
3600Kg
|
Brief
Mountain Welding is a globally sought after provider of industrial production systems. We have more than three decades of experience in the design and production of resistance welding systems. We provide resistance welding systems for customers from a variety of industrial sectors. Since 1992, Mountain Welding has manufactured more than 2000 pieces of equipment used by automobile, agriculture, household appliance, architecture, and railroad industries. They have been applied for the welding of shock absorbers, wheels, fuel tanks, ring gears, drive shafts, drive bearings, rear axles, and more.