Semi-Automatic Welding Machine for Automotive Sensors Technical Solution

 _{Semi-Automatic Welding Machine for}

_{Automotive Sensors Technical Solution}

1. Overall Rendering

Overall Dimensions: Length 870 x Width 800 x Height 1700

2. Welding Mechanism

Spring-loaded mechanism pressure range: approx. 20–100 N;

Linear motion stage travel: approx. 350 mm.

3. Work piece Fixture:

The work piece fixture features a quick-change design; products are manually placed into the fixture, which is then loaded as a complete unit onto the mobile platform for positioning.

1 to 5 products can be loaded at a time.

Work pieces of different dimensions require custom-designed fixtures.

4. Control System Framework

1. The welding pressure signal is output by a pressure sensor mounted on the welding head, then passes through a signal amplifier before entering the PLC for sampling and data processing.

2. The current signal is transmitted from the power supply controller to the PLC via RS485 communication for storage.

3. The RS485 communication link between the PLC and the power supply controller also facilitates the configuration of welding parameters.

4. All production data generated during the welding process is centrally collected by the PLC and transmitted to the touchscreen for storage on a USB drive; the PLC does not require communication with a host computer.

5. The vision system communicates with the PLC via RS485 to transmit inspection results.

5. Production Process:

1. Manually place the fixture—loaded with the product—onto the mobile platform. — 2s

2. Press the clamp-locking button; the pneumatic cylinder activates to secure the fixture. — 1s

3. Press the Start button. — 1s

4. The platform moves to the position of the first welding point. — 2s

5. Weld the first point, then move to the next position (total of 10 points). — 1.5s × 10 = 12s

6. Upon completion of welding, the platform moves to the visual inspection station to capture an image and perform image processing. — 2s

7. The platform returns to the loading station and releases the fixture. — 2s

8. Estimated time to complete one fixture batch (one product): approximately 22 seconds. Estimated production capacity: 163 units per hour. Personnel required: 1 operator.