Spot Welding refers to the welding method in which a cylindrical electrode is used to form a welding spot between the contact surfaces of two overlapping workpieces during welding. In spot welding, the workpiece is first pressed to make close contact, then the current is connected, the workpiece contact is melted under the action of resistance heat, and the welding spot is formed after cooling. Spot welding is mainly used for the welding of sheet metal components with a thickness of less than 4mm, especially for the welding of automobile bodies and carriages and aircraft fuselages.
In order to improve spot welding efficiency and processing quality, STEP has launched a complete set of robotic spot welding solutions for the automotive industry based on robotic welding technology to quickly and consistently produce high-quality spot welding, making it ideal for high-volume production environments.
STEP automotive spot welding solutions appeared at the 2023 Expo
Typical car spot welding pain points
In a typical spot welding operation, the robot positions the welding electrode on the workpiece and applies pressure, and then the power supply sends out a high-current, low-voltage electrical pulse to generate heat and melt and fuse the workpiece together on the spot. In the millisecond welding time, the high current excited the temperature of 2,500 to 3,000 degrees Fahrenheit, and then quickly cooled and solidified the joint.
During the welding process, the system is able to control the process parameters by robots, thus providing excellent accuracy and repeatability, ensuring consistent welding quality throughout the production line.
However, precise control of welding parameters, such as current, welding time, and electrode pressure, is not easy. If these parameters are not properly controlled, they may result in poor welding quality, such as weak welds, excessive indentation, or burn-out. In addition, the solder joints have limited contact, which can be a problem when welding complex structures.
STEP Automotive welding solutions
01 Solution Composition
Robot spot welding system: composed of STEPSR220/2700 robot, Lenny pipeline package, small resistance spot welding power supply, X type resistance spot welding torch and electrode grinding equipment.
02 Solution Features
High precision control:
√ New series large load platform, modular design, high rigidity, high precision, equipped with special spot welding installation interface;
√ Accurate pressure calibration;
√ Support electrode cap wear compensation, welding pliers deflection compensation and other functional algorithms to achieve high-precision and high-quality welding control.
Easy to operate:
√ Develop special resistance spot welding process package, simplify user operation, powerful function, support PN, EIP and other communication methods, suitable for multi-brand servo welding pliers;
√ Tool one-click alignment coordinate system, monitoring, manual operation, equipment configuration, welding machine configuration, welding gun configuration, dedicated interface.
High security:
√ Real-time monitoring of servo welding pliers motor torque, electrode wear compensation state, strict control of welding process parameters.
Scalability:
√ Flexible servo configuration can support three equipment, six welding guns; Support welding gun quick change;
√ Suitable for servo welding pliers, pneumatic welding pliers, support EIP/PN/ECAT bus communication.
At present, automotive welding automation equipment is developing in the direction of large-scale, large-scale, high-efficiency and high-precision, and STEP will continue to exert its technical potential energy in the field of robotics and inject new kinetic energy into the automotive manufacturing industry.