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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.
該項目利用原有生產線預留工位進行改造，新建的車頂激光站采用上下兩層鋼結構布局方式，占地面積6x12x8.5米，一層為輸送滾床、龍門架及左右各1臺激光釬焊機器人，二層鋼平臺上布局2臺車頂抓搬運機器人及4套夾具庫位，可實現混線無縫切換車型車頂夾具。
? 單工位60JPH+4車型柔性生產，節拍CT=52s；
? 該工位目前規劃2+2車型，2臺焊接機器人+2臺夾具搬運機器人；
? 采用“三光斑”焊接工藝,實現高速、高品質激光釬焊焊接；
? 采用了在線質量監控系統，對焊縫表面質量實時自動檢測；
? 工位采用同高科技自主研發的雙層鋁合金的防護系統，并通過德國TUV安全檢測及認證；
項目采用全世界最新“二極管三光斑”激光釬焊工藝，將LaserLine二極管激光器發射的一束激光束通過帶有OR三光斑模塊的激光鏡組，分解為三個焦斑。
三光斑工藝圖
其中焊接方向前的兩個小光斑分布在焊絲左右側，焊接過程中對車頂及側圍表面的鍍鋅層進行清潔，隨后主光斑將焊絲融化并連接車頂和側圍板件，這樣就解決了鍍鋅板焊接過程中鋅蒸汽對焊接質量造成的焊接缺陷，從而最終能夠有效提高焊接速度和焊接質量。
焊接后焊縫兩側的黑線特征
