The automotive industry is experiencing unprecedented changes under the wave of intelligent electric power. The explosive growth of new energy models, the wide application of lightweight materials, and the ultimate pursuit of safety and quality by consumers have forced the production of automotive parts and components to move towards higher levels of precision, efficiency and intelligence. In the face of increasingly complex body structure, high-strength steel welding difficulty and other challenges, the limitations of the traditional manual spot welding process is more and more prominent - precision fluctuations, efficiency bottlenecks, quality consistency is insufficient, has become a key constraint on the upgrade of the industry.

A domestic head auto parts supplier, long-term for the world's leading automobile enterprises to provide stamping parts, welding parts supporting services. With the surge in demand for key components such as new energy battery pack shells and lightweight body frames, the requirements for the precision and stability of the welding process are almost harsh: the strength of the weld seam needs to withstand extreme working conditions, and millimeter-level errors may lead to safety risks for the entire vehicle. The traditional manual mode in the complex three-dimensional trajectory welding, high-strength material processing is not satisfactory, and there is an urgent need to reconstruct the production barriers through automation innovation.

In order to help customers break through the shackles, Estun has a deep understanding of the industry's pain points, tailored to the “software and hardware integration” of the whole scene welding solutions:

Hard power foundation building

1.   High-rigidity body + high-performance motors: Adopting structural topology optimization and high-rigidity mechanical structure to ensure that the robot maintains an ultra-stable attitude during high-intensity continuous operation, and the precision of the welding trajectory reaches ±0.06mm, which completely eliminates the deviation caused by the deformation of the body;

2.    UNO series high-speed and high-precision spot welding robots: equipped with self-developed torch servo motors, response speed increased by 40%, current control accuracy of milliseconds, and adaptive adjustment of the welding parameters, which can easily cope with the demand for high-quality welding of galvanized steel and other dissimilar materials;

3.    Extreme space efficiency: the motor length is reduced by 30%, the overload capacity exceeds 300%, and the compact structure is adapted to the narrow workstation, which helps the flexible layout of the production line.

Soft Power Empowerment

1.    Intelligent process database: integrating more than a thousand combinations of material-thickness-process parameters, calling the optimal welding program with one key, reducing 90% of manual debugging costs;

2.    PDPS full-process digitization: through virtual simulation to prejudge the welding path, torch attitude and beat bottlenecks, realizing “zero-collision, zero-trial-and-error” offline programming, shortening the new product introduction cycle by 60%, and improving the efficiency of production capacity ramp-up significantly.

Improving quality and efficiency for our customers

1.    Efficiency leap: welding beat increased by 35%, single-day production capacity exceeded 10,000 pieces, perfectly matching the customer's production needs;

2.    Quality leap: the consistency of weld strength reaches 99.8%, and the defect rate is close to zero;

Driven by the dual-wheel drive of “dual-carbon” target and intelligent manufacturing, Estun continues to plough into technological innovation, and empowers the automotive industry chain to advance to high-end and green with more agile response and more open ecology. We firmly believe that only by dialoguing with the needs of the times with extreme technology and reshaping the value of the industry with the integration of digital intelligence, can we draw a new picture of intelligent manufacturing with our partners in the wave of global intelligent manufacturing.

Source：Estun

Published by：AHTE Content Marketing Team