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Welding solution on automobile seat

Welding requirement

/ To follow the lightweight trend in auto industry, the thickness of material for manufacturing seat frame is becoming as thin as 0.5mm-0.8mm, which means it's very easy to burn through the base material if using conventional welding process.

/The thickness of thin plates cannot be unified easily, therefore, high gap bridging ability is required in thin plate welding.

/Strict requirment on deformation control to avoid troubles in installation.

/The welding seams on seat frame are short and intensive, leading to high demand on good arc on/off and cycling.

Backrest Parameters

Base metal: Carbon steel
Thickness: 0.8/0.9 mm
Joint form: lap joint
Power source: Fronius TPS 3200 CMT
Process: GMAW
Transfer: CMT & CMT Dyn
Welding speed: 1.02~1.2 m/min
Wire: ER70S-6
Wire diameter: 1.0 mm
Protected Gas: 82% Ar + 18% CO2

Basin Parameters

Base material: carbon steel
Thickness: 0.8/1.0 mm
Joint form: lap joint
Power source: Fronius TPS 3200 CMT
Transfer: CMT & CMT Dyn
Weld speed: 0.9~1.02 m/min
Wire Feed speed: 4.5~4.7 m/min
Wire diameter: 1.0 mm
Protected Gas: 82% Ar + 18% CO2

Advantages

/ Greatly reduce burn through rate and successfully avoid the deformation on thin plate welding due to the extremely low heat input of CMT

/Excellent gap bridging ability

/Much higher speed and better welding result with CMT

TIG

Welding requirement

/No spatter

/Strict requirement on deformation control

/Consistent penetration and more than 10%

Backrest Parameters

Base metal: Carbon Steel
Thickness: 1.42 mm
Joint form: Butt joint
Power Source: MW5000
Process: GTAW
Transfer: TIG Pluse
Welding Position: PA
Welding Current: 195 A
Wwire Feed Speed: Feeder 1=1.3m/min, Feeder 2=12%
Welding Speed: 0.4 m/min
Wire: WH50-6
Wire Diameter: 1.2 mm
Protected Gas: 99.99% Ar

Advantages

/No spatter

/No deformation

/Consistent penetration

MIG/MAG

Welding requirement

/Torsional strength is a key point in slider manufacturing, so the demand for the consistency and the depth of penetration is ver y high (penetration >10% of the base material thickness)

/No spatter and no distortion are required during sliders welding to ensure the flexibility

Parameters

Base metal: Carbon steel
Thickness: 1.5/2.5 mm
Joint form: lap joint, butt joint
Power source: Fronius TPS 3200 CMT
Process: GMAW
Transfer: CMT
Welding current: 191 A
Welding voltage: 14.5 V
Welding speed: 1.2 m/min
Wire: WH50-6
Wire diameter: 1.0 mm
Protected Gas: 90% Ar + 10% CO2

Advantages

/CMT process can bring the stability during wedling to keep the depth of the penetration consistent, and therefore ensure the service time of sliders

/CMT has extremely low heat input and cause nearly no spatter, so the yield can reach 99%

Welding requirement

/High requirement for low heat input and low spatters because of the plastic parts in the center of the seat recliner. With high heat input, the plastic deformation will affects the concentricity and quality of the recliner.

/A tube will be installed through the plastic parts to adjust the angle of the seat, so there is no tolerance for spatter.

/The deformation of the adjuster will cause the recliner stuck

Parameters

Base metal: carbon steel
Thickness: 0.8/3.0 mm
joint form: lap joint
Power source: Fronius TPS 4000 CMT
Process: GMAW
Transfer: CMT
Welding current: 205 A
Welding voltage: 18.2 V
Welding speed: 1.2~1.5 m/min
Wire: ER70S-6
Wire diameter: 1.2 mm
Protected Gas: 100% CO2

Advantages

/Cold metal transfer means extremely low heat input to ensure no deformation happens on the plastic parts

/ Nearly no spatter

/High welding speed and better welding result

Application case value analysis——frame

Fronius advantages actucal benefit in production Cost save up
Nearly no spatter Grinders are saved labor cost
High welding speed Production efficiency is improved (if the annual production keep the same, work stations and operators are reduced) equipment investment & labor cost
Gas consumption per unit product is reduced with higher efficiency gas cost
lower current and voltage, efficient CMT transfer (if the feeding speedkeep the same) Electricity consumption is saved by 20 ~ 30% electricity cost
Pure CO2 replace the former mixed gas Mixed gas is much more expensive than CO2,. It will save up 10000 RMB per month if each power source worked for two work shifts gas cost
1.2mm wire replace the former 1.0mm one
For wires in same material, the thicker the cheaper. So 1.2mm wire can save 10%~20% cost compared to 1.0mm wire base material cost
Stable arc Less destortion rate lead to reduced repair rate and ejection rate
labor cost
Strong bridging ability
High precision, no need to do correction bfore welding labor cost
Low heat input Reduce distortion

Save up cost analysis

Assumed lifecycle cost = fixed cost (equipment investment) + operating cost (labor + wire + electricity +gas) (PS:excluding depreciation cost)

If same work load per unit system, Fronius save cost as follows:
Cost per unit system X brand Fronius
Equipment investment ¥1,000,000 ¥1,056,000
Gas ¥36,000 ¥9,900
Base material ¥55,536 ¥51,792
Electricity ¥17,828 ¥12,308
Labor ¥374,400 ¥334,286
Total cost for the1st year: ¥1,483,764 ¥1,464,286
Prediction of the cost save up in the future five years per unit robot welding system (under ideal state):
Time X brand Fronius Cost save up annually per unit system
1 year ¥1,483,764.00 ¥1,464,286.00 ¥19,478.00
2 year ¥1,967,528.00 ¥1,872,572.00 ¥94,956.00
3 year ¥2,451,292.00 ¥2,280,858.00 ¥170,434.00
4 year ¥2,935,056.00 ¥2,689,144.00 ¥245,912.00
5 year ¥3,418,820.00 ¥3,097,430.00 ¥321,390.00
6 year ¥3,902,584.00 ¥3,505,716.00 ¥396,868.00

Application case value analysis——seat sliders

Fronius advantages actucal benefit in production Cost save up
Nearly no spatter Grinders are saved labor cost
A yield of 95% + Reduce the repair welding labor cost
Low heat input To reduce the deformation, reduce rejection rate gas cost
Strong bridging ability Reduce corrective/repair welding labor cost
1.2mm wire replace the former 1.0mm one Saving the cost of welding wire gas cost
Little splash, qing gun low frequency Reduce downtime, improve production efficiency Cost of production time
A long life Reduce the consumption cost gas cost
Reduce downtime Cost of production time