Assembly and Welding Cell

Challenge

The project required the development of an automated cell for the final assembly and welding of a condenser. The solution needed to ensure precise and efficient welding with a fast cycle time, while maintaining high-quality standards for both aluminum and steel materials.

Implemented Solution

We engineered a solution that integrates both assembly and welding processes with the following key features:

Welding Process: The cell performs a circular welding seam of 100 mm in diameter, around a komo with a diameter of 30 mm. The welding is done using CMT (Cold Metal Transfer) technology, applying a 1.2 mm steel wire to aluminum components in an inert gas environment of 100% Argon.
Rotating Index Table: The machine is equipped with a two-station rotating index table, capable of 180º rotation. One side is dedicated to loading the components, while the other side handles the welding process.
Pre-Welding Preparation: Before welding, a brushing process is carried out on the komo to ensure a clean surface.
Cooling Process: After welding, the assembled parts are cooled for 4 minutes as they exit the cell on a conveyor belt.

The entire process operates with a cycle time of 36 seconds, ensuring both precision and efficiency.

Results

The automated assembly and welding cell delivered consistent high-quality welds, meeting the required precision and durability standards. The integration of CMT technology ensured efficient, low-heat welding, reducing material distortion. The 36-second cycle time optimized production, while the pre-weld brushing process and cooling system enhanced the overall reliability of the final product.