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In January 2019, Tong Hi-Tech undertook the project of FAW Hongqi's welding plant at the Changchun base, and was responsible for the "turnkey project" of the four-door laser flight welding workstation for C229&E115 models. At present, in the process of body development, in order to enhance the visibility of the body, it is necessary to design the narrow frame of the window. This means that the width of the flange side of the window frame is narrow, and the traditional spot welding process cannot meet the manufacturing requirements. At present, there are three main manufacturing processes to solve the narrow frame of the body: small spot welding, Aplas welding and laser welding. Comparison of advantages and disadvantages of several processes:
該項目坐落于一汽紅旗長春基地，激光焊接房與激光源房采用整體式設(shè)計，激光源房和除塵設(shè)備放置在二層鋼平臺上。左右前門（左右后門）共線生產(chǎn)，本項目采用激光飛行熔焊，車門材料為鍍鋅鋼板，采用兩序激光焊接。第一序為Dimple焊接，第二序為激光熔焊。兩序激光焊接目的在于釋放鍍鋅鋼板在焊接過程產(chǎn)生的鋅蒸汽，從而提高焊接質(zhì)量。
? 工位規(guī)劃20JPH，節(jié)拍CT=153s；
? 項目規(guī)劃5車型，預(yù)留1車型。采用三面轉(zhuǎn)轂轉(zhuǎn)臺進行車型切換，本期項目投產(chǎn)兩款車型C229&E115；
? 車門內(nèi)板和窗框均采用機器人上下件，自動化程度高；
? 第一序Dimple焊接，保證兩層板材之間控制0.2mm的間隙，釋放鋅蒸汽，提高焊接質(zhì)量；
? 采用琴鍵式夾具，保證每條焊縫尺寸匹配一致性；
? 采用遠(yuǎn)程振鏡焊接系統(tǒng)，提高焊接效率；
? 激光飛行焊系統(tǒng)采用世界先進主流工藝設(shè)備配置，可實現(xiàn)高品質(zhì)焊接質(zhì)量要求；
? 工位采用同高科技自主研發(fā)的雙層鋁合金的防護系統(tǒng)，并通過德國TUV安全檢測及認(rèn)證；
2D布局圖
項目采用一汽紅旗激光焊接工藝標(biāo)準(zhǔn)， 采用激光飛行焊工藝。焊接搭接形式為疊焊（Overlap，穿透焊接），作為鍍鋅鋼板激光焊接，為了避免焊接過程中鋅蒸汽對焊接質(zhì)量的影響，采用2序激光焊接，第一序Dimple焊接，第二序激光深熔焊。
激光Dimple焊接 激光深熔焊
激光系統(tǒng)整體照片
四門飛行焊激光夾具
