We explain how LEWA Attendorn develops a flexible production concept, which ensures future expansion and integration of other products in the event of volume fluctuations or design modifications according to the ReUse principle.
Customer requirement:
Design of a production system for MIG welding of a complex, heavy duty vehicle seat assembly consisting of backrest (60% and 40%) and seat bench. The goal is 30,000 units per year in a maximum of 616 seconds per seat assembly. The production system is to be manned by one operator. We developed a flexible production concept, which ensures future expansion and integration of other products in the event of volume fluctuations or design modifications according to the ReUse principle.
Application processes:
The total weld length of 8223mm is distributed over three assemblies
Seat structure = 2970mm with 97 welds
LH 60 backrest = 3189 mm with 92 welds
RH 40 backrest = 2064 mm with 49 welds
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Due to large differences in material thickness, more complex welding tasks are required, including -thin sheet welding, through-welds and circumferential welds
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High demands on geometry due to low manufacturing tolerance
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Unsere Lösung:
Fronius PMC/CMT welding at high speed:
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Two LEWA SpeedCells ARC 2.0
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LEWA SpeedFrame with 2,500 mm center width for welding tools weighing up to 750 kg per turntable side. Turning time (180°) < 3.0 sec
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High-precision tooling technology with available adjustment based on in vehicle RPS of +/- 5mm to react to welding distortion and geometry settings
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Particular focus on the design of the assemblies and subassemblies within the tooling to ensure accessibility of the welding torches, accessibility for the operator, and for maintenance.
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The ability to run each nest individually to support spare part requirements
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Standard design for a flexible production concept Expandable program structures as well as the LEWA quick-change tooling mount, allow short set-up times for variants and create flexibility in production planning
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Modular LEWA SpeedCell design - Enables expansion and adaptation for future products
The customer benefit:
Solution from one source:Concept development, equipment and tooling engineering, manufacturing, assembly, programming, commissioning , quality manufacturing – in less then 25 weeks.
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We achieved and surpassed the required machine cycle time of 616 sec by 12% per seat assembly with simultaneous operation by one worker.
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Start-up support for series production
You would like to learn more about LEWA Attendorn? - Sure!
Arrange an introductory meeting or web call with our team to review our capabilites and discuss your automation needs.
