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.
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.
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
Due to large differences in material thickness, more complex welding tasks are required, including -thin sheet welding, through-welds and circumferential welds
High demands on geometry due to low manufacturing tolerance
Fronius PMC/CMT welding at high speed:
Two LEWA SpeedCells ARC 2.0
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
High-precision tooling technology with available adjustment based on in vehicle RPS of +/- 5mm to react to welding distortion and geometry settings
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.
The ability to run each nest individually to support spare part requirements
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
Modular LEWA SpeedCell design - Enables expansion and adaptation for future products
Concept development, equipment and tooling engineering, manufacturing, assembly, programming, commissioning , quality manufacturing – in less then 25 weeks.
We achieved and surpassed the required machine cycle time of 616 sec by 12% per seat assembly with simultaneous operation by one worker.
Start-up support for series production
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