Machine No.8 – laser poppet welding
No. 8 machine of semi-automated production line for assembly of 3rd generation Audi EGR valve with subsequent adaptation for the alternative assembly of the 2nd generation EGR valve.
Machine with two workstations for the laser welding of the stainless steel poppet to the gear wheel stem and assembling the valve cover
Project: Assembly line for the EGR valve – Audi V6
Number of workstations within the machine: 2
Term of delivery: 2015 – 2016
PARAMETERS:
Width: 1900 mm
Depth: 1250 mm
Height: 2550 mm
Weight: 1100 kg
Operating pressure: 0.6 MPa
FEATURES:
The machine´s job is to laser weld the stainless steel poppet to the gear wheel stem and then cover the valve housing.
DESCRIPTION OF THE WORKSTATIONS:
DT1 workstation
After the manual insertion of individual parts, it performs the circumferential laser welding of the stainless steel poppet to the gear wheel stem to a minimum depth of 0.9 mm. After completing the camera check of the quality of the weld and the correct position of all components, the assembly continues at the DT2 workstation.
Control system feedback: camera check of the quality of the weld and proper positioning of components
DT2 workstation
Assembles the valve cover and completes EGR valve assembly with this process. The operator places the cover on the valve housing. The workstation secures the cover with screws automatically supplied from the vibrating feeder located at the machine´s rear.
Parts of the machine (front side):
b) Connection to the welding area´s exhaust system
d) DT1 workstation: Welding the poppet to the valve stem
e) Control box for the DT1 workstation with buttons
g) Camera check monitor
i) Screwdriver control unit
j) OP panel
k) RM1 electrical switchboard
n) Workstation 2: Assembling the valve cover
o) Control box for the DT2 workstation with buttons
Parts of the machine (rear side):
a) Vibrating hopper for screws with vibrating bar
b) Rear door for access to the DT1 workstation
DESIGN OF THE MACHINE:
- Robust steel frame with closed rails for ease of handling with a forklift,
- Solid/polycarbonate panels – as fixed surfaces or as doors
- Workspaces are secured with optical security barriers, electric security locks, or bolted connections
- The operator panel part of the electrical switchboard
- Control buttons of both workstations within easy reach of the operator
- Monitor for displaying the weld inspection above the DT2 workstation
- Connecting the machine to the work area exhaust system.
