From MIG Welding Guide
R GUDMUNDSON, Air Liquide Gas AB, Sweden
Robotic MIG welding is used extensively in automotive production for parts and for car bodies on the main production line. In both cases there is a high demand for quality and reliability as well as productivity. Two cases studies are presented below - welding of a rear support arm and welding car bodies on the main production line.
17.2 Rear Support Arm
The rear support arm for a car is welded in a robot line. There is one robot line for the left and one for the right support arm. Figure 17.1 shows the left support arm. The rear wheels are screwed into the end piece with four bolts. The support arm acts together with a spring to transfer the weight of the car body to the wheels and the shock absorber, which prevents fast oscillations of the body when driving on roads of bad quality. The object is heavily loaded in fatigue.
Figure 17.1: Left support arm.
The steel sheet has a thickness of 2.5 to 3 mm, but the end piece has a thickness of 11 mm in normal conditions but 36 mm in a model with 50 mm wider wheelbase. The total length of the welds is 3.0 m.
The series is 200,000 pieces per year with a maximum capacity in the robot line of 6000 support arms per week.
17.2.1 The Welding Sequence
The support arm is welded in three stations. In the first, the butt weld...
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