Solutions Through Welding Technology

NBC-9593 REAR AXLE ASSEMBLY SLUG WELDING LINE 

 

Application:

This is a proven process of joining automotive rear axles that is more reliable and has less maintenance then arc-puddle welding. In the slug welding process, two axle tubes are radially oriented and pressed into a carrier. The assembly is transferred to the weld stations where slugs are automatically feed and inserted into holes in the cast iron carrier. The slug then goes through a two step process, first the slug is projection welded to the axle tube, second it is heated and hot upset to fill the hole.

 

  

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This axle line produces 4 different models at 180 axles per hour, with a maximum of 15 minutes for model changeover.
 

Production:

This line produces 180 axles per hour. Running four different models with a maximum of fifteen (15) minutes for changeover from model to model. It runs with a 1.67 CpK for accuracy and consistency. It requires four (4) people to run the line and has a 95% uptime.

  

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Typical Axle Components Joined.
 

Optional Operations:

  • Bearing and Seal Insertion
  • Clip Welding
  • Part Marking / Stamping
  • Bracket Pierce and Hole Detection
  • Leak Testing
  • Torque Testing
  • Flange Testing
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Line layout
 

Machine Features:

  • Press capacity - 60,000 lbs. (132,276 Kg) each side with press force monitor with Hi / Lo limits.
  • Quick change, color-coded, pull-pin tooling for model changeover, no loose tooling.
  • Wedge action clamping of carrier housing to avoid potential distortion.
  • Gauged after press to avoid welding any reject parts.
  • Slugs fed by air blow tubes, "Slug Present" detection included.
  • Appropriate stations include axle orientation capability.
  • Automatic axle rotate before unload conveyor for carrier flange up.
 

Sequence of Operation:

  1. Operator (1) loads carrier.
  2. Sealant Station Apply Sealant.
  3. Operators (2) load axle tubes.
  4. Press Station and press.
  5. Gage Station for proper axle length.
  6. Weld Stations (3) insert slug and weld.
  7. Bearing Press and Probe (optional).
  8. Seal Press Station and Lube (optional).
  9. Clip Weld Station (optional).
  10. Bracket Pierce Station.
  11. Operator (1) Unload Station.
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