Automatic Aluminum Alloy Fuel Tank Welding Line

 

This aluminum fuel tank welding production line is an automated integrated system designed for the efficient and precise manufacture of high-quality aluminum fuel tanks. Following typical fuel tank manufacturing processes, the line integrates core procedures from sheet metal forming to final sealing welding, ensuring superior structural strength, sealing performance, and consistency. The overall line design balances the specific requirements of aluminum welding with the efficiency demands of large-scale production.

 

 

The equipment is mainly used for the rolling of aluminum alloy square cylinder, elliptical cylinder, triangular cylinder and circular cylinder. By adjusting the distance between the left and right rollers, round and square workpieces with different diameters can be rolled. After the sheet is pushed in, in order to prevent the sheet from skewing, the belt is automatically positioned left and right and pushed into the appropriate position; the upper support rod has a follow-up function. There should be no obvious arc at the straight seam behind the coil plate of the fuel tank to hinder the straight seam welding.

The processing flow of the equipment 

Feeding → pushing (automatic) → plate automatic alignment → plate entering the plate rolling machine → plate rolling (automatic): CNC four-roll plate rolling machine rolls according to the pre-programmed program Workpiece → unloading (manual) to remove the rolled workpiece.

 

 

This equipment is used for straight seam butt welding of carbon steel, stainless steel, aluminum and other metal barrels (TIG/CO2/MAG/MIG welding can be used ) . After the workpiece is pressed tightly against the stainless steel of the welding main beam, the walking trolley drives the welding torch to perform straight seam welding. After welding to the designated position, the welding stops, the welding torch rises, and the welding trolley quickly returns to the starting point. The welding torch adopts AC frequency conversion motor, the welding speed can be adjusted steplessly, and the welding shape is beautiful.

The equipment is mainly composed of the pressing part, the main beam part, the walking part , the control system, the welding power supply system , etc. The bed is an all-steel welded structure. Do annealing to relieve stress.

 

The processing flow of the equipment 

Feeding (manual, assisted by the lifting roller table): placing the workpiece on the mandrel → the mandrel centering mechanism extends through the cylinder (automatic) → the mandrel hook device locks the positioning mandrel (Automatic)→Key pressing finger presses half of the workpiece (Automatic)→ The mandrel centering mechanism retracts through the cylinder (Automatic)→Key pressing finger presses the other half of the workpiece (Automatic)→The welding gun is lowered to the position (Automatic)→Start welding→ After the welding is completed, the welding torch is raised to the position (automatic) → the key is pressed to release the workpiece (automatic) → unloading (manual): remove the welded workpiece.

 

 

The equipment is mainly used for the circumferential welding of the oil filling and draining screws of the aluminum alloy fuel tank barrel and the screw seat of the oil return port. The workpiece is welded by robots (CO2/MAG/MIG welding). The equipment is mainly composed of robots, Fronius welding power source is composed of base , column, positioning fixture, pneumatic system, electrical control system, etc. The positioning of the workpiece barrel and the parts of the fuel filler is positioned by a special positioning die, and then the pressing cylinder drives the special pressing die to press the fuel filler parts. During welding, the workpiece is not moved, and the robot carries the welding torch to make a circular rotation (during the welding of the fuel filler). The trajectory is realized by the robot programming), so that the welding torch does a copying and rotating motion to match the drop trajectory of the fuel filler). The welding gun adopts a push-pull welding gun, and the welding current is communicated by the robot and the welding power source, which can be changed in real time. Robotic workstation is equipped with gun cleaner and wire cutting mechanism.

The equipment is mainly composed of welding robot, column, workpiece positioning mechanism and other parts. The bed is an all-steel welded structure, and important parts need to be annealed and heat treated.

 

The equipment processing process 

Place the aluminum alloy cylinder on the positioning mandrel, and the hole to be welded must pass through the positioning column (manual) → insert the threaded joint into the positioning column (manual) → press the button, the cylinder Drive the locking fixture to compress the filler pipe joint (automatic) → press the button, the welding robot will automatically find the position to weld the workpiece (automatic) → after reaching the set welding overlap, the welding will automatically stop and the robot will automatically return to the original position (automatic) → remove the workpiece (manual).

 

 

This equipment is used to press-fit the inner interlayer of the barrel after the aluminum alloy fuel tank workpiece is rolled. The working mode adopts the horizontal form. The diaphragm press -fitting adopts a hydraulic system. The equipment control system is mainly based on PLC, which can realize automatic control. The whole machine has reliable quality, high precision, beautiful appearance and convenient operation.

The equipment is mainly composed of a bed and a press -fitting part . The bed is an all-steel welded structure, and important parts need to be heat treated. Since the press-fitting die is fixed on the linear guide, and the linear guide is installed on the bed, the entire bed After the body is welded, the whole body is tempered to relieve stress to ensure that the body of the equipment is not deformed during use.

 

The processing process of the equipment

Feeding (manual) → positioning (manual assistance) → pressing (automatic) → unloading (manual).

 

 

This workstation adopts the welding method of single robot and single station. A robot is fixed on the machine base, the workpiece is installed on a special lifting platform, and the platform can be moved up and down. After the workpiece is fixed on the lifting platform, the platform can be turned 180 degrees, which is convenient for the welding of the two partitions. The robot program is preset, and each program corresponds to the welding workpiece.

The workstation mainly includes arc welding robot, welding power source, laser tracker, robot fixed base, welding tooling and positioning fixture, and safety protection measures.

The workstation adopts the rack and fixtures produced by our company, including the walking beam. For different types of workpieces, corresponding to different welding parts. The robot welding program performs automatic welding of the workpieces on each tooling. Robotic workstation is equipped with gun cleaner and wire cutting mechanism. Workstation areas are equipped with local isolation baffles.

 

 

This equipment is used for the welding of the barrel body and the end cover of the carbon steel, stainless steel, aluminum and other metal cylindrical bodies ( and square , D-shaped oval, etc.) workpieces. The welding is controlled by a three-axis numerical control system. The adjustment part of the welding torch adopts a stepper motor and a ball screw, which can be manually fine-tuned during welding. Reduce the work intensity of the operator and ensure the welding quality.

The equipment is mainly composed of a bed, a spindle chassis, a jacking chassis , a material support mechanism, a positioning mechanism, a welding forming mechanism, and a welding torch fine-tuning mechanism. The bed is an all-steel welded structure, and important parts need to be heat treated . In order to ensure the concentricity of the chassis at both ends, the entire chassis on which the chassis is installed needs to be tempered to relieve stress after welding to prevent deformation. The welding torch fixing bracket also needs to be tempered after welding to prevent deformation during future use and ensure that the welding torch moves. The track does not deviate.

 

The processing process of the equipment

Place the workpiece on the pneumatic bracket → slide the pneumatic bracket to the clamping position → the pneumatic bracket rises in place → the spindle chassis moves to the right in place → push the chassis to move to the left→ the left and right welding guns descend to the same position→ the pneumatic bracket descends→ the spindle chassis head rotates to drive the workpiece to rotate → start the arc to start welding → welding Completion of arc ending → left and right welding torches rise to the same position → pneumatic bracket rises to the same position → the spindle chassis and the jacking chassis move back into place at the same time → remove the workpiece.

 

 

• High degree of automation and continuity: From rolling to end cap welding, key processes are completed by specialized machines or robots, reducing human intervention and improving production cycle time and process stability.
• Excellent and stable welding quality: Welding processes are optimized for the characteristics of aluminum, specialized machine design ensures consistency of key weld parameters, and robotic welding improves the precision and reliability of complex welds, resulting in high overall weld quality and good repeatability.
• High process integrity: The production line covers the entire set of core processes, including fuel tank body forming, accessory welding, internal structure assembly and welding, and final packaging, possessing complete fuel tank welding manufacturing capabilities.
• Significant production efficiency: Automated equipment operates continuously, reducing turnaround and waiting time between processes, making it particularly suitable for mass production and effectively increasing capacity.

 

 

Automatic aluminum alloy fuel tank welding line

 

 

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