A Powerful Tool For New Energy Vehicle Trial Production And Small Batch Production – Dunchuan ESR830 Hydraulic Rivet Gun Solves The Problem Of Lightweight Connection

A powerful tool for new energy vehicle trial production and small batch production – Dunchuan ESR830 hydraulic rivet gun solves the problem of lightweight connection

In the new energy trial production workshop, the biggest problem is not the welding process at all, but when steel and aluminum alloy are mixed and connected, a large number of samples are always scrapped. This situation makes it impossible for an ordinary riveting gun to withstand the work pace of rapidly changing car models.

Welding deadlock in trial production workshop

Aluminum alloys, aluminum-magnesium alloys, and steel aluminum composite plates are now widely used in car bodies and battery trays. Once the welding heat input becomes too large, the aluminum plates will begin to deform and the surface coating will crack. The original insulators and sealants inside the battery pack casing will be directly scrapped. In the trial production stage, every time it needs to be reworked, the riveting and welding assembly service of small batch trial parts will cost tens of thousands of dollars wasted.

The pressure of ordinary pneumatic rivet guns is fixed. When used to process aluminum plates of different thicknesses, problems such as false riveting or base material crushing may occur. What is even more troublesome is that the process parameters completely rely on the master's touch, resulting in data that cannot be retained and must be tried again during the next iteration, which makes the research and development cycle needlessly lengthened.

Hydraulic pressure control maximizes riveting accuracy

The pressure range of Dunchuan hydraulic rivet gun is between 30 and 60KN, which can be continuously adjusted. There is also a pressure sensing system inside. Whether you are making two layers of one-millimeter aluminum plates or three layers of two-mm steel plates, you only need to directly set and match the pressure. The force output during the riveting process is very stable, and there will be no problem of instantaneous high-pressure breakdown of the aluminum substrate.

After the molding consistency of each riveting point is strictly locked, defects that often occur in the trial production stage, such as unilateral bulges and false rivets, basically no longer appear. The pass rate of prototypes in the first proofing stage has been significantly improved, while the scrap rate in the trial production stage has been successfully suppressed from the source.

Portable lithium batteries get rid of the constraints of production lines

The entire machine weighs only 5 kilograms and uses an 18V 4.0Ah lithium battery for power supply, so there is no need to pull the air compressor pipeline or connect to an external power supply. It only takes one hour of fast charging to complete the charging process. It can complete 350 to 400 riveting operations on a full charge, which is completely sufficient for the trial production workshop to conduct prototypes in a single day.

The gun head adopts a compact C-shaped structure , riveting and welding assembly service of small batch trial parts , which can penetrate deep into the body pillars, the groove area of ​​the battery tray, and the small operating spaces that exist at the corners of the chassis. In view of this structural feature, many complex points can be processed without disassembling the entire sample. The operator only needs to hold the tool alone to directly complete the riveting action, thus greatly shortening and saving the overall disassembly and assembly time.

One machine can save investment in trial production tooling

The basic function uses SPR self-piercing riveting. If the mold is changed, it can also complete riveting, drilling and plate leveling. During the trial production and iteration stage, the rivets on the old prototypes must be removed, the plates need to be repaired, and the new prototypes need to be drilled. One piece of equipment can handle all these tasks, and there is no need to purchase tooling for each individual process.

For research institutes and trial production workshops, the amount of money they invest in equipment is directly and significantly reduced. When the plan for a new car model changes, there is no need to wait for the production line to be modified. Instead, they directly pick up gun-like tools to replace the molds. After such an operation is completed, they start working immediately, so their response speed can fully keep up with the rhythm of the research and development stage.

A car company’s trial production record of battery trays

A domestic new energy vehicle manufacturer plans to produce sample parts of a new aluminum alloy battery tray. In the previous stage, they used the welding process. It was found that the deformation rate of the sample was very high. Moreover, this sample has failed several rounds of IP protection tests. Later, the operation was switched to Dunchuan.

The specific method is to rivet the bushing and fix the plate using SPR riveting technology. In doing so, the entire production process is in a state of cold processing. The final result shows that the coating on the pallet surface is intact. Moreover, every riveting point is very full, and there is no abnormal bulging phenomenon.

The trial production team achieved rapid comparison of multiple groups of process plans by flexibly adjusting the pressure parameters. Then the device uses the Bluetooth communication function to automatically record the parameters of each riveting, which facilitates later review and archiving work. Then the reliability tests such as vibration and high and low temperature were all passed in one go, so the trial production cycle of this project was significantly shortened.

Flexible choice for small batch production lines

When conducting small batch trial production ranging from dozens to hundreds of units, the capital cost of purchasing and using large-scale automated riveting special equipment is too high, and the cycle of changing models is very long. Dunchuan can adapt to new parts structures by replacing molds and fine-tuning pressure parameters. Its flexibility has reached a very high level, so it is particularly suitable for use in the transitional stage of small batch production lines.

The equipment adopts a low-noise design of 75 decibels and is equipped with an ergonomic handle, which allows workers to not feel tired when working for a long time. At the same time, the device itself has an overheating protection function and an audible and visual alarm mechanism. When there is an abnormal pressure or the battery power is low, it will automatically send out a prompt message, thus providing a strong guarantee for the safe operation of the trial production workshop.

Could you please tell me about the current riveting operations in your trial production workshop? Do you use pneumatic guns for the operation? Or do you use hydraulic equipment for processing? Everyone is very welcome to communicate and discuss in the comment area. If you think this content is useful, please click like it and forward it to other colleagues to take a look.