Prototype to decide mass production frame CO₂ welding assembly line Thermix
The dimensions of the frame are determined not by the welding conditions, but by constraints and sequence.
Welding of truck and passenger car frames involves long parts and many components, where thermal distortion and cumulative tolerances directly affect dimensions. Thermix designs the jig clamping sequence, welding sequence, and robot posture as an integrated system, establishing a CO₂ welding assembly line for body frames that can be mass-produced. We handle everything from concept to design, manufacturing, installation, and startup in a consistent manner. We have established a design flow that applies newly introduced robot simulation software to the CO₂ welding line, verifying the range of motion, welding posture, torch entry angle, and interference during the design phase. A prototype line is not considered successful just because it operates. We verify quality, productivity, and workability, creating decision-making materials for handing over to the mass production assembly line. - "Frame distortion does not meet specifications" → Review the welding sequence based on the order of constraints and releases. - "There are many reworks in the teaching field" → Pre-check the range of motion and interference through simulation. - "I want to expand the prototype equipment to mass production" → Record measurement points and stopping factors for handover. - "I want to set up the same line in overseas factories" → Provide consistent support from pre-shipment inspections to local supervisors. - "I want to align with the standards of the current line" → Interpret the equipment standards for both mechanical and electrical aspects for design. Please consult us from the stage of organizing what you want to verify on the prototype line.
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【Scope of Work】 - Concept design, equipment design (mechanical and electrical), manufacturing, installation, and commissioning - Pre-verification of movable range, welding posture, and interference through robot simulation - Design of welding jigs: positioning standards, supports and clamps, clamping sequence, release sequence - Control of distortion direction through welding sequence design - Pre-shipment inspection and on-site supervision 【Three Axes to Verify in Prototype Line】 Quality: Dimensional outcomes, distortion trends, bead shape and leg length, locations of spatter occurrence Productivity: Cycle time, frequency of chip and nozzle replacement, time for product changeover Workability: Component set posture, clamping operation, jig cleaning, accessibility to maintenance space 【Features】 - As a line builder integrating production technology, automation, robotics, and control, we prioritize the establishment of the line rather than just individual equipment. - For purchased items with delivery risks, we consider switching to in-house production by obtaining drawings, thinking from the perspective of how to meet deadlines rather than just the scope of responsibility. - We design with mass production in mind, considering the repeat accuracy of jigs, replacement of worn parts, and ease of cleaning. - Any issues identified on-site are documented in-house, and production is handled by local companies. - We begin the design process after interpreting both the equipment standards of new clients and the unique standards that remain in the current line.
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Supported industries: Automotive, commercial vehicles, trucks, etc. Supported work: Vehicle frames, etc. Welding method: CO₂ welding, etc. Supported processes: Parts setting, positioning, clamping, welding, transportation, extraction Supported forms: New lines, modified equipment incorporated into existing lines, mass production development from prototype lines Scope of services: Concept, design, manufacturing, installation, startup, on-site supervision Supported regions: Domestic and overseas automotive factories Target departments: Production technology department, manufacturing department, equipment technology department Consideration stage: Concept for new lines, modification of existing lines, horizontal expansion to overseas Consultation examples: "I want to incorporate modified equipment without stopping the existing line" "I want to expand the same line overseas" Case study: An automotive factory in Thailand. Designed, manufactured, and constructed a prototype line for a CO₂ welding line for pickup truck frames, incorporated into the existing line as modified equipment. For the first time, new robot simulation software was applied to the CO₂ welding line, establishing verification procedures. Electrical work was reviewed in terms of processes and personnel planning, strengthening the system to about twice the initially planned scale to meet the schedule. This prototype line will operate as mass production equipment.
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We, Thermix, a top-tier production line builder with proven expertise, handles automation and line construction for production equipment across diverse fields including automobiles and automotive parts, aircraft bodies, and industrial machinery. We provide full turnkey solutions from concept and specification review through design, manufacturing, installation, commissioning, and maintenance, ensuring reliable mass production launch. Leveraging our production technology expertise, we organize and visualize the current state, including process feasibility, integration with existing equipment, and safety. Utilizing industrial robots, image processing, conveyance/inter-process transfer, and material handling, we propose realistic automation roadmaps without unnecessary strain. We address challenges like “We want to reduce staffing on lines that can't be stopped” or “Equipment investment decisions are difficult,” accompanying you from small-scale PoCs to full-scale deployment with our project management expertise. Leveraging our domestic and international launch experience, we collaborate to create the optimal production line.