Client Overview:
The client, Shanghai Xijian Automotive Suspension Co., Ltd., specializes in automotive shock absorbers and suspension systems for various high-performance vehicle models. The client approached Qiyihang Automation (Chengdu) Co., Ltd., a leading automation solutions provider, to design and implement an automated assembly line for the RIG-A302 ADS shock absorber production.

Challenge:
The client required an efficient and automated assembly line that could handle the production of various shock absorbers, including for models like the Tesla Front Shock Absorber, Ford Raptor, and ADS Shock Absorbers. The system needed to optimize production speed while maintaining precision in every key process, including component assembly, tightening, oil injection, and sealing.

Solution:
Qiyihang Automation, in collaboration with RIG, provided a comprehensive solution: a fully automated shock absorber assembly line. The system was designed to handle all the critical processes, integrating servo press machines, oil injection systems, spring assembly machines, and tightening stations. Key features include:

• Three Manual Assembly Workstations: For easy operator access and integration with other systems.
• Servo Press Machines: Ranging from 1t to 15t to provide the precise compression force required for assembly, with a maximum force of 150kN.
• Automated Oil Injection and Sealing: The line includes automated systems for oil injection (50-300ml with ±5ml accuracy) and sealing with adjustable pressures up to 50kN.
• Lateral Force Loading Unit: This unit ensures the shock absorbers are subjected to necessary lateral forces, with adjustable loading up to 1000N.

The line was also designed to collect critical manufacturing data, such as torque, compression force, displacement, oil injection amounts, and sealing pressure.

Implementation:
Qiyihang Automation’s team handled the design, assembly, and installation of the entire system. After the assembly line was installed, the team conducted comprehensive testing and calibration to ensure that it met the client’s specifications. The system was also equipped with remote monitoring capabilities for ongoing maintenance and optimization.

Results:

• Optimized Production Efficiency: The automated line reduced labor requirements and increased throughput, with a cycle time of approximately 60 seconds per unit.
• Enhanced Product Consistency: The automated systems ensured that each component was assembled with the precise force and torque values required, leading to higher quality and reliability.
• Improved Data Accuracy: The collection and analysis of real-time data provided valuable insights, helping the client improve product quality and make data-driven decisions for future production optimizations.

Conclusion:
The RIG-A302 ADS shock absorber assembly line represents a successful implementation of automation in the automotive sector, improving production efficiency, product consistency, and quality assurance. This case highlights how Qiyihang Automation and RIG provided a robust solution to the client’s complex manufacturing requirements, setting the stage for future collaborations in the automotive industry.