Suzuki frames, not enough penetration!

[Fisty]

I know this is an old story but worrying none the less! Its the poorest welding Ive seen on something so modern.

Does anyone know if the frames are hand welded or done by robots?

Clicky! https://1tail.com/2005_GSXR_frame/default.asp
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TL1000R | Hayabusa | ZXR400 | TL1000S | Bandit 400 V
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[ms51ves3]

The page won't load up for me

[Fisty]

Sorry try this https://1tail.com/2005_GSXR_frame/default.asp
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Quietly and consistently taking the piss.
TL1000R | Hayabusa | ZXR400 | TL1000S | Bandit 400 V
Fatter and faster than Fret

[ms51ves3]

[Whosthedaddy]

Maybe it was owned by Mattspratt?

It seems unlikely that a mass produced, closely scrutinised manufacture could have a weld that breaks so easy, surely?

[colin1]

Phoenix on here used to pick up damaged bikes as his job, and had comments about the strength of modern sports bike frames.

I think suzuki ones had a few scathing words from him, but I cant remember which ones he thought were ok, or what other ones seemed to crack a lot.

Maybe he will see this thread, and be in shortly.
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colin1 is officially faster than god

[daz_d_biker]

One of the racers one of my friend races with had the 2006 or 2007 world championship winning superstock GSXR1000, first trackday she had on it going over the crest at cadwell I think it was, she crashed, over 100mph. Caused the headstock to be ripped completely from the frame. The front end was even intact.

Daz.
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"bikes are replaceable - but a complete nutter aint."

[repsolblade]

wow thats a worry I've spilled my K2 gixer 3 times and its still solid must be good year.
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( TS50 RD80Lc RD125Lc CBR600 ZX7x2 SP1 CBR900 CBR1000rr GSXR750 CBR600)

[the grim reaper]

There have been issues with welds on the Yamaha FZ1 frames as well, the Fazer Owners club has a member whose bike broke in half and threw him down the road.

That one is being sorted out privately but it will be interesting to see if any recalls happen.

Can's open that linke above though.

Cheers

Grim
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[stinkwheel]

There was a time when they just used to weld the bits you could see.
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[SoND]

[ms51ves3]

[m0l0t0v]

I remember reading on Bike( I think) a few months ago that suzuki don't use robots to build the bikes but humans so I would've thought the welding would be done by humans too...
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[ncrn]

They'd probably be better off using robots cause robots don't make mistakes frequently.
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[SoND]

Professional welders don't make mistakes frequently and robots are only as good as the person setting it up.

I'm not sure if they've got robots that can weld every single bit of the frame yet, it would be a very complex machine.
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[Itchy]

Maybe it was a Japanese worker who was tired.... you know those Crazy japanese folks who work 7 days a week 16 hour shifts day in day out until they drop dead.
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[ncrn]

[Ichy]

I wouldn't have thought the number of bikes they build would justify the cost of robotics? TBH I have no idea how many they make each year?

You could easily weld a bike up with two robots, you might even get away with one, there aren't that many welds on a bike.

https://uk.youtube.com/watch?v=mYr-guKHYL0

I think it was on the Rover 75 where they had one robot that would lift up and rotate the body to give access to various parts of the car for the other robots.
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[thefallenange...]

[MaybeGuy]

[SoND]

https://www.manufacturingtalk.com/news/tps/tps142.html

KTM have spent 3 years setting up a pulsed TIG system for their RC8, 90% automation now. If the Austrians are using it then I would have expected the Japanese to be but I can't find anything on it, maybe they don't.


EDIT: Facts getting in the way.
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[St0rmer66]

[ncrn]

[SoND]

Each part would need clamped into a jig and they're all more awkwardly shaped than a golf ball. You could easily spend hundreds of thousands pounds developing a machine just to lift and move the parts nevermind weld them.

Yeah you could make that arm hold some welding equipment but you aren't going to make it weld. To do the likes of a motorcycle frame you're going to need an arm that can move in 5/6 axis accurately and it would need to be taught how to do each individual weld.

That arm is very very slow, no good for industry. £300 isn't going to get you anything useful.

https://uk.youtube.com/watch?v=w__2XjIaBPw
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[ncrn]

To be fair to that arm its limited to about 20% of its speed because of health and safety people in the uni . And that thing which is ancient is massively accurate, it has 6 degrees of freedom which it hasn't ever got wrong in the time I've used it.

Also its so simple to teach a robot positions, you have a hand held device which lets you control all 6 joints, and all you do is move the robot to your designated point, press the teach button and the robot will remember it. So teaching isn't an issue, we taught ours how to sort between real and fake golf balls and stack them accordingly in about 2 and a half hours, and we'd never used the machine before.

But to be fair that machine you found does look a lot more accurate, but then I'm guessing it isn't around 30 years old .
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Past: 55 Sym Jet, 91 ZZR250, 03 NSR125R. Present: 97 ER-5.
https://www.nsr125.co.uk - NSR Owners forum.