A variety of welding machines demonstrate outstanding performance and promising application prospects
2024,11,20
In modern manufacturing, technological innovation and application expansion of welding equipment have always been the key forces driving industrial progress. Recently, various welding equipment fields such as friction welding machines, spot welding machines, butt welding machines, seam welding machines, steel ring laser welding machines and stud welding machines have all witnessed remarkable development trends.
Friction welding machines play a significant role in industrial production due to their unique welding principle - which utilizes the heat generated by the mutual friction of the workpiece end faces to bring them to a plastic state and then complete the welding through upsetting. According to the different energy input methods, friction welding machines are divided into continuous drive type and inertial type.
Continuous drive friction welding is carried out by an electric motor driving one workpiece to rotate while pressing the other workpiece against the rotating one, causing the contact surfaces to rub against each other to generate heat and a certain degree of plastic deformation. Then the rotation stops and a forging pressure is applied simultaneously to complete the welding. Inertial friction welding is driven by an electric motor to reach the required rotational speed, and then a workpiece is pressed against the rotating workpiece clamped on the flywheel shaft. The frictional resistance between the workpieces slows down the flywheel and converts the kinetic energy of the flywheel into the thermal energy required for welding.
Domestic large-tonnage inertial friction welding technology has become increasingly mature and is widely used in the welding of oil drill pipes, such as 160-ton inertial friction welded drill pipes and 250-ton welded weighted drill pipes, etc. Not only that, it also has broad application prospects in the aerospace and military industries. The Picus 2 fully automatic single-head Friction Welding Machine launched by the globally renowned KUKA Company is equipped with a forging force of 8-20 kn. With an integrated handling robot, it features high production efficiency and versatility. Besides being used for welding internal combustion engine valves, it is also expanding its application in new fields such as electric vehicles and general industries.
The Spot Welding Machine adopts the principle of double-sided double-point overcurrent welding. During operation, two electrodes apply pressure to the workpiece, causing the two layers of metal to form a certain contact resistance under the pressure of the two electrodes. When the welding current flows from one electrode to the other, an instantaneous thermal fusion is formed at the two contact resistance points. Its types are rich and diverse. According to their uses, they can be classified into universal type (general type) and special type. According to the number of weld points welded simultaneously, they can be classified into single-point type, double-point type, multi-point type, etc. In practical applications, the spot welding process includes steps such as turning on the cooling water, cleaning the surface of the weldment, applying pressure between electrodes after assembly, electrifying to form a fusion nucleus, cutting off the power and maintaining the pressure to cool and solidify the fusion nucleus to form a weld point, and removing the pressure to take out the workpiece. Xinsheng's medium-frequency spot welding machine, with a current of 60,000A and German precision components, has achieved a 1000Hz high-frequency inverter, adjusting the current 1,000 times per second. Its response speed is 20 times that of traditional AC welding machines, completely solving the problems of welding spatter and false welding, and reducing energy consumption by 40%. It is widely applied in six major industries including new energy vehicles, photovoltaic power, and smart home appliances.
Butt welding machines, also known as butt welding machines, are mainly used for butt welding of various metal materials. By closely adhering the end faces of two workpieces and then applying current and pressure, the contact areas of the workpieces are rapidly heated and melted, ultimately achieving welding. It can ensure the strength and sealing of welded joints and plays an important role in the manufacturing fields of pipes, profiles, etc.
Seam welding machines continuously or intermittently weld workpieces through roller electrodes to form continuous weld seams. It is often used in the manufacture of various containers, pipes and products that require sealed welding. During its operation, the roller electrode rolls while being electrified, enabling the workpiece to complete the welding in continuous movement. The welding speed is fast and the weld quality is stable. For instance, in the production of automotive fuel tanks, radiators and other components, the application of seam welding machines is extremely extensive.
The steel ring Laser Welding Machine is specially designed for steel ring welding. It uses a high-energy-density laser beam as the heat source and has significant advantages such as high welding accuracy, fast speed, and a small heat-affected zone. In industries such as automotive wheel hub manufacturing, steel rim laser welding machines can achieve high-quality welding, ensuring the strength and dynamic balance performance of steel rims, and meeting the automotive industry's requirements for high-precision and high-reliability components.
Stud welding machines are widely used in fields such as mechanical manufacturing, the automotive industry, shipbuilding, and construction engineering. The CNC stud welding system of Hongbai Technology is computer-controlled to achieve fully automated management of the stud welding process, ensuring the consistency of welding quality and the improvement of production efficiency. Its energy storage Stud Welding Machine uses large-capacity capacitors as the source of welding energy. The discharge time is precisely controlled by thyristors, and the stud tip is rapidly melted in the form of a momentary low voltage - strong current, quickly merging the gap between the stud and the working surface, and firmly welding the stud onto the working surface. The entire process lasts approximately 1-3 ms. It is relatively common in fields such as sheet metal engineering and switch cabinets in the electronics industry. Short-cycle arc stud welding directly discharges after voltage reduction through a transformer/rectifier. Its working principle is similar to that of electric welding and is more widely used in fields such as automotive manufacturing and shipbuilding.
These welding devices have been constantly innovating and developing in their respective application fields, not only enhancing welding quality and production efficiency, but also providing strong support for the transformation and upgrading of the manufacturing industry. With the continuous advancement of technology, it is believed that they will play a significant role in more emerging fields and drive the manufacturing industry to a higher level.
