Other Special Welding Machine

The Low Voltage Appliance Industry, encompassing circuit breakers, contactors, sockets, and relays, demands ultra-high reliability to ensure electrical safety. Resistance welding machines, operating on the Joule’s law-driven "resistance heat generation + pressure bonding" principle, have become irreplaceable in this sector. They enable precise joining of diverse metal components (copper conductors, silver-plated contacts, galvanized steel shells) while preserving material performance, directly determining the safety and service life of low voltage appliances.​

 

1. Silver-Plated Contact Welding: Contacts in circuit breakers and contactors (typically silver-copper alloy with 0.1-0.3mm silver plating) require low-resistance, anti-oxidation joints. Micro-spot resistance welders with precision electrode heads (diameter 0.8-2mm) deliver 5-15kA pulsed current and 50-200N pressure, completing welding in 10-30ms. This ensures contact resistance ≤5mΩ (meeting IEC 60947 standards) and avoids silver layer melting, preventing overheating-induced appliance failure.​

2. Socket Terminal & Shell Sealing: For plastic-steel composite sockets, seam resistance welders bond galvanized steel shells (thickness 0.5-1.2mm) to copper terminals. With a welding speed of 1-2m/min, they form airtight welds with tensile strength ≥250MPa, blocking dust and moisture intrusion. This is key to extending socket service life beyond 10 years in household environments.​

3. Contactor Coil Lead Bonding: The enameled copper wire leads of contactor coils (diameter 0.3-1mm) need to connect to brass terminals without damaging the enamel insulation. Projection resistance welders use localized heat (8-20kA current) at pre-formed terminal projections, melting only the wire’s enamel layer and forming a solid joint. This maintains coil insulation resistance ≥100MΩ, ensuring stable electromagnetic switching performance.​

1. Micron-Level Precision: Equipped with servo pressure control and digital current regulation, these machines achieve 0.1ms time accuracy and 0.1N pressure precision—critical for welding components as small as 3mm (e.g., relay contacts), keeping defect rates below 0.2%.​

2. Mass Production Adaptability: Integrated into automated production lines, they can weld 3-8 components per second. A typical socket production line with 4 resistance welding stations achieves a daily output of 120,000 units, matching the industry’s large-scale demand.​

3. Cost Optimization: Eliminating the need for welding wire, flux, or protective gas cuts material costs by 15%. Additionally, core components like copper electrodes have a service life of 8-15 months, reducing maintenance frequency and costs.​

4. Material Versatility: Specialized electrode materials (e.g., chromium-copper for copper welding, tungsten-copper for high-temperature applications) enable welding of copper, steel, silver-plated, and galvanized metals without damaging surface treatments.​

1. AI-Driven Intelligent Welding: Integrated with machine vision and AI algorithms, machines will automatically identify component size and material (e.g., distinguishing silver-plated vs. bare copper contacts) and adjust parameters in real time. Welding data will be synchronized to MES systems for full-life-cycle quality tracing, complying with the industry’s strict safety certification requirements (e.g., UL 943).​

2. Green Energy Saving: Adopting IGBT inverter technology will reduce energy consumption by 30% compared to traditional AC welders, aligning with the low voltage appliance industry’s carbon neutrality goals (e.g., EU’s Ecodesign Directive).​

3. Compact Modular Design: New-generation machines with a 40% smaller footprint (down to 0.5㎡) fit into dense production lines for miniaturized appliances, such as slim smart sockets (thickness ≤15mm), supporting the industry’s product miniaturization trend.​

As a cornerstone of low voltage appliance manufacturing, resistance welding machines will continue to evolve with technological innovations, empowering the industry to produce safer, more durable, and more eco-friendly electrical products.​