Welding Equipment Types
1. Cold Welder A cold welder utilizes the principle of high-frequency electric spark discharge to join workpieces without generating heat. This type of welding is ideal for repairing defects such as wear, scratches, pinholes, cracks, deformation, reduced hardness, and damage on metal components. It offers a simple operation process with minimal heat input, ensuring that the mold remains undistorted, unannealed, and free from residual stress or structural changes. The coating thickness can range from microns to millimeters, and only polishing is needed afterward. Additionally, it supports various machining processes like turning, milling, planing, and grinding, along with post-processing techniques such as electroplating.
Welding Equipment
(1) Manual Arc Welding Equipment This equipment is straightforward in design and offers flexibility in application. However, it requires skilled operators. It is suitable for welding materials like carbon steel, low-alloy steel, stainless steel, copper, and copper alloys.
(2) Submerged Arc Welding Equipment This system consists of a power source, a submerged arc welding machine, and auxiliary tools. It can operate with AC, DC, or both. There are two types: semi-automatic and automatic machines.
(3) COâ‚‚ Gas Shielded Welding Equipment A semi-automatic COâ‚‚ gas shielded welding setup typically includes a power source, gas supply system, wire feeding mechanism, and a welding torch.
(4) Inert Gas Shielded Welding Equipment Manual inert gas welding systems include a welding torch, power supply, control unit, and gas and water supply systems.
(5) Plasma Arc Welding Equipment These systems consist of a power source, control system, welding torch, pneumatic system, and cooling water channels.
Welding Equipment System Structure Characteristics
Mechanical Device
The spot welding system comprises three parts: mechanical device, power supply unit, and control system. To meet welding requirements, the welding tongs use a fast pneumatic transmission mechanism. By adjusting the stroke control handle, the opening size of the tongs can be changed to accommodate different welding needs. Normally, the tongs are in a short-stroke open position. When the control button is set to "energized," the clamping pressure is applied, and after completing a welding cycle, the system returns to an open state.
2. Power Supply Unit
The main power circuit includes a resistance welding transformer, thyristor unit, main switch, and welding circuit. Most modern welding equipment uses a single-phase AC resistance welder with a 200kVA power rating and a secondary output voltage of 20V. Due to the need to weld high-strength steel and low-carbon steel sheets, the welding tongs must transmit large mechanical force and current. Therefore, they require high strength, rigidity, thermal conductivity, and cooling via water. These tongs can withstand up to 400 kg of pressure.
3. Control Device
The control device manages signal control, turns the welding current on and off, regulates its value, and monitors and handles any faults.
Welding Process in Industrial Development
There are over 40 types of metal welding methods, generally divided into three categories: fusion welding, pressure welding, and brazing. Fusion welding involves heating the joint of the workpiece to a molten state without applying pressure. During this process, the heat source melts the interface, forming a molten pool that moves forward and solidifies into a continuous weld. If the atmosphere comes into contact with the molten pool, oxidation and other defects can occur, affecting the quality of the weld.
To improve welding quality, protective measures such as gas-shielded arc welding have been developed. For example, when welding steel, deoxidizing agents like ferrotitanium powder are added to the electrode coating to prevent oxidation and ensure high-quality welds.
Pressure welding achieves atomic bonding under pressure, also known as solid-state welding. Resistance butt welding is a common method where current heats the joint to a plastic state, then applies axial pressure to integrate the materials. Unlike fusion welding, pressure welding does not involve melting, so there is less risk of alloy element loss and fewer defects.
Brazing involves using a filler metal with a lower melting point than the base material. The filler is heated to a temperature above its melting point but below that of the base material, allowing it to wet and fill the joint, creating a strong bond through atomic diffusion.
The weld bead is the seam formed by joining two pieces. The heat-affected zone around the weld undergoes structural and property changes, which can lead to issues like embrittlement or softening if not properly managed. Proper preheating, heat preservation, and post-weld treatment are essential to maintain quality.
Modern welding techniques now produce defect-free welds with mechanical properties equal to or better than the base material. The joint's strength depends on the weld quality, geometry, and working conditions. Common joint types include butt joints, lap joints, T-joints, and corner joints.
Welded structures are lighter than riveted, cast, or forged ones, saving weight and energy. They are also more efficient for manufacturing containers and can be combined with casting or forging to create cost-effective structures.
In modern industries, welding has become indispensable due to its efficiency and versatility. It is developing rapidly, with a significant portion of steel structures being welded. Future advancements will focus on improving quality, safety, and automation, including intelligent systems and robotic welding.
Plastic welding involves fusing surfaces of thermoplastic materials using heat and pressure. Automation in welding improves productivity, quality, and safety while reducing costs. Modern automation relies heavily on computer control, enabling precise and efficient welding operations.
As welding technology advances, new opportunities emerge for the industry. High-strength steels, for instance, require advanced welding techniques to maintain structural integrity and performance. This trend will drive innovation and growth in the welding sector.
International welding equipment companies are expanding their presence in the Chinese market, driven by the country’s rapid economic growth and demand for industrial equipment. While domestic production is growing, many high-end systems still rely on imports.
Choosing the right welding robot system involves considering factors like efficiency, lifespan, and adaptability. Domestic robots offer competitive advantages in simpler applications, while imported models excel in complex tasks. However, they often come with higher costs and maintenance challenges.
In conclusion, welding plays a crucial role in modern manufacturing, and its continued development will shape the future of industrial production. Whether through traditional methods or advanced robotics, the goal remains the same: to achieve high-quality, reliable, and efficient connections in metal structures.
1. Cold Welder A cold welder utilizes the principle of high-frequency electric spark discharge to join workpieces without generating heat. This type of welding is ideal for repairing defects such as wear, scratches, pinholes, cracks, deformation, reduced hardness, and damage on metal components. It offers a simple operation process with minimal heat input, ensuring that the mold remains undistorted, unannealed, and free from residual stress or structural changes. The coating thickness can range from microns to millimeters, and only polishing is needed afterward. Additionally, it supports various machining processes like turning, milling, planing, and grinding, along with post-processing techniques such as electroplating.
Welding Equipment
(1) Manual Arc Welding Equipment This equipment is straightforward in design and offers flexibility in application. However, it requires skilled operators. It is suitable for welding materials like carbon steel, low-alloy steel, stainless steel, copper, and copper alloys.
(2) Submerged Arc Welding Equipment This system consists of a power source, a submerged arc welding machine, and auxiliary tools. It can operate with AC, DC, or both. There are two types: semi-automatic and automatic machines.
(3) COâ‚‚ Gas Shielded Welding Equipment A semi-automatic COâ‚‚ gas shielded welding setup typically includes a power source, gas supply system, wire feeding mechanism, and a welding torch.
(4) Inert Gas Shielded Welding Equipment Manual inert gas welding systems include a welding torch, power supply, control unit, and gas and water supply systems.
(5) Plasma Arc Welding Equipment These systems consist of a power source, control system, welding torch, pneumatic system, and cooling water channels.
Welding Equipment System Structure Characteristics
Mechanical Device
The spot welding system comprises three parts: mechanical device, power supply unit, and control system. To meet welding requirements, the welding tongs use a fast pneumatic transmission mechanism. By adjusting the stroke control handle, the opening size of the tongs can be changed to accommodate different welding needs. Normally, the tongs are in a short-stroke open position. When the control button is set to "energized," the clamping pressure is applied, and after completing a welding cycle, the system returns to an open state.
2. Power Supply Unit
The main power circuit includes a resistance welding transformer, thyristor unit, main switch, and welding circuit. Most modern welding equipment uses a single-phase AC resistance welder with a 200kVA power rating and a secondary output voltage of 20V. Due to the need to weld high-strength steel and low-carbon steel sheets, the welding tongs must transmit large mechanical force and current. Therefore, they require high strength, rigidity, thermal conductivity, and cooling via water. These tongs can withstand up to 400 kg of pressure.
3. Control Device
The control device manages signal control, turns the welding current on and off, regulates its value, and monitors and handles any faults.
Welding Process in Industrial Development
There are over 40 types of metal welding methods, generally divided into three categories: fusion welding, pressure welding, and brazing. Fusion welding involves heating the joint of the workpiece to a molten state without applying pressure. During this process, the heat source melts the interface, forming a molten pool that moves forward and solidifies into a continuous weld. If the atmosphere comes into contact with the molten pool, oxidation and other defects can occur, affecting the quality of the weld.
To improve welding quality, protective measures such as gas-shielded arc welding have been developed. For example, when welding steel, deoxidizing agents like ferrotitanium powder are added to the electrode coating to prevent oxidation and ensure high-quality welds.
Pressure welding achieves atomic bonding under pressure, also known as solid-state welding. Resistance butt welding is a common method where current heats the joint to a plastic state, then applies axial pressure to integrate the materials. Unlike fusion welding, pressure welding does not involve melting, so there is less risk of alloy element loss and fewer defects.
Brazing involves using a filler metal with a lower melting point than the base material. The filler is heated to a temperature above its melting point but below that of the base material, allowing it to wet and fill the joint, creating a strong bond through atomic diffusion.
The weld bead is the seam formed by joining two pieces. The heat-affected zone around the weld undergoes structural and property changes, which can lead to issues like embrittlement or softening if not properly managed. Proper preheating, heat preservation, and post-weld treatment are essential to maintain quality.
Modern welding techniques now produce defect-free welds with mechanical properties equal to or better than the base material. The joint's strength depends on the weld quality, geometry, and working conditions. Common joint types include butt joints, lap joints, T-joints, and corner joints.
Welded structures are lighter than riveted, cast, or forged ones, saving weight and energy. They are also more efficient for manufacturing containers and can be combined with casting or forging to create cost-effective structures.
In modern industries, welding has become indispensable due to its efficiency and versatility. It is developing rapidly, with a significant portion of steel structures being welded. Future advancements will focus on improving quality, safety, and automation, including intelligent systems and robotic welding.
Plastic welding involves fusing surfaces of thermoplastic materials using heat and pressure. Automation in welding improves productivity, quality, and safety while reducing costs. Modern automation relies heavily on computer control, enabling precise and efficient welding operations.
As welding technology advances, new opportunities emerge for the industry. High-strength steels, for instance, require advanced welding techniques to maintain structural integrity and performance. This trend will drive innovation and growth in the welding sector.
International welding equipment companies are expanding their presence in the Chinese market, driven by the country’s rapid economic growth and demand for industrial equipment. While domestic production is growing, many high-end systems still rely on imports.
Choosing the right welding robot system involves considering factors like efficiency, lifespan, and adaptability. Domestic robots offer competitive advantages in simpler applications, while imported models excel in complex tasks. However, they often come with higher costs and maintenance challenges.
In conclusion, welding plays a crucial role in modern manufacturing, and its continued development will shape the future of industrial production. Whether through traditional methods or advanced robotics, the goal remains the same: to achieve high-quality, reliable, and efficient connections in metal structures.
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