The large round steel flash butt welder is a flash butt welding machine for butt welding large round steel tailored to customers according to customer needs, according to product materials and welding processes. It is automatic welding. The personnel only need to put the product workpiece, no need to pull the handle, which solves the problem of tiredness and complaints. The use of a microcomputer high-precision flash welding controller guarantees the welding quality. . The customer found us in the scene:
I. Customer background and pain points
Chongqing WC Engine Company, a leading engine company in China, needed butt welding of ф80 high-strength steel at that time, the maximum cross-sectional area was 5024 square meters, but encountered the following problems:
• The welding quality is not up to standard, and the yield is low : because the product is high-strength steel, the existing ordinary hand-type welding is easy to be brittle, and the defective rate is 75%, and the weld cannot be inspected;
• The efficiency is too low, and the employees complain a lot : the site is ordinary hand-type welding, the operation is very slow and tired, only 100 pieces can be welded a day, the welding efficiency is too low, and the employees complain a lot;
The above two customers are very distressed and have not been able to find a solution.
Second, customers have high requirements for equipment
WC found us online on March 15, 2018, discussed with our sales engineers and wanted to customize the special welding equipment with the following requirements:
1. Ensure welding quality and ensure that it cannot be brittle after welding;
2. To improve welding efficiency, it must be at least 150% higher;
3. It is no longer necessary to pull by hand and needs automatic welding;
According to the requirements of customers, the original resistance butt welding machine cannot be realized at all, what should I do?
Third, according to customer needs, research and development of custom large round steel flash butt welding machine
According to the customer's requirements, the company's R & D department, welding process department, and sales department jointly held a new project research and development meeting to discuss the process, fixture, structure, feeding method, and configuration, list key risk points, and make one by one The solution, the basic direction and technical details are determined as follows:
1. Sample proofing test : Anjia Welding Technician made a simple fixture for proofing at the fastest speed, used our existing flash butt welder to proof test, and did a flaw detection test to basically determine the welding parameters;
2. Equipment selection : R & D engineers took the workpiece and customer requirements to calculate the selection power, and communicated with the welding technician to confirm, and finally confirmed that it was a hydraulic 500KVA flash butt welding machine;
”； 3. Stability of equipment : Our company adopts all " import configuration " of core components;
4. Equipment performance characteristics :
1) High welding efficiency : One-time automatic flash welding can weld 300 pieces per day, which is an increase of 300% from the original, and because of automatic welding, the staff only needs to put the product workpiece without the need to pull the handle, which solves the problem of tiredness and complaints problem;
2) High yield : using microcomputer high-precision flash welding controller, the flash distance can be controlled, the upset time and current can be controlled, the welding heat can be controlled to ensure the welding quality, and the yield is improved from the original 25% to more than 95% ;
3) The welding machine is easy to operate : ordinary workers can operate, no professional welder is needed, saving labor costs.
4. Delivery time: 40 working days.
Anjia fully discussed the above technical solutions and details with the WC company. After the two sides reached an agreement, they signed a "Technical Agreement" as the standard for equipment R & D, design, manufacturing, and acceptance, because our nuancedness touched the customer, and in May 2018, An order agreement was reached with WC on the 20th.
Fourth, fast design, on-time delivery, professional after-sales, and get praise from customers!
After confirming the equipment technical agreement and signing the contract, Anjia's project manager held the production project launch meeting as soon as possible, and confirmed the mechanical design, electrical design, machining, outsourced parts, assembly, joint adjustment time nodes and customers to come to the factory for pre-acceptance. , Rectification, general inspection and delivery time, and orderly issue work orders of each department through the ERP system, supervise and follow up the work process of each department.
After 40 working days in a flash, the WC custom-made 500KVA large round steel flash butt welder was finally completed after aging tests. Our professional after-sales engineer installed and debugged the technical and operation and maintenance training at the customer site for one day. The equipment has been put into production normally And all reached the customer's acceptance criteria.
WC Company is very satisfied with the actual production and welding effect of the flash butt welding machine for 500KVA large round steel, which has helped them improve production efficiency, save labor, improve yield, and can be operated by ordinary workers, and they have fully affirmed and praised them. !!
Fifth, meet your customization requirements is the growth mission of Anjia!
The customer is our mentor. What material do you need to weld? What welding process do you need? What welding requirements? Need full-automatic, semi-automatic, production line or assembly line? ”。 Please do not hesitate to mention that Anjia can " research and develop " for you.
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