2-6mm Iron Wire Mosquito Net Lamp Shade Special Gantry Welding Machine
2025-05-28
I. Equipment Definition and Industry Positioning
(I) Professional Attribute Definition
This equipment is an industrial-grade welding system deeply customized for iron mosquito net lamp shade production. It adopts a gantry frame structure (span 1.8m × height 2.2m), integrating medium-frequency inverter welding power supply, dual-station servo pressure mechanism, and high-precision linear guide rail transmission system. It realizes automatic line welding and projection welding for 2-6mm iron wire materials, serving as the core key equipment connecting lamp shade skeleton forming and surface treatment.
(II) Industry Value Benchmark
Production Capacity Baseline: Stable output of 8-10 pieces/min (calculated based on 300mm diameter standard lamp shade), meeting the needs of large-scale production lines with daily output exceeding 10,000 pieces
Precision Standard: Welding spot position deviation ≤±0.5mm, nugget diameter consistency deviation <3%, compliant with GB/T 15169-2020 Welding Quality Assessment for Fusion Welding Equipment
Energy Consumption Level: Unit product energy consumption ≤0.3kWh/piece (45% lower than Industrial frequency welding machine conventional frequency welding machines)
![2-6mm Iron Wire Mosquito Net Lamp Shade Special Gantry Welding Machine 1]()
Precision Standard: Welding spot position deviation ≤±0.5mm, nugget diameter consistency deviation <3%, compliant with GB/T 15169-2020 Welding Quality Assessment for Fusion Welding Equipment
Energy Consumption Level: Unit product energy consumption ≤0.3kWh/piece (45% lower than Industrial frequency welding machine conventional frequency welding machines)
II. Detailed Explanation of Core Technical Parameters
(I) Electrical System Parameters (Core Power Unit)
| Parameter Category | Spot Welding Mode | Projection Welding Mode | Technical Feature Description |
|---|---|---|---|
| Rated Power | 180kVA | 230kVA | Adopts IGBT medium-frequency inverter technology, power factor ≥0.92 |
| Input Voltage | Three-phase AC 380V±10% | Three-phase AC 380V±10% | Wide voltage adaptation range, supports power grid fluctuation compensation |
| Duty Cycle | 10%@5min | 10%@5min | Definition: Full-power operation for 30 seconds within a 5-minute cycle, suitable for intermittent high-load welding |
| Output Frequency | 1000Hz | 1000Hz | Medium-frequency power advantage: Low thermal inertia, welding time control precision up to 1ms level |
| Maximum Short-Circuit Current | 50kA (peak) | 50kA (peak) | Instantaneous high-current output capability ensures welding of thick plates (6mm iron wire welding penetration ≥4mm) |
(II) Mechanical System Parameters (Actuator Configuration)
| Component Name | Technical Parameters | Performance Advantages |
|---|---|---|
| Pressure Mechanism | 2 sets of pneumatic servo cylinders | Pressure control precision ±2%, response time <50ms |
| Electrode Stroke | 30mm | Adjustable range 10-50mm, suitable for workpieces of different heights |
| Fixture System | Magnetic quick-change fixture | Model change time <3 minutes, repeat positioning accuracy ±0.2mm |
| Travel System | Linear guide rail + servo motor | Travel speed adjustable 0-2000mm/s, positioning accuracy ±0.1mm/m |
| Working Range | 1500×1200mm | Maximum weldable lamp shade size: diameter 500mm×height 300mm |
(III) Process Parameter System (Welding Process Window)
-
Spot Welding Process Package (Frame Connection)
Application Scenario: 4-point fixed welding of lamp shade frame (φ3mm iron wire)
Typical Parameters: Welding current 8-12kA, welding time 12-16 cycles (240-320ms), electrode pressure 3000-4000N
Quality Indicators: Spot weld pull-off force ≥800N, surface indentation depth <0.3mm -
Projection Welding Process Package (Mesh Reinforcement)
Application Scenario: 8-16-point mesh projection welding (φ2mm iron wire grid)
Typical Parameters: Welding current 6-9kA, welding time 10-14 cycles (200-280ms), electrode pressure 2000-3000N
Quality Indicators: 100% projection fusion rate, grid deformation <1mm
III. Five Core Technical Breakthroughs
(I) Dynamic Thermal Equilibrium Control Technology
Innovation: PID power regulation algorithm based on infrared temperature measurement feedback, real-time monitoring of electrode temperature (precision ±2℃), automatic compensation for heat attenuation caused by electrode wear (compensation speed <200ms)
Application Effect: Welding parameter stability improved by 60%, electrode life extended by 35% (from 8,000 times to 12,000 times)
Application Effect: Welding parameter stability improved by 60%, electrode life extended by 35% (from 8,000 times to 12,000 times)
(II) Dual-Station Collaborative Welding Technology
Structural Design: Left-right symmetrical dual-pressure mechanisms (adjustable spacing 800-1200mm), supporting single-station independent operation/dual-station synchronous welding
Capacity Optimization: Cycle time shortened to 50s/cycle in dual-station mode, 40% efficiency improvement over single-station mode (requires supporting dual-bin feeding system)
Capacity Optimization: Cycle time shortened to 50s/cycle in dual-station mode, 40% efficiency improvement over single-station mode (requires supporting dual-bin feeding system)
(III) Intelligent Process Database
Data Capacity: Built-in 20 sets of standard process parameters (covering 2-6mm wire diameters and different mesh density processes)
Self-Learning Function: Capable of welding quality traceability and parameter optimization suggestions, reducing new workpiece debugging time from 45 minutes to 10 minutes
Self-Learning Function: Capable of welding quality traceability and parameter optimization suggestions, reducing new workpiece debugging time from 45 minutes to 10 minutes
(IV) Low-Splash Welding Technology
Technical Path: Adopts gradual current rise/fall control (adjustable slope 0.5-2kA/ms), combined with anti-splash coating electrodes (material: chromium-zirconium copper + nano-ceramic layer)
Test Data: Occurrence rate of splash particles >0.5mm diameter reduced from 15% in traditional welding machines to below 3%
Test Data: Occurrence rate of splash particles >0.5mm diameter reduced from 15% in traditional welding machines to below 3%
(V) Modular Maintenance Design
Structural Features: Detachable electrode arms (quick-release interface design), independent water-cooling modules (replacement time <15 minutes), drawer-type electrical control cabinet (maintenance space ≥600mm)
Maintenance Cost: Vulnerable part replacement efficiency improved by 50%, annual maintenance downtime reduced by 40%
![2-6mm Iron Wire Mosquito Net Lamp Shade Special Gantry Welding Machine 3]()
Maintenance Cost: Vulnerable part replacement efficiency improved by 50%, annual maintenance downtime reduced by 40%
IV. Technology Development Blueprint
(I) Intelligence Upgrading Path
2025Q4: Launch AI welding expert system to achieve welding spot quality prediction (accuracy ≥95%)
2026Q2: Integrate collaborative robots to realize welding of complex curved surface lamp shades (curvature radius ≥50mm)
2026Q4: Develop cloud monitoring platform to support real-time equipment OEE monitoring (data refresh frequency 10Hz)
2026Q2: Integrate collaborative robots to realize welding of complex curved surface lamp shades (curvature radius ≥50mm)
2026Q4: Develop cloud monitoring platform to support real-time equipment OEE monitoring (data refresh frequency 10Hz)
(II) Green Manufacturing Upgrading
Energy Saving Improvement: Develop energy recovery device (expected power saving 15%), cooling water recycling rate increased to 95%
Material Innovation: Test carbon nanotube electrode coating (life extended by 50%), reducing copper resource consumption
Material Innovation: Test carbon nanotube electrode coating (life extended by 50%), reducing copper resource consumption
As the core equipment for intelligent manufacturing of mosquito net lamp shades, this gantry welding machine achieves the leap from traditional welding to digital welding through precise parameter design, innovative process technology, and intelligent management systems. We always take "30% efficiency improvement, 25% cost reduction, 98% quality stability" as our R&D goal, continuously providing cost-effective welding solutions for the iron art products industry. We look forward to joining hands with you to build a green and efficient intelligent production future.
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Foshan Jinchun is a technology-intensive industrial company specializing in the development of welding technology and equipment research and manufacturing, integrating scientific research, production and sales.
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Address: No.25 Sanle Road, Beijiao Town, Shunde district, Foshan City, Guangdong Province, People's Republic of China