Circular Storage Tray Manufacturing: Core Equipment - Ring Making and Butt Welding All-in-One Machine

Ⅰ. Equipment Overview

Equipment Name: Ring Making and Butt Welding All-in-One Machine

Application Industry: Specialized in the full-process production of circular storage trays, covering the manufacturing of iron circular components such as household storage trays, kitchen organizer trays, and industrial part pallets. It realizes automated closed-loop production from iron wire feeding to finished ring frames.
Technical Positioning: Aimed at 3-8mm iron wire materials, integrating three processes of ring making, cutting, and butt welding, with ±0.5mm-level precision and high-speed production capacity of 15-18 pieces/min. It subverts the low-efficiency mode of traditional manual ring making and welding, becoming a key equipment for large-scale production of circular storage trays.

Ⅱ. Analysis of Core Performance Parameters

(1) Production Efficiency: Coexistence of High-Speed Mass Production and Flexible Adaptation

• Standard Capacity: 10-15 pieces/min (universal diameter range). Taking an 80mm diameter storage tray as an example, the capacity can reach 15-18 pieces/min, increasing efficiency by 8-10 times compared to traditional manual operations.
• Flexible Diameter Adjustment: The ring making diameter is adjustable from 30mm to 700mm, suitable for full-specification production from small jewelry storage trays to large industrial transfer trays (e.g., 3mm iron wire can make rings over 400mm, and 6-8mm iron wire supports a maximum diameter of 700mm).
• Dynamic Efficiency Matching: The production speed decreases linearly with the increase of diameter. The system automatically optimizes wire feeding, ring making, and welding parameters to ensure stable output of different specifications.

(2) Material and Process Precision: Millimeter-Level Control for Iron Wire Processing

• Wire Compatibility: Specialized in 3-8mm low-carbon steel wires, supporting various cross-sectional shapes such as round and flat wires, adapting to the strength welding requirements of Q235 carbon steel, galvanized iron, and other materials.
• Precision Indicators:
  • Ring making diameter tolerance ±0.5mm ensures the consistency of the roundness of the storage tray frame;
  • Circumference tolerance ±0.3mm provides precise interfaces for multi-ring stacked welding;
  • Flatness <0.5mm meets the flatness requirements of the storage tray base.

(3) Electrical and Power System: Industrial-Grade Stable Output

(4) Mechanical and Auxiliary Systems: Long-Term Operation Guarantee

• Ring Making Mechanism: Made of Cr12 die steel (hardness 58-62HRC), through a 360° rotating die head and adjustable positioning columns, it realizes quick model change for different diameter ring frames, with a die life of over 100,000 times.
• Welding Module: Equipped with pneumatic butt welding fixtures and copper alloy electrodes, combined with a 50L/min circulating water cooling system, supporting continuous operation under a 50% duty cycle (5 minutes of full-load work every 10 minutes).
• Pneumatic System: Driven by 0.6MPa compressed air, controlling actions such as feeding, positioning, and welding, with a response time <50ms and action synchronization accuracy of ±0.2mm.

Ⅲ. Core Advantages of the Equipment

1. Intelligent Production Closed Loop: Equipped with a PLC 32-bit control system, supporting the storage of 400 groups of production data. After inputting the ring diameter parameters, it can automatically complete the entire process of "wire feeding - straightening - ring making - cutting - butt welding", with a model change time <3 minutes.
2. Precision Consistency Guarantee: Through the closed-loop control of the servo motor and encoder, it avoids dimensional deviations caused by manual operations, with a product qualification rate of over 98.5% in batch production, greatly reducing rework costs.
3. Energy Saving and Durability: The total power is about 5.8KW, saving 30% more energy than traditional equipment; the water cooling system combined with a cooling fan keeps the temperature of core components below 65℃, and the equipment service life exceeds 8 years.
4. User-Friendly Operation: Touch screen + button dual-operation mode, supporting Chinese/English interface switching. Novices can work independently after 2 hours of training, reducing manpower dependence.

Ⅳ. Application Scenarios: Full Category Coverage of Circular Storage Trays

• Household Storage Field:
  • Kitchen iron art dinner plates: 30-200mm in diameter, used for welding baking molds and fruit plate borders;
  • Desktop storage boxes: 100-300mm in diameter, realizing the connection between the borders and bases of multi-layer stacked storage trays.
• Industrial Parts Storage:
  • 400-700mm diameter transfer trays for scratch-resistant storage of automobile parts and electronic components. The ring making precision ensures the stacking stability of the trays.
• Customized Products:
  • Special-shaped circular components such as pet food bowl borders and garden flowerpot iron frames. Non-standard diameter production can be quickly achieved through adjustable molds.
    

Ⅴ. Technical Specifications Table