Coiling & Butt Welding All-in-One Machine: The Light-Shadow Shaping Hub for Intelligent Lighting Protective Shield Manufacturing

In the wave of the lighting industry’s transformation towards customization and artistry, the protective shield, as the "visual soul" and "safety line" of lighting fixtures, sees its styling precision and production efficiency directly determine the product’s market premium space. The 2-6mm full-servo coiling & butt welding all-in-one machine, specially developed for lighting protective shields, has become a key hub connecting creative design and industrialized production, with a mass production speed of 10-15 pieces/minute, ±0.2mm perimeter control precision, and a wide-range coiling capability of 25-550mm. This high-end equipment integrating servo drive, precision welding, and intelligent control is pushing the manufacturing of lighting protective shields from "manual shaping" to "digital forming", making every coil of iron wire a precise carrier of light-shadow art.

The equipment adopts a 380V three-phase industrial power configuration, with a 50KVA high-frequency welding transformer matched with a 50% duty cycle design, meeting the 8-hour continuous mass production demand for lighting protective shields. The power matrix composed of a 2.6KW/3000rpm servo wire feeding motor and a 1.0KW servo cutting motor achieves a high-speed wire feeding of 35m/min. Combined with a coiling diameter range of 25-550mm (coiling large circles over 400mm is possible for wire diameters above 3mm), it comprehensively covers multiple scenarios such as circular protective shields for chandeliers, hollow frames for wall lamps, and spiral bases for table lamps. Test data shows that when processing 4mm iron wires to make a 300mm diameter chandelier protective shield, the equipment controls the coiling diameter tolerance within ±0.5mm and the flatness error <0.5mm, ensuring the assembly gap uniformity between the shield and the lamp body ≤0.3mm to meet the optical transparency requirements of high-end lighting.

The intelligent parameter adaptation system forms the technical core: 2-2.5mm wire diameters correspond to 25-300mm coil diameters, 3-4mm to 30-400mm, and 4-6mm to 55-550mm. The system automatically matches the optimal coiling pressure and rotation speed according to the input wire diameter. The 800KG body (2400×1450×1500mm) adopts a high-strength alloy steel structure, optimizing stress distribution through finite element analysis, with an operation vibration amplitude ≤0.01mm to ensure the shape stability of 6mm iron wire coiling. The 0.6MPa compressed air and 50L/min cooling water circulation system keep the welding module at a constant temperature during continuous operation, avoiding virtual welding or discoloration of weld points due to overheating.

Traditional shield production requires three processes: "manual marking→manual coiling→spot welding fixation", with a daily production capacity of less than 200 pieces and discrete weld point strengths. The coiling & butt welding all-in-one machine compresses the single-workpiece production cycle to 4-6 seconds through the fully automated process of "wire feeding-coiling-cutting-butt welding", achieving a daily production capacity of 9,000 pieces at 15 pieces/minute—45 times higher than traditional processes. When processing a 400mm diameter European-style chandelier shield, the equipment first feeds wire at 35m/min, precisely controls the coil diameter through the servo system, and then completes butt welding by the 50KVA welding unit. The weld point tensile strength reaches 85% of the iron wire base material, withstanding a 10kg vertical pull without breakage—far exceeding the lighting industry’s 5kg safety standard.

Modern lighting designs often feature ellipses, waterdrop shapes, and multi-ring nested structures, imposing strict requirements on processing equipment. The all-in-one machine’s 360° rotating coiling mold supports parameterized programming—designers can input parameters like coil diameter and arc through the 10.4-inch touchscreen interface, and the equipment automatically generates motion trajectories. When processing a "Möbius strip" concept wall lamp shield, the equipment achieves precise 180° torsion forming of the ring surface through ±0.5mm diameter control—this shape was difficult to mass-produce in traditional processes due to uncontrollable metal springback. The built-in 4,000-group program storage function (supporting CAD drawing import via USB) shortens model change time from 2 hours on traditional equipment to 10 minutes, perfectly adapting to the lighting industry’s "small orders, fast response" model.

The quality of shield weld points directly affects light transmission—traditional manual weld point protrusions cause shadows, while the equipment’s butt welding process achieves "invisible welding" through three technical innovations: ① The 50KVA high-frequency power supply provides a stable arc, with weld point diameter ≤1.5mm and surface roughness Ra≤3.2μm; ② The pressure closed-loop control system ensures uniform welding pressure, avoiding iron wire discoloration caused by local annealing; ③ The automatic deburring function makes weld point peripheries smooth, allowing direct entry into the electroplating process without subsequent grinding. Application data from a 轻奢 (luxury) lighting brand shows that after adopting this equipment, shield light transmission uniformity increased by 30%, product premium rate rose by 25%, and it successfully entered the European high-end home market.

Under the traditional production model, designers often abandon complex circular structures due to processing limitations. The coiling & butt welding all-in-one machine enables the realization of innovations like "multi-layer gradient spiral rings" and "three-dimensional nested circles" through its 25-550mm coiling range and ±0.2mm perimeter control. For example, the shield of a modern art chandelier consists of 12 iron rings with diameters decreasing from 550mm to 25mm—the equipment completes coiling and welding of all rings within 1 hour by calling preset programs, saving 48 hours compared to manual production, with concentricity error of each ring ≤0.8mm to ensure regular light-shadow gradient effects when light passes through.

The equipment’s servo system uses energy feedback technology, saving 40% more electricity than traditional hydraulic equipment—calculated at 10 hours of daily operation, it saves about 12,000 kWh annually. The 800KG lightweight design saves 30% workshop space; after a lighting cluster enterprise introduced 5 units, production capacity increased 3 times within the original plant area. More importantly, the equipment increased the shield yield rate from 75% in traditional processes to 99.2%. It is estimated that a medium-sized enterprise can reduce rework costs caused by poor weld points by 280,000 yuan annually, with quality costs decreasing by 60%.

Batch consistency of lighting protective shields is the cornerstone of brand reputation. The equipment ensures quality stability through three quality control mechanisms: ① Temperature sensors monitor welding module temperature in real time, with automatic overheat warning; ② Encoders feedback coiling displacement data in real time, automatically correcting deviations exceeding 0.3mm; ③ Pressure sensors monitor welding pressure, triggering compensation when fluctuations exceed 5%. Testing data from a Guangdong lighting manufacturer shows that after using this equipment, the shield coil diameter qualification rate increased from 82% to 99.8%, customer complaint rate decreased by 90%, and it successfully became the designated supplier for an international chain home brand.

As the lighting industry transforms towards "smart lighting + customization", the coiling & butt welding all-in-one machine is embracing industrial change through technological upgrades. The reserved RS485 communication interface can access the factory MES system, uploading real-time data such as coiling quantity, welding current, and mold life to provide data support for intelligent scheduling; the Chinese-English bilingual control system (supporting remote program updates) facilitates collaborative development by transnational design teams. If an AI visual inspection module is integrated in the future, the equipment can achieve the function of "automatically identifying wire defects - intelligently adjusting coiling parameters", further enhancing the production flexibility of special-shaped shields.

From the circulating ring light of chandeliers to the delicate protective mesh of wall lamps, the coiling & butt welding all-in-one machine empowers light-shadow art with industrial precision, making every coil of iron wire a container of light. It is not just a production device but a key fulcrum for the lighting protective shield industry to shift from "experience-driven" to "data-driven"—here, the precise rotation of servo motors collides with designers’ creativity, finally freezing into light-shadow symbols combining function and aesthetics in the spaces of thousands of households. When the tolerance of coiling diameter resonates in sync with the angle of light refraction, this technological revolution in metal forming is redefining the value dimension of the lighting industry.