Technical Proposal for Specialized Looping and Butt Welding Integrated Machine for Gas Stove Brackets

I. Equipment Positioning and Core Value

(A) Industry-Tailored Equipment

(B) Core Application Value

• Efficiency Innovation: Stable production capacity of 10-15 pieces/min, a 40% efficiency improvement over traditional manual + single-machine combined models.
• Quality Assurance: Process parameters optimized for iron-based materials (low-carbon steel), solving industry pain points such as easy deformation during wire processing and spatter during welding.
• Flexible Production: Full compatibility with 2-6mm wire diameters and quick switching of 25-550mm loop diameters, adapting to over 95% of annular component specifications for gas stove brackets.
  

II. Core Technical Parameters and Performance Advantages

(A) Material Processing Compatibility

(B) Production Efficiency Parameters

• Standard Capacity: 10-15 pieces/min (measured with Φ100mm burner cover positioning ring, including looping-cutting-welding full processes).
• Intelligent Speed Regulation: System automatically optimizes production rhythm based on loop diameter:
  ・Small diameter loops (<100mm): 15 pieces/min
  ・Medium diameter loops (100-300mm): 12 pieces/min
  ・Large diameter loops (>400mm): 8 pieces/min
• Continuous Production Capacity: Stable 24-hour operation, annual capacity up to 700,000 pieces (calculated based on 16-hour daily operation).

(C) Precision Control System

1. Looping Formation Precision
   • Circumference Tolerance: ±0.2mm (equivalent to diameter tolerance ±0.064mm), meeting the precise fitting requirements of annular bracket components and bases.
   • Flatness Error: <0.5mm/Φ300mm (measured on a horizontal inspection platform), ensuring no 晃动 (晃动) after installation of stove support rings.
   • Diameter Roundness: ≤0.3mm (coordinate measurement value for Φ200mm loop diameter), solving the industry problem of excessive ovality in traditional equipment.
2. Welding Quality Parameters
   • Weld Point Strength: ≥85% of wire body strength (destructive tension test), certified for high-temperature resistance in gas stoves.
   • Spatter Rate: <3% (equipped with medium-frequency inverter power supply + anti-spatter coating mold), reducing subsequent grinding process costs.
     

III. Key System Configurations and Technical Highlights

(A) Full Servo Drive System

1. Wire Feeding and Cutting Unit
   • 2.6KW Servo Wire-Feeding Motor: Equipped with a 20-bit absolute encoder, feeding precision up to 0.01mm/pulse, combined with ball screw transmission to achieve "zero slip" precise feeding.
   • 1.0KW Servo Cutting Motor: 50ms ultra-fast response cutting, cutting error of ±0.1mm for 6mm wire, blade life ≥500,000 times (with automatic lubrication system).
2. Intelligent Control System
   • 10.1-inch Touch Screen: Supports storage of 100 sets of process parameters, allowing one-click calling of processing programs for different bracket components (e.g., customized specifications for brands like 方太 / 美的).
   • Dual Sensor Monitoring: Laser rangefinder real-time loop diameter detection + tension sensor dynamic compensation of wire-feeding tension, with automatic alarm and correction for out-of-tolerance.

(B) Process Mold Optimization Design

• Material-Adapted Molds:
  • Small Diameter Loops (2-3mm Wire Diameter): Uses Cr12MoV precision molds (hardness HRC58-62), inner wall polished to Ra0.2μm to avoid surface scratches on wires.
  • Large Diameter Loops (4-6mm Wire Diameter): Thickened mold support structure combined with servo motor torque compensation algorithm to solve springback deformation during large-diameter looping.
• Quick Mold Change Design: Snap-on mold installation enables mold switching for different wire diameters within 5 minutes, suitable for multi-specification small-batch production.
  

IV. Typical Application Scenarios and Customer Value

(A) Application Scenarios in Stove Bracket Subcategories

(B) Customer Value Analysis

• Cost Optimization:
  • Labor Cost: One machine replaces 3-4 skilled workers (looping, cutting, welding processes).
  • Yield Rate Improvement: Intelligent detection system reduces scrap rate from 5% with traditional equipment to below 1%.
• Delivery Capability:
  • Rapid response to small-batch multi-specification orders: No hardware adjustments needed, can switch between bracket specifications for different stove brands via parameter settings.
  • Scalable production adaptation: Supports multi-machine parallel networking, combined with automatic feeding racks (500KG capacity) for 24-hour unattended production.