Batch welding of small parts: Breaking the cycle of human fatigue and production capacity limits
Small items such as hanging accessories for bathroom hardware, brackets for electronic accessories, etc., although the length of the single weld seam is only 10-50mm, the daily demand often exceeds 10,000 pieces.
When welding manually, the welder needs to frequently change the workpiece and adjust the welding gun, which can easily lead to missed welding and poor welding due to fatigue. A certain bathroom company once experienced a batch quality accident caused by missed welding, with direct losses exceeding 500,000 yuan. More importantly, the manual daily production capacity is difficult to break through 5,000 pieces, and orders are often lost during the peak season due to insufficient capacity.
The welding robot of Chaohong is designed for such scenarios. With a lightweight arm design, the repeat positioning accuracy can reach ±0.03mm, and in combination with 1.5kW laser welding equipment, the welding time of a single weld seam can be controlled within 1.5 seconds. The rotary fixture adopts a dual-position design. When the robot is welding at position A, the operator can load and unload at position B, achieving a seamless transition between "welding - loading and unloading", and the equipment utilization rate is increased to 95%.
To meet the diverse needs of small parts, the system is equipped with a quick changeover module: the fixture is changed in ≤30 seconds through a combination of magnetic attraction + positioning pins; the diameter of the welding gun nozzle can be quickly switched from 0.8mm to 2.0mm to meet the needs of different wire diameters. After the application of a certain electronic accessories factory, the welding capacity of the USB interface bracket increased from 4800 pieces per day to 15000 pieces, and the virtual welding rate was reduced from 8% to less than 0.5% through the constant voltage wire feeding control of the robot. Calculating the labor cost of 0.3 yuan per product, the annual labor cost is saved by more than 2 million yuan, and at the same time, due to the stable quality, the number of customer complaints decreased by 90%, which is suitable for efficient welding of various small parts.
