Ring gear flash butt welding machine

1. Customer background and pain points

TJBST company is mainly engaged in international equipment trade. The existing international friends and enterprises need a ring gear butt welding machine. After consulting many domestic and foreign butt welding machine manufacturers, they still face many problems.

Low welding quality: Ring gear butt welding is different from ordinary welding. It is used in auto parts and has particularly high requirements for welding quality.

Low product quality: The customer visited the country for several months to see the equipment, and most of the equipment was not particularly suitable.

The scale of the enterprise is small: Most of the friends are unprofessional and do not understand the qualifications and processes required for import and export, so customers have to consult repeatedly.

2. Customers have high requirements for equipment

TJBST found us through the network introduction in January 2023, discussed with our sales engineers and wanted to customize welding machines with the following requirements:

1. To ensure effective welding strength, the pass rate needs to reach 99%;

2. All conditions that may affect the quality must be solved with corresponding devices on the equipment;

3. The welding process needs to be monitored to control the stability of welding quality;

4. The welding efficiency must be high and the welding should be completed within 2 minutes.

   According to the customer’s request, the existing production method cannot be realized at all, what should I do?

3. According to customer requirements, research and develop customized ring gear flash butt welding machine

According to the various requirements put forward by the customer, the company’s R&D department, welding technology department, and project department jointly held a new project research and development meeting to discuss the process, fixture, structure, feeding method, configuration, list key risk points, and make one by one. The solution was identified, the basic direction and technical details were determined.

According to the above requirements, we basically determined the plan and developed the flash butt welding machine. The equipment has the functions of preheating, welding, tempering, current display, parameter recording and other Internet of Things information functions. The details are as follows:

1. Workpiece proofing test: Anjia welding technologist made a simple fixture for proofing at the fastest speed, and used our existing flash butt welding machine to do proofing test. After 10 days of back-and-forth testing by both parties and pull-out flaw detection, Basically determine the welding parameters and welding equipment process;

2. Equipment selection: R&D engineers and welding technologists communicated together and calculated the selection power according to customer requirements, and finally confirmed that it was a ring gear flash butt welding machine;

3. Stability of equipment: Our company adopts all “imported configuration” of core components to ensure the stability of equipment operation;

4. Equipment advantages:

1. Technological innovation and quality improvement: The flash welding method is adopted, which is different from traditional butt welding equipment, and the welding process is subdivided to improve stability.

2. The special structure ensures a consistent welding environment: A special structure is designed for the circular shape of the workpiece to ensure that all external conditions are consistent before welding.

3. Automatic quality inspection, high yield rate: By combining industrial computer and other equipment, effective data such as welding process parameters can be set and monitored, and the quality of welding products can be judged from the source whether it is qualified, and the pass rate can reach more than 99%.

Anjia discussed the above-mentioned technical plan and details with TJBST, and finally the two parties reached an agreement and signed the “Technical Agreement”, which was used as the standard for equipment R&D, design, manufacturing, and acceptance, and reached an order agreement with TJBST on February 30, 2021. .

4. Rapid design production capacity and professional after-sales service are highly recognized by customers

After confirming the equipment technical agreement and signing the contract, Anjia’s project manager held the production project start-up meeting immediately, and determined the time nodes of mechanical design, electrical design, machining, purchased parts, assembly, joint debugging and customer’s pre-acceptance at the factory , rectification, general inspection and delivery time, and through the ERP system orderly dispatch work orders of each department, supervise and follow up the work progress of each department.

After 30 working days in a flash, TJBST customized ring gear flash butt welding machine has passed the aging test. After our professional after-sales service, we have gone through 2 days of installation and commissioning and technical, operation and maintenance training at overseas customer sites. It has been put into production normally and has all reached the customer’s acceptance criteria. TJBST company is very satisfied with the actual production and welding effect of the ring gear flash butt welding machine. It helped them solve the problem of welding yield, improve welding efficiency, save labor, save welding material costs, and exceeded the customer’s own requirements. Customers are very happy and give us high recognition and praise!

5. It is Anjia’s growth mission to meet your customization requirements!

    Customers are our mentors, what material do you need to weld? What welding process is required? What welding requirements? Need fully automatic, semi-automatic, workstation, or assembly line? Please feel free to ask, Anjia can “develop and customize” for you.