Welding Platform Case

The three-dimensional flexible welding fixture system, with its modular design and reconfigurable characteristics, has become a key process equipment in the field of modern intelligent manufacturing. This innovative welding solution perfectly adapts to diverse welding needs from precision components to large structural parts through standardized interfaces and intelligent positioning technology. The following is a deep analysis of its typical application scenarios:

In the field of new energy vehicles and components

In the manufacturing process of new energy vehicles, the three-dimensional flexible tooling system demonstrates excellent adaptability. Taking the welding of battery pack shells as an example, the system effectively controls welding deformation through high-precision positioning modules (repeated positioning accuracy ± 0.02mm) and specialized aluminum alloy fixtures, ensuring that the flatness of the sealing surface is ≤ 0.08mm. For key components such as electric drive system shells, the rapid changeover function of the tooling (average changeover time<15 minutes) perfectly matches the production needs of multi variety mixed lines. A case study of a mainstream car company shows that adopting this solution increases production line utilization by 35% and reduces tooling investment costs by 60%.

Heavy engineering equipment manufacturing

In the face of welding large structural components such as excavator buckets and crane turntables, the system demonstrates strong load-bearing capacity (single point load capacity ≥ 5 tons). Its innovative distributed hydraulic locking mechanism can achieve multi-directional synchronous clamping, controlling welding deformation within 0.3mm/m. Especially when welding ultra long arm frames (length>12m), the system's multi-point support design and temperature compensation function effectively overcome the problem of thermal deformation. The practice of a certain heavy industry enterprise has shown that the welding qualification rate has increased from 90% to 99.6% after adopting this scheme.

Aerospace precision manufacturing

In the welding of key components such as aircraft engine casings, the system meets the precision welding requirements of high-temperature alloy materials through special alloy fixtures and micrometer level adjustment mechanisms (with a minimum adjustment of 0.005mm). The integrated laser tracking system can monitor the position of the weld seam in real time and dynamically compensate for thermal deformation. According to application data from a certain aerospace manufacturing unit, this solution has increased the welding qualification rate of titanium alloy components to 90% and significantly improved product consistency.

Special welding of energy equipment

For special equipment such as LNG storage tanks and nuclear grade pressure vessels, the system innovatively integrates anti magnetic interference design and all position welding function. Its modular rotating worktable (adjustable speed of 0.1-2r/min), combined with a dedicated roller frame, achieves precise circumferential welding of ultra large diameter cylinders (Φ>8m). The application case of a certain pressure vessel manufacturer shows that after adopting this scheme, the welding efficiency is improved by 40%, and the one-time pass rate of non-destructive testing is increased to 98.5%.

Integrated application of intelligent production line

In the construction of digital factories, the system builds flexible manufacturing units through intelligent linkage with welding robots, AGVs, and other equipment. Its standard RFID identification interface and force control sensing system enable automatic matching and optimization of process parameters. A certain intelligent manufacturing demonstration project has shown that integrating this solution reduces production time by 80% and overall energy consumption by 25%.

This innovative welding solution combines standardization (80% universal modules) and customization (20% specialized modules) to significantly improve equipment reuse while ensuring process reliability. Its core values are reflected in the improvement of welding deformation control ability by more than 50%, the reduction of tooling preparation cycle by 70%, and the reduction of comprehensive manufacturing costs by 30-45%. It has become an important technical support for the transformation and upgrading of the manufacturing industry.