Along with the changes of the electric motor manufacturing, manufacturer puts forward the requirements of clean, quick and accurate joining methods for enamelled copper wire welding, motor winding welding. Oxymetal and electric soldering are traditional technology used in metal welding for decades and might involve some drawbacks on operating costs, clean combustion flame stability, carbon contamination, and production efficiency.
Today, many manufacturers are using the oxyhydrogen generator as an advanced high-tech solution in copper wire solder/copper wire brazing and precision joining. The modern hydrogen welding machine generates hydrogen and oxygen through splitting water with electricity, which has the advantages of no gas cylinder without the need, and a hydrogen combustion flame without pollution, which has excellent welding characteristics for fragile copper conductor welding.
The motor technology department proposes the improvement of the enameled wire welding method based on the optimization of the motor production process, and an oxyhydrogen welding machine is recommended to replace the company’s existing welding equipment such as oxyacetylene welding in the motor workshop, electric iron soldering or butt welding in the assembly line workshop.
This article is reviewing the advantages of the application of an industrial hydrogen welding system with regard to the production efficiency, welding quality and working safety when producing motors and corelated industries.
Industry Overview
The customer is in the electric motor manufacturing business, manufacturing electric motors for industrial equipment, HVAC, pumps, automotive and household appliances. Their production also includes the manufacture of transformers, the production of generators, as well as coil winding, and the manufacture of enamelled copper wire welding, motor winding welding, copper wire brazing is an important manufacturing process.
Good connection of each conductor is critical given that electrical performance is greatly reliant on having a robust and low-resistance connection. High volume manufacturers thus need to achieve uniform quality welding and speed up production rate.
Customer Production Requirements
There are few breaks in the production line during motor winding on the entire line. All the welded connections need to have the proper electrical conductivity and have no influence on surrounding insulation.
Deficient heat-control during enamel insulation removal is also detrimental to the effective removal of heat from the enamel while not harming neighboring windings. Because thousands of joints are being made every day, the welding system must become a part of continuous weld manufacturing processes without change to the flame characteristics.
Existing Welding Method
Traditional oxy acetylene flame welding and manual electric soldering practices were used on the shop as the method of processing parts before upgrading. Brazing was accomplished by the use of gas cylinders, conventional torches and solder materials.
This was an operation that was functional but demanded a high cylinder replacement rate, an adjustment of the flame, and highly-skilled welders to ensure suitable weld quality.
High Operating Cost
The most frequent recurring cost was that of acetylene and oxygen cylinders. High labor costs were also obtained due to the frequent refilling process, transportation costs, storage facilities and security management.
Additionally, the factory had to cease production when gas cylinders were replaced, thereby decreasing overall manufacturing efficiency.
Unstable Welding Quality
The typical wavelength welding process resulted in inconsistent temperatures because of the heat variations. Sometimes hot temperatures affected wire insulation, sometimes cold temperatures caused poor soldered joints.
This irregularity led to higher reworking rates and had an impact on the quality of enamelled copper wire welding, thereby impairing the consistent production level.
Safety Risks
There was a large amount of flammable gas cylinder, which also caused severe work area safety problems. There was a need for continued monitoring of storage and transport conditions and fire protection measures.
The manufacturer desired a safe alternative to the hydrogen welding machine that would help to reduce their supply of compressed fuel gas.
Low Production Efficiency
The welded quality depended on the operator experience, a consequence of manual flame adjustment factor. Additionally, production was delayed when cylinders needed to be replaced, causing unwanted downtimes.
The manufacturer required an oxyhydrogen welding machine which is more automatic and can operate continuously with stable flame output.
Key Decision Factors
On the basis of assessment of a number of technologies, the client has opted for the use of an oxyhydrogen generator which allows the production of hydrogen and oxygen according to the required demand, without requiring the use of gas cylinders.
The hydrogen-oxygen mixture ensures a stable flame and decreases the temperature variations during copper wire brazing. The cleaner combustion process also has a significantly reduced and smaller carbon residue and will also reduce the long-term operating costs.
Plus, the overall system can be seamlessly integrated with automatic manufacturing lines, enabling continuous production in industrial manufacturing.
Technical Advantages Considered
The several technical advantages swayed the decision – on-demand gas generation stability, accurate flame control, clean combustion, minimal logistics requirement for the cylinder and low maintenance requirements.
The impregnator is also particularly proud of the fact that the oxyhydrogen flame welding process results in practically no carbon contamination, contributing to the production of more clean electrical joints.
Equipment Setup
The set of industrial hydrogen welding systems consists of a high quality oxyhydrogen generator, a precise welding torch, electrolysis camera, water tank, flame arrestor, gas control system and safety monitoring elements.
All these contribute to the stability of hydrogen production and long term operation of industrial application.
Working Principle
In the hydrogen welding machine, purified water is broken down into hydrogen and oxygen gases by the process of water electrolysis.
These gases are mixed together in a controlled mixture of hydrogen with oxygen before being even delivered directly to the welding torch.
To start this fire, certain components are mixed together to produce a high-temperature “clean” combustion flame that will quickly burn off the enamel insulation on copper wire without significant oxidation.
The correct heat during welding with enamelled copper wire is just sufficient to remove the insulation and finish the brazing process. The liquid filler material is brought together with the exposed conductors and upon cooling it creates an excellent electrical and mechanical bond between the contacts.
The flame is free from carbon based fuel and the joint produced is clean and only requires minor after work on.
Welding Application Details
The solution is widely used for motor winding welding, copper wire brazing, joining lead wire, stator coil assembly, terminals of transformer coils, and fine copper conductor joining.
The copper wire welding machine is also widely employed in the joining of magnet wire, fine electrical connections and other more complicated weldable strainers in delicate assemblies for which the accuracy of the control of the flame is crucial.
The oxyhydrogen generator can be used by manufacturers in all aspects of electric motor production, transformer manufacturing, generator assembly, coil winding factories, and electrical equipment production.
In order to ensure good welding quality for motors, the following sectors rely on consistent enamelled copper wire welding and high-quality motor winding welding.
In addition to motors and transformers, the technology is being increasingly used in EV motor production, HVAC compressor production, water pump assembly, industrial automation equipment and power tool making.
For this type of industry, and there are other sectors, copper wire brazing machine solutions have to be reliable, to be able to support precision production. The equipment offers appropriate welding power for the following applications: copper conductor joining/welding, magnet wire welding, fine electrical conductor assembly, precision soldering etc. and these applications are all suitable for flame characteristics to clean.
PTXSON is a professional manufacturer and global supplier of oxyhydrogen generators, Hydrogen welding equipment, and hydrogen gas generation systems. The company has expertise in the design and manufacture of industrial hydrogen solutions for metal welding, brazing, flame cutting, engine carbon cleaning, hydrogen generation in the laboratory, boiler combustion. It supplies equipment to industrial facilities, laboratories, and manufacturers all over Asia, Europe, North America, Middle East and other international markets.
PTXSON has over 10 years of expertise in the field of hydrogen generation technology and provides industrial grade oxyhydrogen generators for challenging manufacturing plants. The company is engaged in the production of hydrogen welding machines, industrial hydrogen welding systems, and oxyhydrogen generators which produce stable, on-demand hydrogen-oxygen gas by water electrolysis. PTXSON solutions are broadly applied in the field of enamelled copper wire welding, motor winding welding, copper wire brazing, transformer manufacturing, generator production, EV motor assembly, HVAC equipment manufacturing, jewellery welding, etc. in the precision metal joining field.
We supports manufacturers with application-specific engineering services in order to get hydrogen welding into production lines. As for whether customers need an enamelled wire welding machine, motor winding welding machine, copper wire brazing machine or a whole industrial hydrogen welding system, PTXSON can help them choose the equipment, optimize the welding process and configure the system according to the production needs. The company’s technical skills serve industries which require precise heat control, clean combustion and reliable electrical conductor joining.
PTXSON is not only an experienced manufacturer of hydrogen welding equipment, supplier of oxyhydrogen generators, copper wire welding equipment, motor coil welding machine, but also an OEM supplier for all kinds of manufacturers, distributors, etc. serving all over the world. The company provides OEM/ODM manufacturing, international shipping, installation guidance, technical training and comprehensive after-sales support. It’s hydrogen generation technologies are enabling companies to optimize production, move away from conventional fuel gases, and reduce their carbon footprint and reliance on non-renewable resources in a variety of industrial processes.
The industrial oxyhydrogen generators adopt the alkaline electrolysis method to reduce the production cost and improve the high efficiency of electrolysis.3500L/h Oxyhydrogen flame welding machine is with flange type joint electrolytic cell,1., which can be disassembled for thorough maintenance and repair in the later stage. It is suitable for high flow gas production.
The working medium of oxyhydrogen generator is pure water and electricity, which is electrolyzed with water to produce hydrogen and oxygen gas. Purified water is then supplied and can be added at the daily time, It is operated with low cost and convenient to use.
