Schneider Custom Friction Stir Welding Equipment Successfully Delivered, Empowering High-End Manufacturing Welding Innovation

1. Key Parameters and Highlights of the Custom Friction Stir Welding (FSW) Equipment

Dongguan Zhihui Welding Technology Co., Ltd. provided Schneider with custom Friction Stir Welding (FSW) equipment, specifically tailored for power busbar products, with the following technical highlights:

• Welding Material Compatibility: The equipment supports high-precision welding of materials such as aluminum alloy and red copper, making it ideal for power busbar welding, new energy vehicle battery trays, and other applications requiring high strength and low resistance.

• Welding Thickness Range: The equipment can handle welding tasks with a material thickness range of 1-20mm, After welding, the conductivity of the product can reach more than 98% of the parent material，covering a wide array of industrial applications and capable of addressing welding challenges in materials of various thicknesses.

• High-Efficiency Spindle: The equipment is equipped with a 3000RPM spindle rotary speed, ensuring even heat distribution during the welding process, thus maintaining the stability and consistency of the weld quality, especially when welding aluminum alloys and red copper.

• High-Precision Stroke Design:

• X-Axis Stroke: 2300mm, providing ample space for longer workpieces.

• Y-Axis Stroke: 1500mm, meeting the requirements for most standard welding workpieces.

• Z-Axis Stroke: 300mm, ensuring flexible height adjustments to accommodate welding demands for different workpieces.

• Max. Z Force: The equipment offers 60kN of top force, ensuring precise pressure control during the welding process and providing stable mechanical support for welding materials like aluminum alloys and red copper. This is particularly critical for high-load production of power busbar products, ensuring the welded joints are strong and reliable.

2. Schneider’s Application Needs for Welding Equipment

As a global leader in energy management and automation solutions, Schneider faced high-intensity welding challenges in power busbar production, with specific requirements:

• Power Busbar Welding Challenges: The special requirements of power busbar materials made traditional welding methods inadequate to meet the strength and precision demands, especially in mass production where maintaining welding quality was a challenge.

• Customized Welding Solutions: Schneider needed a highly customized solution that could support power busbar products of varying sizes and materials while maintaining stable and consistent welding quality.

Cooperation Background:

• 5 Years of Deep Collaboration: Dongguan Zhihui Welding Technology Co., Ltd. has worked with Schneider's China factory for over 5 years, successfully solving welding bottlenecks in power busbar production and significantly improving production efficiency and product quality.

• Breakthrough in Mass Production: Our custom FSW equipment helped Schneider break through mass production challenges, ensuring stability and consistency in large-scale production, earning Schneider’s high praise.

• International Delivery: After successful delivery in the Chinese market, our custom FSW equipment is now being delivered to Schneider’s factories in the United States, Mexico, and India, further strengthening our global partnership.

3. Equipment Delivery Cycle, Commissioning Process, and Quality Testing

Equipment Delivery Cycle:

• Delivery Time: The custom FSW equipment is generally produced and delivered within 8-16 weeks after design confirmation, ensuring a fast response to Schneider’s production demands.

Commissioning Process:

• Commissioning Time and Expertise: Based on our extensive project experience, the commissioning process can typically be completed within 7-14 days, and once commissioned, the equipment is ready for mass production, ensuring Schneider can quickly start operations.

• Technical Support: We provide on-site technical expert support to help Schneider’s operators quickly familiarize themselves with the equipment’s operation, ensuring efficient and stable equipment performance.

Quality Testing:

• All equipment undergoes strict quality testing before delivery, including but not limited to testing for welding quality, equipment stability, and welding efficiency, ensuring each machine meets international standards and Schneider’s high-quality requirements.

• Lifecycle Support: In addition to delivery and commissioning, we offer ongoing technical support and regular maintenance, ensuring the equipment operates smoothly and with minimal downtime.

Conclusion

The custom Friction Stir Welding (FSW) equipment provided to Schneider not only solved welding challenges in the mass production of power busbar products but also enhanced production efficiency and welding quality, providing strong technical support for Schneider’s global production expansion. We look forward to deepening our strategic cooperation with Schneider and driving welding technology innovation in the high-end manufacturing sector.