In the production of electric heating tubes, welding is a key process step that significantly impacts the quality and performance of the final product. The following details the standard operating procedures for the welding process in the electric heating tube production line, focusing on five critical aspects.
1. Ensuring Tight Contact Between Lead-Out Rod and Resistance Wire
During the production of electric heating tubes, the connection between the lead-out rod and the resistance wire is fundamental to the welding process. The lead-out rod and the resistance wire must ensure tight contact after insertion. This not only guarantees stable current transmission but also prevents the resistance wire from loosening and detaching during use. To achieve this, the insertion process must be strictly controlled to ensure the resistance wire accurately fits into the lead-out rod and maintains sufficient tightness.
2. Importance of Welding Firmness
The firmness of the weld directly affects the service life and safety of the electric heating tube. To ensure welding firmness, it is essential to ensure that the resistance wire does not slip off the lead-out rod during the welding process. Operators must carefully inspect the contact between the resistance wire and the lead-out rod during welding and use appropriate welding techniques and process parameters to ensure the firmness and reliability of the weld.
3. Adjustment of Spot Welding Current
Adjusting the spot welding current is crucial for ensuring welding quality. The optimal spot welding current should be adjusted to a level where the welding does not produce sparks and smoke. The welding point should be at least 2mm away from the end face of the lead-out rod where the wire is inserted, with no fewer than two welding points. For the end coil wire head, special spot welding is required to ensure the wire head does not rise. This operation not only ensures the firmness of the weld but also prevents overheating during welding, thereby extending the service life of the electric heating tube.
4. Application of Oxy-Fuel Welding
For resistance wires with a diameter greater than 0.8mm, oxy-fuel welding should be used. The welding point should ensure that the resistance wire penetrates the lead-out rod, with special attention given to the spacing between the first and second coils at the end of the resistance wire. The rest of the area near the flame should be wrapped with asbestos thread to prevent localized annealing, which can cause uneven drawing of the wire. Oxy-fuel welding provides higher welding temperatures and effectively prevents quality issues caused by overheating during the welding process.
5. Handling of Finished Products and Quality Inspection
During the production process, the handling and storage of finished products also require special care. Operators should handle finished products gently to ensure that the resistance wire does not deform. Additionally, finished products must undergo a strict inspection by quality inspectors before proceeding to the next process step. Only products that pass inspection can enter the next production stage, ensuring the quality of the final product.
Tools and Equipment
In the production of electric heating tubes, energy storage spot welders, oxy-fuel welding equipment, and welding wires are essential tools and materials. Energy storage spot welders provide stable welding currents, oxy-fuel welding equipment is used for high-temperature welding, and high-quality welding wires ensure the firmness and durability of the welding points.
Tongli Machinery, as a professional manufacturer of automated electric heating tube production equipment, holds a high reputation and influence in the industry. The company offers a complete range of products, integrating R&D, production, and sales to meet the needs of the domestic market and export worldwide. Tongli Machinery, with its advanced technology and high-quality service, has become an industry leader and occupies an important position in the global market. Whether in terms of product quality or customer satisfaction, Tongli Machinery remains at the forefront of the industry, leading the development direction of electric heating tube production technology.
