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Custom Welding Machines & Electronic Components | PDKJ Seam Welder for Sensor Sealing Discs Delivered To Chongqing, Facilitating Precision Welding of Stainless Steel Sensor Housings
Views: 0 Author: Site Editor Publish Time: 2026-09-19 Origin: Site
In this case study, the sensor sealing disc welding machine custom-developed by PDKJ has been completed, delivered, and put into mass production at the customer's workshop. The system provides an automated welding solution for sealing stainless steel housings of electronic components and sensors.
Ⅰ Project Background
Customer Profile
The customer is a high-tech enterprise specializing in the R&D and manufacturing of MEMS semiconductor sensor chips and sensor modules. Its products are widely used in industrial automation, automotive, medical, chemical, and other industries.
Project Requirements
As demand for sensor products continued to increase, the customer required higher consistency and efficiency in the welding of metal sensor housings.
The customer planned to further automate the existing welding process through a dedicated welding machine, with the goal of addressing practical production issues such as thin-sheet welding deformation, unstable sealing welds, and slow production cycles, while establishing a more standardized process for mass production.
Ⅱ Identifying the Actual Welding Challenges
From the customer's production requirements, several key challenges needed to be addressed.
① Thin Workpieces Require Precise Welding Control
Thin metal components are sensitive to welding current, welding time, electrode pressure, and other process conditions.
If welding parameters or pressure are not properly controlled, problems such as unstable weld formation and over-welding may occur.
Therefore, the welding process needs to be specifically matched to the material and thickness of the workpiece.
② Circumferential Welding Cannot Be Replaced by Conventional Spot Welding
This project does not simply require several independent weld spots. The sensor housing requires continuous circumferential welding around the sealing area.
The workpiece therefore needs to rotate smoothly during welding while maintaining stable contact between the welding wheel and the workpiece.
③ Repetitive Manual Operations Are Not Ideal for Mass Production
When workpiece loading, clamping, rotation, welding, and unloading all rely on manual operations, the number of steps required for each product increases.
Once production reaches a certain volume, reducing repetitive manual operations and allowing the welding sequence to be completed automatically according to a fixed process becomes an important part of the automation upgrade.
Ⅲ Key Features of the PDKJ Sensor Sealing Disc Welding Machine
Based on the workpiece characteristics and actual workshop conditions, the PDKJ engineering team customized the power supply, mechanical structure, workholding fixtures, and control system as an integrated solution.
The overall machine dimensions are 1200 × 1000 × 1700 mm, making it suitable for installation within the customer's production environment.
1. Dedicated Seam Welding Structure for Continuous Circumferential Welding
To match the welding requirements of the sensor sealing disc, the machine uses a dedicated seam welding mechanism.
The welding wheel works together with the rotating workpiece to complete continuous circumferential welding.
Compared with conventional individual spot welding, this structure is better suited to the workpiece design and required welding path of the project.
2. Stable Clamping and Rotation for Consistent Welding
For circumferential seam welding, stable positioning and rotation of the workpiece are important factors affecting welding quality.
The customized machine uses a lower clamping and rotating mechanism to secure the workpiece while coordinating with the welding mechanism during rotation.
After the operator loads the workpiece and starts the machine, the system automatically performs the programmed clamping, rotation, and welding sequence, supporting stable and continuous production.
3. Adjustable Welding Parameters for Process Optimization
The control system allows welding parameters to be configured according to different product requirements and supports the storage and recall of multiple welding specifications.
The system also provides process control functions including preheating, welding, and tempering.
If different product specifications or welding process requirements are introduced in the future, the machine can be adapted through parameter adjustments.
4. Integrated Safety Protection for Production Environments
The machine is equipped with a protective enclosure, safety light curtain, manual start mode, and integrated water and pneumatic systems.
These features provide appropriate safety protection for operators while supporting stable operation in a production environment.
Based on a workpiece diameter of 50 mm, the complete production cycle is approximately 35 seconds per piece, including loading, unloading, and welding, meeting the customer's mass-production requirements.
Ⅳ Equipment Delivery and Production Application
The custom sensor sealing disc seam welding machine successfully passed factory pre-acceptance before shipment and was subsequently delivered to the customer's facility.
PDKJ engineers completed on-site installation and commissioning and provided training for the customer's production and maintenance personnel, including machine operation and welding parameter adjustment.
The equipment has now been put into production and is being used for stable welding of stainless steel sensor housings.
Every customized welding machine starts with a detailed understanding of the customer's product, welding process, and production environment.
From welding process evaluation and solution design to equipment manufacturing, delivery, commissioning, and operator training, PDKJ focuses on practical implementation and helps manufacturers address real welding challenges while improving quality, reducing production costs, and increasing efficiency.
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Professional Services by Guangdong Pudian Automation Technology Co., Ltd.
Guangdong Pudian Automation Technology Co., Ltd.
20 years of expertise in resistance welding, laser welding, and automated welding equipment
Focus on high precision, high stability, and customized solutions
Full coverage of processes including spot welding, projection welding, seam welding, rolling welding, laser welding, and automated production lines
One-on-one customized welding solutions based on material, thickness, and production volume
Serving multiple industries and solving complex welding challenges
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Founded in 2006, PDKJ is a professional supplier of welding automation solutions. The company has passed the ISO9001 international quality management system certification, has more than 90 officially authorized and applied national patents, and a number of core technologies in the welding field fill the technical gap at home and abroad. It is a national high-tech enterprise.
