PDKJ Automated Welding Machine

▷ Industry: New Energy Vehicle Manufacturing
▷ Welding Application: Automotive Tailgate Motor

With the rapid development of the new energy vehicle (NEV) industry, manufacturers of automotive motors and components are demanding greater welding stability, higher production efficiency, and improved product consistency. More and more companies are adopting automated welding equipment to enhance productivity and meet the requirements of high-volume manufacturing.

In this case study, PDKJ successfully designed and delivered a custom Rotor Commutator Welding Machine for an automotive manufacturer. The equipment has been fully installed, commissioned, and officially put into production, where it is primarily used for the automatic copper wire welding of automotive tailgate motors.

Ⅰ Project Background

Customer Profile

The customer specializes in the research, development, and manufacturing of new energy vehicles and automotive components. Its products are widely used in:

• Electric drive systems

• Automotive motors

• Intelligent vehicle applications

Project Requirements

As market demand continued to grow, the customer planned to upgrade its tailgate motor manufacturing process by introducing automated welding equipment.

The objectives were to:

• Improve welding efficiency

• Ensure consistent weld quality

• Increase product consistency

• Meet growing mass-production requirements

After extensive discussions and product evaluations, PDKJ developed a customized rotor commutator welding solution tailored to the customer's workpiece structure and manufacturing process.

Ⅱ Customer Welding Challenges

During the project evaluation, the customer identified several key production requirements.

1. Stable Weld Quality

Resistance welding between the rotor copper wire and the commutator is one of the most critical manufacturing processes.

Weld quality directly affects motor performance, so the customer required highly stable welding output while minimizing quality variations caused by manual operation.

2. Continuous Multi-Point Welding

Each motor rotor requires multiple weld points.

Manual repositioning after every weld reduces productivity and affects weld consistency.

The customer wanted a solution capable of performing continuous multi-point welding automatically.

3. Fast Product Changeover

The factory manufactures multiple rotor models.

The customer required quick switching between different product specifications to minimize production downtime.

Ⅲ PDKJ Customized Welding Solution

Based on the customer's product structure and manufacturing requirements, the PDKJ engineering team developed a dedicated Rotor Commutator Resistance Welding Machine.

The machine integrates:

• Automatic positioning

• Pneumatic clamping

• Automatic rotation

• Resistance butt welding

to achieve continuous multi-point welding while improving production consistency.

Automatic Welding Process

✔ Manual workpiece loading and positioning

✔ Dual-hand safety start

✔ Pneumatic clamping of the workpiece

✔ Pressure resistance welding

✔ Automatic rotation to the next weld position

✔ Repeat until all weld points are completed

✔ Automatic clamp release and unloading

The fully automated welding cycle ensures smooth and continuous operation while maintaining consistent weld quality.

1. More Consistent Weld Quality

The combination of pneumatic clamping and automatic rotary positioning ensures every weld is completed at the exact programmed location, minimizing positioning errors caused by manual operation.

2. Optimized for Mass Production

The machine achieves a standard welding cycle time of ≤30 seconds.

Compared with the customer's previous equipment, production capacity increased by approximately 25%.

The machine also supports a 5-piece adjustable pre-welding program, stabilizing electrode conditions before production begins to ensure consistent weld quality for automotive component manufacturing.

3. Faster Product Changeover

Multiple welding programs can be stored and recalled with a single touch.

Different rotor models only require changing the positioning fixture, allowing fast product changeovers while maximizing equipment utilization.

4. Higher Level of Automation

The machine automatically performs:

• Clamping

• Positioning

• Rotation

• Welding

This significantly improves production efficiency while reducing operator workload.

5. Enhanced Safety Protection

To ensure safe production, the equipment is equipped with:

• Safety light curtains

• Dual-hand start buttons

• Three-color warning tower lights

These safety features protect operators while maintaining efficient production.

Ⅳ Successful Equipment Delivery

The complete machine was delivered within a standard lead time of 60 working days.

Before shipment, PDKJ completed sample welding tests using the customer's rotor components.

After installation at the customer's factory, PDKJ engineers provided:

• Equipment installation

• System commissioning

• Operator training

• Welding parameter optimization

• Maintenance support

Since entering production, the equipment has operated reliably, successfully supporting continuous automatic welding of automotive tailgate motor copper wires across multiple production batches.

It now provides dependable automated welding support for the customer's production line.

Every successful equipment delivery marks not only the completion of a project but also the beginning of a customer's new stage of efficient manufacturing.

PDKJ remains committed to providing customized welding solutions based on each customer's products, welding processes, and production requirements, helping manufacturers achieve more stable, efficient, and intelligent production.

Take Action Now

Choose PDKJ and enjoy five key guarantees for worry-free cooperation:

1. Free Sample Testing – Try Before You Buy
   Test your parts first and proceed only when satisfied

2. Factory Direct Supply – Cost Savings
   No middlemen, direct factory pricing

3. Professional Technical Support – Full Guidance
   One-on-one engineering support for welding solutions

4. Full Machine Warranty – Reliable Service
   Original components with comprehensive warranty

5. Customized Solutions – Tailored to Your Needs

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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

Making Welding Simpler, Making Production More Efficient

Across industries such as automotive components, micro-motors, new energy, precision hardware machining, and home appliance manufacturing, PDKJ provides tailored welding equipment and process support to address technical challenges—including copper wire spot welding, dissimilar metal welding (copper-aluminum), and precision resistance welding—based on specific product characteristics.

If your company manufactures:

• Welding efficiency fails to keep pace with order growth;

• Difficulty in recruiting welders and continuously rising labor costs;

• Inconsistent welding quality;

• Heavy workload for subsequent grinding and finishing;

• Desire to upgrade to automation or intelligent systems;

Please feel free to contact the PDKJ team:

Simply provide your product drawings, samples, or welding requirements. We will evaluate the best welding solution for your specific operational needs and offer sample testing services to help you find the equipment that best fits your production requirements.

PDKJ Welding Machines: We craft every unit with dedication and create value for our customers through real-world applications.

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If you have welding machine requirements, please contact Ms. Zhao

E-Mail: pdkj@gd-pw.com

Phone: +86-13631765713