PDKJ Dedicated Aircraft Delivery Case
In the metal-sheet fabrication sector, the welding accuracy, speed and inter-operational harmony of door hinges and reinforcement ribs directly determine end-product quality and on-time delivery. Recently, Guangdong PDKJ Automation Technology Co., Ltd. (“PDKJ”) delivered a customized multi-head spot-welding machine for door hinges to a hardware-and-sheet-metal customer in Jiangmen. The system precisely tackles the customer’s core pain points—low welding speed, cumbersome process hand-offs and insufficient weld-spot accuracy—bringing a high-efficiency upgrade to the entire production flow.
I. Client and Project Background
The Jiangmen-based customer specializes in manufacturing door-panel hardware and sheet-metal parts. Two critical operations—hinge welding and reinforcement-rib welding—had long been carried out with conventional equipment, creating three major bottlenecks:
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Insufficient welding speed: a single-head welder forced operators to reposition the panel for every spot, so welding the multiple hinges on one door took far too long to keep pace with high-volume orders.
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High inter-station losses: hinges and ribs were welded on two separate machines, so panels had to be shuttled between stations. Manual handling raised labor cost and frequently caused edge dents that lowered the final pass rate.
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Poor weld-spot repeatability: manual alignment varied with operator skill and fatigue, shifting hinge spots and producing uneven weld strength; the result was binding hinges at final assembly and a high rework rate.
To break through these limits, the customer urgently needed a tailor-made machine that could combine hinge and rib welding in one setup while boosting both accuracy and throughput. They chose PDKJ, a company that has focused on welding automation for almost twenty years.
II. Highlights of Customized Welding Equipment
After dissecting the customer’s line-side realities, running parametric simulations and piloting every critical step, PDKJ delivered a dedicated multi-head spot-welder for door-panel hinges. The machine is built around three design pillars—higher speed, merged operations and guaranteed accuracy:
1. Simultaneous weld heads, 3-5× faster
The frame carries several independent weld heads that fire in sequential “press-discharge” cycles, completing all spots in a single clamping. Compared with the former single-head unit, throughput jumps by 300-500 %. Each head has its own programmable current, force and weld time, so spots on different areas share the same quality and the first-pass yield stays above 99 %.
2. Dual-function integration, one flow
Instead of limiting itself to hinge welding, the same station also accepts reinforcement-rib panels—no machine change-over, no extra handling. Optimised head geometry and quick-change fixtures reach deep or narrow cavities that used to create blind zones and manual mis-locations.
3. Intelligent, low-skill operation
A user-friendly HMI stores and recalls parameter sets; a new operator is productive after a short briefing, cutting dependency on veteran welders. Modular construction with premium-grade components keeps the line stable and makes routine service simple, minimising downtime.
4. Customisable for every panel
Drawing on PDKJ’s mature custom-engineering platform, head count and pitch can be adjusted to the exact size and spot map of any door. Head spacing is variable from 50 mm to 300 mm, covering the full product range. Whether the material is stainless, galvanised steel or an odd-shaped profile, a tailored tool layout provides an exact fit and can be tied into an automated transfer line, leaving a clear upgrade path for future capacity increases.
III. Project Results
Since the tailor-made machine was commissioned on the customer’s floor, production data have confirmed four clear gains:
- Throughput: welding time per panel has been cut by more than 40 % compared with the previous equipment, enabling batch output to match order deadlines.
- Quality: spot accuracy and strength consistency have improved, driving door-panel rework below 3 % and lifting overall yield.
- Cost: merging two operations into one station has eliminated manual transfers and part damage, while the machine’s OPEX has come in lower than budgeted.
- Flexibility: quick fixture and head-pitch adjustments let the line switch between different panel sizes in minutes, supporting product-mix changes and future growth without extra capital outlay.
PDKJ remains committed to delivering high-quality welding solutions. In this project, the multi-head door-hinge spot-welder not only met the customer’s demands for speed and accuracy, but—through PDKJ’s customized engineering—also slotted perfectly into the existing production flow.
PDKJ stays true to its mission: “Make Metal Welding Easy for the World.” Drawing on deep technical expertise, decades of industry experience and an exact understanding of every customer’s needs, PDKJ delivers tailor-made welding solutions for any sector. Whether you produce home appliances, new-energy vehicles, semiconductors, sheet-metal parts or anything in between, PDKJ is ready to design the machine that solves your metal-joining challenge.
Customized service invitation - Unlock new possibilities in welding now!
If you need to weld stainless-steel stiffeners, enclosure frames, cabinet-door hinges, elevator panels or any other sheet-metal parts—or if you require a custom-built, non-standard welding system—talk to Guangdong PDKJ Automation Technology Co., Ltd. Our dedicated technical team, premium welding equipment and full-service support will deliver the solution that fits your line perfectly. Let PDKJ become your trusted partner on the welding journey: together we’ll solve every joining challenge, raise product quality and boost productivity, powering your company’s growth. PDKJ—your welding expert, always at your side. We look forward to working with you!
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If you have welding machine requirements, please contact Ms. Zhao
E-Mail: pdkj@gd-pw.com
Phone: +86-13631765713
