Dual-Station Galvo Laser Welding Machine

▷ Application Industry: New Energy Industry
▷ Welding Workpiece: Computer Chassis Enclosures

In this project, PDKJ designed and customized a dual-station galvo laser welding machine based on the customer's welding requirements for computer chassis enclosures. The equipment has completed manufacturing, commissioning, and delivery, and has been put into production at the customer's workshop.

The project focuses on automated welding of computer chassis enclosures. By combining dual-station positioning with galvo laser welding, the system coordinates manual loading and unloading with automated welding. While meeting the welding process requirements of the products, it also provides a more suitable automated welding solution for the customer's production environment.

Ⅰ Project Background

Customer Profile

The customer is a manufacturing company operating in the new energy industry, providing related products and supporting manufacturing services for new energy and industrial applications. Its production involves a large number of sheet metal structures such as chassis and enclosures.

Project Requirements

For this type of chassis enclosure, welding typically involves multiple fixed positions and welding points. As order volumes and production output increase, relying entirely on manual welding places higher demands on operator consistency, production efficiency, and workforce allocation.

Therefore, the customer's requirement was clear: to develop an automated welding machine specifically suited for the mass production of its existing computer chassis products.

Based on the workpiece structure, welding positions, and production workflow, PDKJ carried out a targeted solution design and ultimately selected a dual-station galvo laser welding machine for the project.

Ⅱ What Welding Challenges Did the Customer Face?

For this type of chassis enclosure welding application, the main challenge was not simply whether the products could be welded, but how to make the welding process more suitable for repetitive and batch production.

① Fixed and Repetitive Welding Positions

Computer chassis enclosures are typical sheet metal products. During mass production, similar products require the same or similar welding operations to be repeated continuously.

If positioning, clamping, and welding are performed manually for every workpiece, a considerable amount of repetitive work is required.

For batch production, converting these repetitive operations into a more standardized and mechanized process is an important direction for automation upgrades.

② Stable Positioning and Welding

During chassis enclosure welding, the workpiece needs to remain in a relatively stable position.

If the workpiece is placed differently each time, the welding position may also vary accordingly.

Therefore, this project did not simply rely on operators holding a welding gun manually. Instead, PDKJ designed dedicated positioning fixtures so that the workpiece could first be positioned and clamped before entering the laser welding process.

③ Single-Station Welding Can Be Affected by Loading and Unloading

With only one welding station, the operator must wait until welding is completed before removing the finished workpiece, placing a new one, and repositioning it.

For batch production, the coordination between loading, unloading, and welding becomes increasingly important.

The solution therefore adopts a dual-station structure, allowing the two workpiece stations to operate alternately and making the welding process more suitable for continuous repetitive production.

Ⅲ Key Advantages of the PDKJ Welding Solution

Based on the structure of the customer's chassis enclosures and the actual production workflow, the PDKJ technical team developed a customized dual-station galvo laser welding solution. The overall welding process and fixture structure were specifically optimized for the sheet metal chassis welding application.

Clear Operating Process

✔ Manual loading
✔ Fixture clamping
✔ Automated galvo laser welding
✔ Manual unloading

The next workpiece is then loaded into the fixture for the following production cycle.

The overall process is designed around manual loading and unloading + automated welding + dual-station cycling, creating a coordinated production workflow between operators and the welding machine.

1. Dual-Station Design for Continuous Production

After welding is completed at Station 1, the system switches to Station 2 for welding.

Operators can load and unload workpieces while the other station is performing the welding operation, allowing manual operations to coordinate with the machine's welding cycle.

For chassis enclosure production with a certain level of batch demand, the operating sequence can be further optimized according to the actual process cycle.

2. Dedicated Positioning Fixtures Reduce Repositioning

For automated welding of standardized products, the fixture is an important factor affecting production stability.

This project uses dedicated positioning fixtures with quick-clamping mechanisms, allowing workpieces to be placed and secured according to predefined positions.

Compared with relying entirely on manual positioning, dedicated fixtures are better suited to repetitive production of standardized products.

3. Galvo Laser Welding for Automated Machine Integration

The project uses a galvo laser welding system. The machine performs the corresponding welding operations according to the preset welding program.

For production involving standardized products and fixed welding positions, welding operations can be integrated into the automated machine cycle, reducing the need for manual intervention during the welding process.

4. Protective Enclosure for Machine-Based Production

The equipment is equipped with an aluminum-profile protective enclosure, creating a relatively independent working space around the welding area.

This structure also makes the complete welding machine more suitable for automated production environments.

Ⅳ From Solution Design to Equipment Delivery

From the customer's initial requirement for automated welding of computer chassis enclosures, through PDKJ's solution design, equipment manufacturing, commissioning, and final delivery, the dual-station galvo laser welding machine for computer chassis enclosures has now entered the customer's production facility and is providing welding support for new energy-related chassis products.

Automation does not necessarily mean that every production step must be completely unmanned. Instead, it means assigning suitable processes to automated equipment according to the actual product requirements, allowing operators and machines to perform the tasks best suited to each.

PDKJ always focuses on real-world production applications, ensuring that welding equipment is aligned with production line requirements and delivers practical value to manufacturing operations.

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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

Different products have different structures, materials, weld locations, welding quantities, and production cycles, requiring different welding equipment solutions.

If you are producing chassis and cabinets, sheet metal parts, new energy structural components, metal enclosures, mechanical parts, etc., and need to improve the automation level of welding, or if existing manual welding methods are insufficient to meet production demands, you can provide PDKJ with product samples, drawings, welding locations, and production volume requirements.

PDKJ can evaluate your product based on actual product conditions, considering welding processes, equipment types, tooling positioning, and automation processes, to provide a welding solution more tailored to your specific production needs.

Where there are products, there are welding needs; where there are welding needs, there is PDKJ.

Please feel free to contact the PDKJ team for welding process evaluation, solution consultation, and sample testing. First, understand which equipment is suitable for your product, then decide how to invest, ensuring that welding equipment truly serves production.

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

E-Mail: pdkj@gd-pw.com

Phone: +86-13631765713