Classification of sheet metal products in the low-voltage electrical appliance industry
Sheet metal products in the low-voltage electrical industry are classified into five main categories: prefabricated house/container integrated systems, cabinets, chassis, insert frames, and small hardware parts.
Features of general-purpose cabinet sheet metal products
The product disassembly diagram of the general-purpose server rack reveals the following characteristics: In addition to using self-made general-purpose sheet metal parts, it also incorporates profiles such as Rittal's mainstream nine-fold profiles, sixteen-fold profiles, and other profiles to develop different products. The product materials are generally cold-rolled steel, hot-rolled steel, pre-galvanized steel, stainless steel, and 5052 aluminum. The product roughly consists of a base, frame, door panels, side panels, and top cover.
1—Top Cover 2—Bottom Frame 3—Front Door 4—Side Door 5—Left Rear Door 6—Right Rear Door 7—Lock 8—Mounting Beam 9—Square Hole Strip 10—Base 11—Cast
Sheet metal base
The base is typically made of T2.5 or larger sheet metal, bent and welded, or channel steel, welded together. Surface treatment processes include hot-dip galvanizing or powder coating. Figure 5 shows a welding example of a base product sample. Depending on the product material, the base welding uses either argon arc welding or carbon dioxide shielded welding. Welding process parameters include: welding machine current, voltage, welding wire material, diameter, wire feed speed, welding method, direction, and weld length.
Sheet metal frame
The frame is typically constructed from T1.5 or larger steel plates, bent and spliced (riveted or screwed) or welded. Surface treatment includes powder coating or no treatment (except for cold-rolled steel plates). Figure 6 shows examples and simulations of frame welding. The frame design generally involves assembly or welding; welding methods vary depending on the product material, using either argon arc welding or CO2 shielded welding. Welding process parameters include: welding machine current, voltage, welding wire material, diameter, wire feed speed, welding method, direction, and weld length. Key aspects of frame welding include controlling diagonal tolerances and deformation; batch production places even higher demands on the reliability of pre-made welding fixtures.
Sheet metal door panel
Door panels are typically made of T1.2 or larger sheet metal, bent and welded (corner edges are welded). Surface treatment involves spraying. Figure 7 shows a mesh door panel. Door panel welding varies depending on the material, employing argon arc welding, CO2 shielded welding, or flat-plate spot welding. Welding process parameters include: welding machine current, voltage, welding wire material, diameter, wire feed speed, welding method, direction, and weld length. For mesh door panels, careful control of welding stress and deformation is crucial. Figure 8 shows an example using automatic welding.
Sheet metal top cover
The top cover is typically made of T1.0 or larger sheet metal, bent and welded (with corners welded), and the surface treatment is spray painting. Top covers are generally divided into indoor and outdoor types; welding methods vary depending on the product material, using either argon arc welding or carbon dioxide shielded welding; welding process parameters include: welding machine current, voltage, welding wire material, diameter, wire feed speed, welding method, direction, and weld length. For outdoor top cover welding, careful control is crucial to manage the impact of full welding on flatness and diagonal tolerances. Excellent tooling and fixture solutions will significantly improve welding quality and efficiency.
Sheet metal internal mounting parts
Internal assembly typically involves structural component installation and component installation, and must be carried out strictly in accordance with the "XX Product Assembly/Electrical Assembly Work Instruction". After electrical assembly is completed, various performance tests are generally required.
Characteristics and Trends of Sheet Metal Products
By analyzing the above component breakdown and module interpretation, we can see that sheet metal products have the following three characteristics:
(1) Profile standardization. This facilitates platform-based design of products, and mass production helps reduce costs.
(2) Modular design. Based on the characteristics of each module, the design is flexible, allowing for modular procurement and assembly, which helps to shorten the procurement cycle.
(3) Serialization. Platform products are developed according to different configuration requirements to meet system requirements, forming a series of products, solidifying processes, and using molds for production, thereby improving production efficiency and shortening the supply cycle.
Conclusion
In summary, the low-voltage electrical appliance industry is showing a stable development trend. Sheet metal fabrication suppliers supporting this industry are giving more thought to new product design, new process development, production automation, and improving equipment uptime and inventory turnover. They are also promoting "lean manufacturing," and with the advent of the "Industry 4.0" concept, the industry is moving from manufacturing to "intelligent manufacturing." They are also leveraging network resources to move beyond the low-profit margins of sheet metal fabrication, elevating sheet metal fabrication in the low-voltage electrical appliance sector to a new level. Facing both opportunities and challenges, providing customers with safer, smarter, and greener electrical solutions is an inevitable trend.
