A beam of light illuminates the Trinity quality in the millimeter!

At the past March Day commendation reception, the development and application project of laser welding technology of the heavy boom won the "Excellent Project Award". This self-developed innovative process uses laser composite welding to overcome the industry's ultra-high technical problems, and practices Sany quality values with millimeter-level paranoia.

Previously, conventional arc welding was being processedcraneThere is a significant bottleneck in the boom thin plate, which is deformed, difficult to control and unstable, and there is a large gap compared with the world-class welding level. In order to improve product quality and market competitiveness, Sany Heavy Lifting Welding Process aims at laser welding technology innovation, and simultaneously replaces traditional manual operation with robot automatic welding, and strives to break through the double limit of production efficiency and product accuracy.

There is no ready-made experience to follow in this process, and it is necessary to face the unpredictable technical risks and implementation difficulties. The process team strictly followed the standardized process of project management, and after thousands of tests, systematically overcame the key technical difficulties of the boom barrel group such as gap accuracy control, non-groove butt welding, external spot welding, single-sided welding and double-sided molding, and finally successfully developed the advanced process of laser-arc composite welding.

Compared with the traditional process route of "bevel + manual root welding + double-wire cover welding", the process streamlines the two processes, improves the welding efficiency by 60%, reduces the welding deformation by 70%, and maintains the first-pass rate of weld X-ray flaw detection at more than 95%, and the process technology and welding quality are industry-leading.

In the project, the process team independently developed a variety of new laser processes such as handheld laser positioning welding, laser welding wire filling, laser welding process, laser composite horizontal welding, laser cleaning, etc., without teaching programming, to achieve mass production, and build a laser welding technology system covering 3.5-100T products, completely solve the stubborn problem of boom wave deformation, and greatly improve product quality.

Nowadays, in the crane production workshop of Ningxiang Industrial Park, this technology has fully replaced the traditional process, covering the large, medium and small cylinders of the crane, taking the welding of high-altitude vehicles as an example, the width of the cover weld is reduced from 13-14mm to 5-6mm, and the consumption of welding wire is reduced by more than 50% compared with the traditional process.

Every advancement of the manufacturing process is engraved with Sany's persistent pursuit of quality - from the millimeter control of welding deformation to the accuracy optimization of the flaw detection pass rate, this quality ruler engraved into the gene has always led Sany products to continue to upgrade to high-end!