Fully Automated Welding Machine for Polish Lampshades

Client: D*D D***d N**d***a, Polish Manufacturer of Household Lighting Fixtures

Project Background:
The customer contacted us in 2021 inquiring about an automatic welding machine for lampshade brackets. They required a quantity of 3 or 6 lampshade brackets, with a fixed specification for the central ring, where wires needed to be uniformly welded onto the central ring. After welding, the brackets should be bent and then automatically unloaded. Currently, the client is employing manual spot welding, which is considerably slow. Additionally, labor costs are high, and there are frequent holidays, making it impossible to meet production demands. Hence, opting for automated equipment is their preferred solution.

Product Images:

Project Process:
Our business compiled the customer's requirements and product information upon receiving the inquiry. Having handled similar machinery cases in the past, we provided a comprehensive technical proposal (inclusive of detailed technical specifications and 3D/CAD schematics) and quotation to the client within 24 hours.
At that time, the client initially provided specifications for a single type of lampshade, which led to some queries about the data in the proposed solution. For instance, inquiries arose about the length range of the brackets and how to handle different bending angles. We requested all product blueprints from the client, totaling four variations of lampshades. Our engineers studied the drawings and devised a universal plan enabling a single machine to produce all four products concurrently. This solution was highly satisfactory to the client.

To ensure the welding reliability, the client sent us samples for testing. Given that this machine was a custom order and not readily available, we initially used a standard spot welding machine for trial welding and conducted tensile tests to verify the weld strength. The entire process was documented via video and images for the client's review. The trial welding results met the client's requirements.

The client's initial goal was to acquire a highly efficient fully automatic machine. They sought a solution that not only fulfilled the requirement for full automation but also met their efficiency standards. We calculated that the machine could achieve a production rate of 300 units per hour, surpassing the client's anticipated output.
Once all details were confirmed, the client signed the contract and technical agreement with us. Following the signing, they arranged to provide us with a 50% deposit. Upon receipt of the deposit, we began designing the machine and mold drawings for client approval. Once the client confirmed the designs, we commenced equipment production, with the entire project taking approximately 45 days. After the equipment was completed, the client sent us 100 sets of samples for testing. We manufactured samples of the four lampshade specifications and filmed the production process for client inspection. Once testing was completed without issues, we notified the client to come to the factory for final acceptance. Upon successful acceptance, the shipment was arranged.