First, the industry dilemma: the three fatal shortcomings of traditional welding technology
1. Space limitations: the gap of dense pipelines is often less than 15mm, and manual welding requires the help of magnifying glasses and special fixtures, and the operation efficiency is only 30% of the theoretical value
2. Technical dependence: welding quality is highly dependent on the experience of technicians, the training cycle of excellent welders is as long as 2-3 years, and labor costs account for 28% of production costs
3. Quality risk: the leakage rate of manual welding is as high as 12-15%, and a leading enterprise has lost more than 2 million yuan due to welding defects in a single batch of products
According to data from the China Refrigeration and Air Conditioning Industry Association, in 2024, the industry's direct economic losses due to welding problems will reach 3.7 billion yuan, and the indirect impact on production capacity will exceed 12 million sets.
2. Technological breakthroughs: the four core innovations of the MWH series
Through 15 years of deep technical cultivation, Shanghai Meizhu Technology has developed an intelligent welding system specially designed for heat exchanger U-tube welding, and realized the systematic solution of industry pain points:
1. Micro all-position welding system
The world's first compact welding torch: with a diameter of only 12mm, it can be welded 360° deep into the pipe of Φ9.52mm without dead angles
Three-dimensional dynamic compensation technology: equipped with a six-axis robotic arm, it can automatically compensate for the pipe processing error of ±0.15mm
Water-cooled circulation system: the cooling module imported from Germany is used to achieve 2000 times of continuous welding without stopping
2. AI intelligent welding platform
Expert process database: built-in 200+ welding parameter models, support automatic matching of pipe diameter/wall thickness, and increase the efficiency of parameter setting by 90%
Adaptive control system: real-time collection of 12 parameters such as arc voltage and current, and dynamic adjustment of welding speed and energy output
3. Efficient production mode
Two-person operation: A single machine can control two welding guns at the same time, and the cycle time is reduced to 45 seconds/piece
Modular design: It supports quick changeover, and it only takes 5 minutes to switch between Φ9.52mm and Φ25mm pipe diameter
Ergonomic optimization: 7-inch touch screen + manual control switch, 60% reduction in operating fatigue
4. Precision welding process
Self-melting technology without filler wire: self-melting of the base metal by using high-frequency pulsed arc with weld strength up to 98% of the base metal
Multi-layer gas protection: Triple gas protection system is adopted to control the oxygen content of the weld below 20ppm
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3. Value reconstruction: a chain reaction from cost control to industrial upgrading
The application of the MWH series welding machine is causing a deep production change in the HVAC industry:
1. Disruptive breakthroughs in the cost dimension
According to data from a leading refrigeration equipment company, after adopting the MWH-16A model, the annual comprehensive cost of a single equipment is reduced by 1.12 million yuan, and the payback period is only 7 months.
2. Comprehensive upgrade of quality system
Pressure resistance: The burst pressure of the weld is up to 3.5MPa, far exceeding the industry standard of 2.5MPa
Sealing performance: Helium mass spectrometry leak detection leak rate ≤5×10⁻⁹ Pa・m³/s
Appearance quality: Weld seam forming uniformity up to ±0.05mm, can be directly certified to ISO 5817 class B
3. Intelligent transformation of production mode
Data-driven decision-making: Welding parameters are uploaded to the MES system in real time, and the response time of yield fluctuation warning is shortened to 15 seconds
Flexible production capacity: support multi-model mixed line production, order switching efficiency increased by 400%
Green manufacturing: 35% less energy consumption than traditional processes, in line with EU CE PED 2014/68/EU standards
Fourth, the selection logic of industry benchmarks
The choice of global refrigeration and heating enterprises confirms the technical value of the MWH series of American welding:
Case 1: A leading air-conditioning company
Before the transformation: an average daily output of 2,000 U-shaped pipes, requiring 8 technicians to operate, and the annual labor cost was 1.2 million yuan
After the transformation: 4 MWH-16AJSG models are adopted, and the average daily production capacity is increased to 6,000 pieces, and only 2 general workers are needed to manage them
Comprehensive benefits: annual cost savings of 2.1 million yuan, order delivery cycle shortened from 15 days to 7 days
Case 2: A multinational refrigeration group
Pain point: 5% customer claim rate due to welding defects in export products
Solution: Deploy the MWH-25A model and integrate the online inspection system
Results: Claim rate reduced to 0.3%, and customers received an additional 30 million yuan in orders
5. Future prospects: the road to industrial transformation of intelligent welding
With the advancement of the "dual carbon" goal, the HVAC industry is accelerating the transformation to high efficiency and energy saving. Meihua Technology leads the industry upgrading through three strategic layouts:
Technology iteration: Research and development of argon arc composite welding technology, the weld depth is increased to 3mm
Ecological construction: Establish an "intelligent welding laboratory" with colleges and universities to cultivate professional and technical talents
Global layout: The products have entered the European Union, North American market, and Northeast Asian market
