How to make ”perfect” metal wire circles?

I. Process Innovation: Overcoming Traditional Limitations

Traditional Challenges

Separate rounding/welding processes requiring repeated alignment

Manual operations causing >30% quality variance

Burr removal consuming >15% production time

Modern Solution

Integrated coil forming & welding systems deliver:

✓ Full automation: Shaping → Precision cutting → Auto butt welding

✓ 1 operator manages 3-5 machines simultaneously

✓ 90% reduction in process transition losses

II. Core Manufacturing Technologies

1. Precision Forming System

Dual-wheel design: Alloy feed rollers (HV800 hardness) + 9-axis straightening wheels

Vacuum heat treatment for >10,000-hour service life

Forming tolerance: <0.05mm

2. Intelligent Control Hub

Dedicated PLC controller ensures:

▶ Production counting error <0.1%

▶ Forward/reverse switching in <0.3 seconds

▶ Smart energy consumption adjustment

3. High-Precision Welding Unit

Resistance butt welding specs:

→ Instant current density: 1,500 A/mm²

→ Upsetting pressure: 60 MPa

→ Weld flatness: Ra 3.2 μm

III. Precision Standards

1. Dynamic Processing Parameters

Material compatibility:

▶ Low-carbon steel: Ø6-10mm

▶ High-carbon steel: Ø4-8mm

Production speed:

▶ Ø150mm: 35 units/min

▶ Ø300mm: 15 units/min

▶ Ø600mm: 8 units/min

2. Quality Certification

Radial runout: <0.12mm/m

Coaxiality tolerance: ±0.15mm

Weld strength: ≥95% base material

Surface roughness: N7 grade

IV. Equipment Performance Assurance

1. Power Systems

Servo drive: 3.9kW (±1% torque accuracy)

Hydraulic unit: 4kW (<0.5% pressure fluctuation)

2. Environmental Controls

Compressed air: 0.6 MPa (smart pressure stabilization)

Water cooling: 50L/min (±2% flow control)

V. Secrets to Perfect Coils

1. Material Prep

Wire straightness: ≤1mm/m

Surface cleanliness: Sa2.5 grade

2. Parameter Optimization

Wire-to-power matching:

Ø6mm → 40 kVA

Ø8mm → 63 kVA

Ø10mm → 80 kVA

3. Quality Protocols

3D inspection on first daily batch

Forming wheel temperature checks every 2 hours

Dual-stage air filtration

 

This precision manufacturing system (0.2mm forming tolerance + 95% weld strength + 99.2% yield rate) paired with standardized workflows achieves zero-defect coils:

✓ Radial runout <0.15mm

✓ Weld flatness Ra 3.2

✓ Batch consistency ±0.1mm

Meeting true industrial-grade "perfect coil" standards.