How to Operate a 10-Cylinder Reciprocating Gantry Welding Machine Like a Pro：A Comprehensive Guide for Industrial Welding

Why Choose Gantry Welding for Industrial Production?

The 10-cylinder reciprocating gantry welding machine is a specialized solution designed for automatic resistance projection welding of sheet metals, particularly suitable for carbon steel and stainless steel wires. As a key equipment in the metal processing industry, it offers the following advantages:

✅ High Efficiency: Equipped with two 315KA AC power supplies and a PLC control system, it can achieve rapid welding and automatic feeding, significantly improving production efficiency.

✅ Precision and Stability: The adjustable electrode spacing and stroke compensate for electrode wear, ensuring consistent welding quality. The automatic lifting of the lower electrode avoids collisions with fixtures during operation.

✅ Flexibility: Capable of storing 10 sets of programs (each with up to 50 welding steps), it can easily adapt to different workpiece specifications and welding processes.

? Essential Equipment and Key Components

Equipment/Component	Purpose	Key Features	Brand/Specification
Welding Power Supply	Provide welding current	Two sets of 230KVA AC power supplies, stable current output	Customized
PLC Control System	Centralized control of machine operations	Mitsubishi PLC with a 7-inch touchscreen HMI, supports manual/auto modes, program storage, and fault diagnosis	Mitsubishi (Japan)
Pneumatic Pressurizing Mechanism	Apply welding pressure	20 sets of adjustable pneumatic cylinders, providing up to 5000N of pressure at 0.5MPa	AirTac (Taiwan)
Servo Feeding System	Precise fixture movement	4.3KW Delta servo motor, with a maximum feeding speed of 500mm/s	Delta (Taiwan)
Cooling System	Ensure equipment safety and stability	Water-cooled system with a flow rate of 30L/min and an alarm for low water flow	Customized

? Step-by-Step Operation Process

1. Machine Setup and Initialization

Power Connection: Connect to a 3-phase AC 380V ± 10% power supply with a 600A circuit breaker and a 95mm² copper wire. Ensure the grounding wire is greater than 14mm² for safety.

Pneumatic and Cooling Preparation: Adjust the air pressure to 0.5-0.7MPa and check the cooling water pressure (0.2-0.3MPa) and flow rate (70L/min). Ensure no leaks in the pipelines.

Fixture Installation: Place the workpiece on the fixture and adjust the lateral spacing of the electrodes according to the workpiece dimensions (minimum opening and arm extension can be adjusted for different welding positions).

2. Parameter Setting and Program Input

Manual Mode: Use the (forward/backward) buttons to move the fixture to the welding position. Set the manual movement speed (0-200mm/s) in the (work monitoring) interface. Press the (welding start) button to start single welding.

Teach Programming: Enter the (teach programming) interface, set the teaching speed, and move the fixture to each welding position using the direction buttons. Record the movement distance, speed, and welding parameters at each step. Save the program with a specific number (up to 10 sets can be stored).

Automatic Mode: Select the desired program in the (program selection) interface. Ensure the fixture is at the origin, set the switch to(auto), and press the dual (start) buttons within 2 seconds to initiate the automatic cycle.

3. Welding Parameter Reference (for Carbon Steel Sheets)

Parameter	Description	Recommended Value
Welding Current	Adjust according to material thickness	50-80% of the maximum short-circuit current (42kA)
Electrode Pressure	Controlled by air pressure (0.5-0.7MPa)	5000N at 0.5MPa
Feeding Speed	Forward speed during welding	500mm/s (default for automatic mode)
Electrode Stroke	Compensation for electrode wear	60-80mm (adjustable via mechanical structure)

? Advanced Techniques for Optimal Performance

1. Joint Adjustment and Multi-Station Collaboration

Lateral Spacing Adjustment: Each electrode can be individually adjusted laterally to adapt to different welding joint types (such as butt, lap, and T-joints). This is particularly useful for complex workpiece structures.

Program Optimization: Use the (program editing) function to fine-tune the movement distance and speed at each step. For large workpieces (up to 2000X6000mm), divide the welding process into multiple steps to ensure uniform welding quality.

2. Electrode Maintenance and Wear Compensation

Regular Inspection: Check the electrode wear condition after every 1000 welding cycles. Replace the electrode tips when the wear exceeds 2mm to maintain the welding pressure and current stability.

Stroke Adjustment: Manually adjust the lower electrode stroke through the mechanical handle to compensate for wear, ensuring the workpiece is properly pressed during welding.

⚙️ Troubleshooting Common Issues

Problem	Possible Cause	Solution
No Welding Current	1. Power supply failure 2. Contactor malfunction 3. Welding cable loose	1. Check the power voltage and circuit breaker 2. Inspect and replace the contactor 3. Tighten the cable connections
Inconsistent Weld Quality	1. Electrode spacing uneven 2. Air pressure unstable 3. Welding parameters mismatch	1. Re-adjust the electrode lateral spacing 2. Calibrate the air pressure regulator (0.5-0.7MPa) 3. Re-set the welding current and pressure according to the process sheet
Fixture Movement Jamming	1. Guide rail lubrication insufficient 2. Servo motor error 3. Inductive switch misalignment	1. Apply lubricating oil to the guide rails regularly 2. Check the servo motor fault code and restart the system 3. Adjust the position of the inductive switch to ensure proper detection

? Industry Applications

Hardware and Home Appliances: Widely used in welding wire baskets, shelves, and fan guards, ensuring high-strength and aesthetically pleasing joints.

Lighting and Decorations: Suitable for welding stainless steel lamp brackets and decorative metal structures, achieving precise and durable connections.

Electronics and Communications: Used in manufacturing battery brackets and electronic component frames, meeting the strict requirements for conductivity and mechanical strength.

⚠️ Safety and Environmental Considerations

Personal Protection: Always wear heat-resistant gloves, safety glasses, and a flame-retardant apron during operation. Ensure the work area is well-ventilated to avoid inhaling metal fumes.

Environmental Requirements: Install the machine in a clean, dry environment with a temperature range of 0-45°C, free from strong vibrations, dust, and corrosive gases. Recycle used electrodes and lubricants according to environmental regulations.

❓ FAQ Section

Q: How to set up the welding program for a new workpiece?

A: Use the (teach programming) mode: manually move the fixture to each welding position, set the corresponding parameters, and save the program. Up to 10 sets of programs can be stored for quick switching between different workpieces.

Q: What is the maintenance cycle for the key components?

A:

Electrode tips: Replace every 500-1000 cycles (depending on wear).

Guide rails and screws: Lubricate every 8 working hours.

Cooling system: Clean the filters every month to prevent blockage.

Q: Can the machine handle aluminum materials?

A: The standard configuration is optimized for carbon steel and stainless steel. For aluminum welding, please consult our technical team for customized electrode and process adjustments.

Conclusion

Mastering the operation of the 10-cylinder reciprocating gantry welding machine requires a combination of precise parameter setting, proper equipment maintenance, and strict safety compliance. By following the step-by-step guide and leveraging the advanced features such as program storage and automatic feeding, you can achieve high-efficiency, high-quality industrial welding. Whether for large-scale production or customized workpiece processing, this machine provides a reliable solution for modern metal manufacturing.

Ready to Enhance Your Welding Production?

Contact JINCHUN Mechanical Equipment Co.,Ltd for professional technical support and customized solutions. Our team offers comprehensive training, on-site installation, and a one-year warranty for peace of mind. Let's work together to elevate your welding operations to the next level!

Company Address: Room 101, Building 5, Integrated Innovation Park, No. 25 Sanle East Road, Beijiao Town, Shunde District, Foshan City, Guangdong Province

Contact: Carl  +86 15015830219

Email:[email protected]