The low-voltage electrical industry encompasses a variety of sheet metal products, which can be broadly categorized into five types: boardroom and container integrated systems, cabinets, chassis, frames, and small hardware. These products play a crucial role in ensuring the functionality and durability of electrical equipment.
General-purpose sheet metal products typically include profiles like the main nine-fold and sixteen-fold profiles, which allow for the creation of diverse products. The materials used range from cold-rolled sheets and hot-rolled sheets to pre-galvanized sheets, stainless steel sheets, and aluminum sheets like 5052. A standard cabinet consists primarily of a base, a frame, a door panel, side panels, and a top cover. As illustrated in Figure 3, both nine-fold and sixteen-fold profiles are commonly employed.
The base of a sheet metal product is often constructed using T2.5 or thicker plates through bending or channel welding. Surface treatments typically involve hot-dip galvanizing or powder coating. An example of a welded base product sample is shown in Figure 5. Welding parameters include machine current, voltage, wire material, diameter, wire feed speed, welding method, direction, and segment length.
The framework is usually formed by bending or splicing T1.5 or thicker materials, with surface treatments ranging from spraying to no treatment (except for cold-rolled steel). Frameworks can be designed for assembly or welding, with welding parameters similar to those for bases. Attention must be paid to controlling diagonal tolerance and deformation, especially in batch production where pre-welded tools require higher reliability.
Door panels are typically made from T1.2 or thicker plates through bending or welding (for welded corners). The surface treatment involves spraying, and Figure 7 illustrates a mesh door panel. Welding techniques vary based on material, including argon arc welding, carbon dioxide protection welding, or flat welding. Parameters such as current, voltage, wire material, and welding length need careful control to manage stress-induced deformation.
The top cover is usually formed by bending or welding T1.0 or thicker plates, with surface treatments involving spray coating. Top covers are categorized into indoor and outdoor types, with welding parameters similar to those for door panels. Outdoor top covers require special attention to flatness and diagonal tolerance, and excellent fixtures can enhance welding quality and efficiency.
Internal mounting components are generally divided into structural parts and accessories, requiring strict adherence to assembly guidelines. After completing the electrical equipment, various performance tests must be conducted.
Sheet metal products exhibit several trends: first, profiles facilitate product platform expansion and cost reduction through mass production. Second, modularity allows flexible design and modular purchasing and assembly, shortening procurement cycles. Third, serialization enables product development based on platform configurations, forming standardized series, optimizing processes, and improving production efficiency.
In conclusion, the low-voltage electrical industry continues to evolve steadily. Sheet metal production suppliers are increasingly innovative, focusing on new product design, process development, and automation to achieve lean production. The advent of Industry 4.0 concepts encourages transitioning from manufacturing to smart production, utilizing network resources to escape the "low-profit" status quo. This pushes sheet metal production in low-voltage electrical appliances to new heights, addressing both opportunities and challenges while providing safer, smarter, and greener electrical solutions.
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