The low-voltage electrical industry encompasses a variety of sheet metal products, which can be categorized into five main types: boardroom/container integrated systems, cabinets, chassis, frames, and small hardware components. These products play a crucial role in the industry, offering both functionality and durability.
General-purpose sheet metal cabinet products are designed with versatility in mind. They often incorporate profiles such as the popular nine-fold and sixteen-fold profiles, among others, allowing for the creation of diverse products. The materials used typically include cold-rolled sheets, hot-rolled sheets, pre-galvanized sheets, stainless steel sheets, and aluminum sheets like 5052. A typical cabinet comprises several key components: a base, a frame, door panels, side panels, and a top cover. Figure 3 provides an illustration of a nine-fold profile alongside a sixteen-fold profile.
The base of these cabinets is generally fabricated using T2.5 or thicker plates through either bending or channel welding techniques. Surface treatments often involve hot-dip galvanizing or powder coating. As shown in Figure 5, the base welding process depends on the product material, utilizing either argon arc welding or carbon dioxide shielded welding. Parameters such as welding current, voltage, wire material, diameter, wire feed speed, welding method, direction, and segment length must be carefully controlled.
The framework of sheet metal cabinets is typically constructed using T1.5 or thicker materials, either bent or spliced together via riveting or screwing. Surface treatments may include spraying or no treatment at all, depending on the material. Framework designs can be assembled or welded, with welding again relying on the product material, often involving argon arc welding or carbon dioxide shielded welding. Key welding parameters are similar to those mentioned earlier. Ensuring precise diagonal tolerances and minimizing deformation are critical during the welding process, especially when working with batches that require high reliability.
Door panels are usually crafted from T1.2 or thicker sheets, employing bending and welding techniques (such as welding corner edges). The surface treatment involves spraying, as illustrated in Figure 7 for mesh door panels. Welding methods depend on the material type, including argon arc welding, carbon dioxide shielded welding, or flat welding. Controlling welding stress and deformation is essential for mesh door panels. Figure 7 showcases a mesh door panel.
The top cover of sheet metal cabinets is typically formed by bending or welding (with welded corners) using T1.0 or thicker sheets. Surface treatments involve spray coating. Top covers are categorized into indoor and outdoor types, with welding techniques and parameters closely resembling those for the framework. Outdoor top covers must maintain flatness and diagonal tolerances, and excellent fixtures can significantly enhance welding quality and efficiency.
Internal mounting components are generally divided into structural parts and accessories, requiring strict adherence to assembly guides such as the "XX Product Assembly/Electrical Installation Guide." After completing electrical installations, performance testing is essential. Sheet metal products exhibit three key trends: profile integration facilitating modular design and cost reduction, modularity enabling flexible design and component assembly, and serialization ensuring adaptability to various configurations while maintaining process standardization.
In conclusion, the low-voltage electrical industry continues to evolve steadily. Sheet metal production suppliers are embracing innovative approaches, from product design to automation, aiming to optimize equipment utilization and inventory turnover. The adoption of Industry 4.0 concepts pushes production toward lean manufacturing, leveraging network resources to move beyond traditional micro-profit margins. This evolution positions sheet metal production in low-voltage electrical appliances at a higher level, addressing both opportunities and challenges by providing safer, smarter, and greener electrical solutions.
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