Automatic Ironing Board Rack Production Line with Fully Unmanned Operation, Patented Clamping System, and Multi-Point Welding

The production line achieves true end-to-end automation: automatic tube feeding → punching → bending → combination welding → product unloading. Operators are only required for periodic material replenishment and quality inspection, reducing direct labor from 4-6 workers per shift to 1-2 monitoring personnel. This translates to significant labor cost savings and eliminates human-induced quality variation.

Hwashi's proprietary clamping mechanism (Patent No. CN202511755556.6) ensures workpieces are precisely located and firmly held before welding current is applied. The system features:

• Spring-loaded positioning jaws that automatically adapt to tube diameter variations
• Electrical contact confirmation—welding current only flows after the clamping system verifies correct part positioning
• Integrated safety interlock preventing welding on misaligned or missing parts

This eliminates common defects such as missed welds, offset joints, and inconsistent penetration that plague semi-automatic operations.

Multiple welding heads operate simultaneously to complete all joint connections in a single cycle. For a typical ironing board X-frame, this means both the top frame corners and the leg pivot joints are welded at once—reducing cycle time by 60-70% compared to sequential single-point welding. Each welding head features independently adjustable current, time, and pressure parameters for optimal results at each joint location.

High-precision CNC servo bending units deliver consistent bend angles and radii across thousands of production cycles. The bending parameters are stored as part of the product recipe, enabling instant changeover between different ironing board designs with zero manual recalibration.

For customers requiring the highest weld quality, the line can be equipped with MFDC (medium-frequency DC) power supplies instead of conventional AC systems:

• Color touch screen HMI with intuitive menu navigation
• Recipe management: store and recall welding programs for multiple product models
• Real-time production monitoring: cycle count, weld quality indicators, fault alerts
• Password-protected parameter access prevents unauthorized changes
• Automatic fault detection with error code display and alarm
• Data retention during power loss (10-year battery backup)

The line supports rapid switching between different ironing board specifications—varying frame widths, leg geometries, and tube diameters—through stored welding programs and quick-change fixture modules. Typical changeover time is under 30 minutes, enabling economical production of multiple SKUs on a single line.

For customers requiring the highest weld quality, the line can be equipped with MFDC (medium-frequency DC) power supplies instead of conventional AC systems:

• Superior current control precision with faster response time
• Higher power factor (0.85-0.90) for energy savings
• Balanced three-phase load with minimal grid impact
• Reduced spatter and heat-affected zone for cleaner joints