New Product Launch, Mass Production Delivery of Fully Automated Welding Solution for New Energy Liquid-cooled Pipelines

Single-sided welding with double-sided forming, weld pass rate of 98.6%, suitable for new energy liquid-cooled straight pipes, tees, and flange fittings, providing bulk supply for energy storage and new energy vehicle temperature control industry chain.

With the rapid development of the liquid cooling and cooling industries for energy storage, servers, and new energy power batteries, water cooling plates, liquid copper tubes, and refrigerant piping have become core components of temperature control systems. Wuxi BoHan automated orbital closed pipe welding machines are now deeply integrated with liquid cooling components for mass production.

The raw materials for liquid-cooled workpieces are mostly copper, aluminum alloy, and thin-walled 304/316 stainless steel pipes. Circulating coolant is required inside the pipelines, with zero weld leakage, no weld slag protrusions on the inner wall, and a clean inner cavity as rigid production standards. Traditional manual welding is prone to weld smudges, cold soldering, and internal wall oxidation burrs. Burr detachment can easily clog fine runners, causing overall machine heat dissipation failure. The BoHan automated tubesheet welding machine uses a sealed inner cavity with argon protection technology, isolating air oxidation throughout the welding process. The weld inner wall is smooth and flat, with no spatter residue. The pass rate for pressure resistance and leakage protection testing of finished products far exceeds that of manual welding, meeting industry standards for pressure and leak prevention in liquid-cooled pipelines.

In terms of sub-application scenarios, the products cover three major areas: prefabrication of water-cooled pipelines for energy storage boxes in energy storage power stations, processing of liquid coolers for big data servers, and welding of water-cooled plate pipelines for new energy vehicle battery packs. The equipment can preset multiple welding programs and switch between copper, aluminum, and stainless steel material parameters with one click. It meets the needs of R&D manufacturers for small-batch prototyping and trial production, as well as continuous mass production on large-scale assembly lines. One person can operate multiple machines, significantly reducing the labor costs for experienced special welders and shortening the processing cycle for liquid cooling components.

For the production environment of liquid cooling production lines with frequent coolant evaporation and dust, the equipment requires periodic maintenance. Stop work daily to clean metal debris from welding gun fixtures and wipe the sealed protective chamber; Weekly check of argon supply pipelines and guide rail lubricating oil levels, and calibrate servo travel accuracy; Monthly calibration of the arc pressure tracking system cleans oil stains in the welding machine's cooling ducts, preventing dust and oil from eroding precision components, ensuring long-term welding stability of liquid-cooled workpieces.