Frame Welding Station for Medium Voltage Switchgear Assembly

Product Specifications

Technical details and manufacturing context for Frame Welding Station

Definition

The Frame Welding Station is a critical component within the Medium Voltage Switchgear Assembly Line, dedicated to the precise joining of metal structural members to form the rigid frame or chassis of the switchgear unit. This station ensures the dimensional accuracy and structural integrity required to house and protect internal electrical components like circuit breakers, busbars, and insulation systems. The station is designed to accommodate standard frame sizes up to 2000×1200 mm (L×W) and can handle frame weights ranging from 1000 to 2000 kg. It provides a positioning accuracy of ±0.5 mm for clamping repeatability, ensuring consistent alignment during welding. The welding process typically employs MIG (Metal Inert Gas) or MAG (Metal Active Gas) methods, with a welding current range of 50–350 A and a duty cycle of 60% at rated current. The station operates on a three-phase supply voltage of 380 V AC (±10%) at 50/60 Hz, with a rated power of 5–15 kVA for welding equipment and auxiliaries. It is designed for an operating temperature range of -10 to 45 °C and a relative humidity of ≤90% (non-condensing). The ingress protection rating is IP54 per IEC 60529, providing dust and splash water protection. The frame material is carbon steel structural grade Q235 per GB/T 700, and the table surface hardness is 40–50 HRC for wear resistance. The net weight of the station ranges from 800 to 1200 kg. Materials typically used include structural steel grades such as S235JR or S355JR, and welding wire such as ER70S-6. All specifications are reference values; verify model-specific details with the legal manufacturer or supplier.

Working Principle

Operators or automated systems position pre-cut steel sections (beams, plates, angles) into a welding jig or fixture. The station typically employs MIG (Metal Inert Gas) or MAG (Metal Active Gas) welding processes. A welding power source generates an electric arc between a consumable wire electrode and the workpiece, melting the metals to form a permanent joint. The fixture ensures alignment and minimizes thermal distortion during the welding sequence. The station's clamping system provides repeatable positioning within ±0.5 mm, and the welding current is adjustable within 50–350 A to suit different material thicknesses. The duty cycle of 60% indicates the proportion of time the welding equipment can operate at rated current without overheating. The station is designed to maintain dimensional accuracy and structural integrity of the frame, which is essential for the subsequent assembly of electrical components.

Common Materials

Structural Steel (e.g., S235JR, S355JR), Welding Wire (e.g., ER70S-6)

Technical Parameters

Parameter	Typical range	Notes & selection driver
Working Area (L×W)	2000×1200 mm	Accommodates standard frame sizes
Load Capacity	1000–2000 kg	Maximum frame weight
Positioning Accuracy	±0.5 mm	Clamping repeatability
Welding Current Range	50–350 A	For MIG/MAG welding
Duty Cycle	60 %	At rated current
Supply Voltage	380 ±10% V AC	Three-phase, 50/60 Hz
Rated Power	5–15 kVA	For welding equipment and auxiliaries
Operating Temperature	-10–45 °C	Ambient range for operation
Relative Humidity	≤90 %	Non-condensing
Ingress Protection	IP54	Dust and splash water protectionIEC 60529
Frame Material	Q235	Carbon steel structuralGB/T 700
Table Surface Hardness	40–50 HRC	Wear-resistant work surface
Weight	800–1200 kg	Net weight of station

Ranges are indicative industry figures for RFQ preparation, not a supplier commitment. Confirm every value and standard with the legal manufacturer before ordering.

Components / BOM

Welding Fixture / Jig
Holds and precisely locates all frame components during the welding process to ensure dimensional accuracy and repeatability.
Welding Power Source & Torch
Generates the welding arc and delivers the electrode wire and shielding gas to the joint.
Fume Extraction System
Removes welding fumes and particulate matter from the operator's breathing zone and the general work area.
Clamping System
Holds the pre-cut sections against the jig so the frame comes out square.

Applied To / Applications

This component is essential for the following industrial systems and equipment:

Medium Voltage Switchgear Assembly Line

View system integration details

Manufacturers of Frame Welding Station

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Frequently Asked Questions

What is the working area of the Frame Welding Station?

The working area is 2000×1200 mm (L×W), accommodating standard frame sizes. Verify the exact dimensions for your specific model with the manufacturer.

What welding processes does the station support?

The station supports MIG (Metal Inert Gas) and MAG (Metal Active Gas) welding processes, with a welding current range of 50–350 A.

What is the positioning accuracy of the clamping system?

The positioning accuracy is ±0.5 mm, ensuring repeatable clamping for consistent weld quality.

What are the electrical requirements for the station?

The station requires a three-phase supply voltage of 380 V AC (±10%) at 50/60 Hz, with a rated power of 5–15 kVA for welding equipment and auxiliaries.

Data Basis

Editorial classification, named public sources where available, and source-reviewed manufacturer records.

Preliminary Technical Classification

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pressure:	Atmospheric (no pressure containment required)
other spec:	Max frame dimensions: 2.5m x 1.5m x 1.2m, Power supply: 380-480V 3-phase, 60A, Duty cycle: 60% at 300A welding current
temperature:	Ambient to 50°C (operating environment), welding zone up to 1500°C (localized)

Frame Welding Station

Product Specifications

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