Analysis of the differences between welding and riveting processes in electric wheelchair manufacturing

Analysis of the differences between welding and riveting processes in electric wheelchair manufacturing
In the manufacturing process of electric wheelchairs, welding and riveting are two common key processes, each with unique characteristics and application advantages. For international wholesale buyers, a deep understanding of the differences between the two processes will help to better understand the manufacturing process, quality characteristics and applicable scenarios of the products, so as to make more informed purchasing decisions. This article will conduct a detailed comparative analysis of the welding and riveting processes of electric wheelchairs from multiple dimensions.

1. Process principle
Welding: Welding is a processing technology that achieves atomic bonding of welded parts by heating or pressurizing, or both. In the manufacture of electric wheelchairs, such as the splicing of frames, welding can be used. The metal material is melted at high temperature, so that the welding rod and the base material, and the base material and the base material are fused with each other, and a strong welded joint is formed after cooling, thereby connecting multiple metal parts into a whole. Some high-strength electric wheelchair frames are often manufactured by welding methods such as argon arc welding to ensure the stability and load-bearing capacity of the frame.
Riveting: Riveting is a method of connecting two or more parts together using rivets. It does not require heating and melting the material, but uses mechanical force to pass the rivet through the pre-made hole, and then deforms the tail of the rivet to form a riveted joint. In the connection of some parts of the electric wheelchair, such as the connection of some thin plate structures, riveting can play a good role. For example, if riveting is used to connect the backrest and the seat plate of some electric wheelchairs, a firm connection can be completed without excessive heat treatment of the material.

2. Comparison of differences in working principles
Connection method:
Welding: Welding is to form a continuous connection between metals, so that the two metal parts are fused into a whole in the welding area. For example, the frame welding of the electric wheelchair, the weld connects the various steel parts tightly. From a macroscopic point of view, the welded frame is like a complete piece of steel. This continuous connection method can withstand large tensile forces, pressure and other multi-directional forces, and provides strong support and stability for the overall structure of the electric wheelchair.
Riveting: It is to punch holes in the connected parts, then insert the rivets into the holes, and use tools such as rivet guns to rivet the rivets, so that the two ends of the rivets form rivet heads, thereby fixing the parts together. The connection is achieved through friction and shear force between rivets and part holes. At the connection of some movable parts of electric wheelchairs, such as the connection between the pedals and the frame, riveting can ensure a certain connection strength while allowing a certain amount of activity space between the parts to meet the user’s flexibility needs during use.
Stress conditions:
Welding: The integrity of the welded connection is good, and the stress can be evenly distributed on the entire weld. When subjected to complex forces such as bending and torsion, the weld can work as a whole like the parent material, with high load-bearing capacity and good fatigue resistance. Take the welding connection between the wheel and the frame of an electric wheelchair as an example. When the wheelchair is driving on an uneven road and the wheel is subjected to impact forces in all directions, the welding connection can effectively transmit and disperse these forces, reduce local stress concentration, and extend the service life of the product.
Riveting: The force of riveting is mainly concentrated on the rivet, and the force on each rivet is relatively large. When subjected to tensile force, the rivet mainly relies on the extrusion between the nail head and the nail hole to withstand the tensile force; when subjected to shear force, the rivet relies on its own shear strength to resist shear deformation. However, due to the influence of factors such as the number and arrangement of rivets, when riveting is subjected to a large load, the rivets may be sheared or the nail heads may be crushed. Therefore, when designing the riveted structure, the number, diameter, spacing and other parameters of the rivets need to be accurately calculated and reasonably arranged.

3. Equipment and Materials
Welding equipment and materials: Commonly used equipment for electric wheelchair welding includes electric welders, argon arc welders, etc., and corresponding welding materials such as welding rods, welding wires, and fluxes are also required. Different welding methods and materials are suitable for different metal materials and welding requirements. For example, for electric wheelchair parts made of stainless steel, argon arc welding is often used, and the welding wire used is stainless steel welding wire to ensure the quality and performance of the welded joints. Welding equipment usually requires higher power and stable power supply, and also has certain requirements for the welding environment, such as good ventilation and avoiding moisture, to prevent welding defects.
Riveting equipment and materials: The main equipment used for riveting is a rivet gun and rivets of various specifications. The materials of rivets are generally steel, aluminum, copper, etc., which are selected according to the material and use requirements of the connected parts. Compared with welding equipment, riveting equipment is relatively simple, easy to operate, and has low environmental requirements. It does not require complex power supplies and gas protection devices. On the production line of electric wheelchairs, riveting equipment can be easily operated at various workstations to improve production efficiency.

4. Connection strength and stiffness
Welding: In general, welding can provide higher connection strength and stiffness. This is because welding realizes the combination of weldments at the atomic level to form a continuous overall structure. In the key stress-bearing parts of electric wheelchairs, such as the main frame of the frame, the battery mounting bracket, etc., the use of welding technology can ensure that these parts can withstand large loads and long-term fatigue, and maintain the overall stability and safety of the wheelchair. The strength of welded joints that have been reasonably designed and standardized can be comparable to that of the parent material, and even exceeds the strength of the parent material in some cases.
Riveting: Although the connection strength of riveting is slightly lower than that of welding, it can also meet the connection requirements of many electric wheelchair parts. In the riveting process, the tightening force and friction between the rivet and the connected parts are the key factors to ensure the connection strength. For some non-critical parts or parts with less stress, such as the decorative cover and backrest bracket of the wheelchair, riveting can provide sufficient connection strength. Moreover, the rigidity of riveting is relatively low, which makes the riveted structure have a certain buffering effect when subjected to impact load, which can reduce the damage of parts caused by rigid impact.

5. Appearance quality
Welding: The appearance quality after welding mainly depends on the welding process and operation level. A good welded joint should have a uniform weld, a smooth surface and less deformation. If the welding parameters are improperly selected or the operation is not standardized, defects such as rough weld appearance, residual welding slag, undercut, and weld nodules may occur, which not only affects the aesthetics of the product, but also may have an adverse effect on the performance of the joint. In the manufacture of electric wheelchairs, in order to improve the appearance quality of welding, the welded parts are usually polished and polished to ensure the neatness and beauty of the wheelchair appearance.
Riveting: The appearance of riveting is mainly determined by the shape and size of the rivet head. The standard rivet head should have a regular shape, such as a semicircular, flat head, etc., and fit closely with the surface of the connected part. The appearance of the connection part after riveting is relatively simple, and there will be no weld bulges like welding. At the same time, since riveting does not require melting and a large amount of heat treatment of the material, it has little effect on the surface quality of the material and can maintain the original characteristics and appearance accuracy of the part surface.

6. Production efficiency
Welding: The production efficiency of welding is relatively high, especially with the application of automated welding technology, which can achieve fast and efficient welding operations. For the large-scale production of electric wheelchairs, the use of automatic welding equipment can significantly improve production efficiency and reduce production costs. However, the welding process also requires high technical level and experience of operators, especially in manual welding. Skilled welders can ensure welding quality and efficiency, while unskilled welders may cause welding defects and rework, thus affecting the overall production progress.
Riveting: The production efficiency of riveting is generally lower than that of welding, especially when manual riveting is used, rivets need to be installed and riveted one by one, and the speed is slow. However, with the emergence of efficient riveting tools such as pneumatic rivet guns, the production efficiency of riveting has also been improved to a certain extent. In the small-batch production of electric wheelchairs or the local connection of parts, riveting is still a more convenient and efficient connection method.

7. Cost factors
Welding: The cost of welding mainly includes equipment investment, welding materials, energy consumption and labor costs. The price of welding equipment such as electric welders and argon arc welders is relatively high, and welding materials such as welding rods and welding wires also need to be consumed continuously. In addition, the welding process consumes a lot of electricity, especially in long-term continuous welding operations, and the energy cost cannot be ignored. However, in large-scale production, due to the high efficiency and good connection performance of welding, the production cost of unit products can be reduced and the overall economic benefits of products can be improved.
Riveting: The cost of riveting mainly includes the cost of rivets and riveting equipment. The price of rivets is relatively low, and a large amount of auxiliary materials are not required during the connection process. The price of riveting equipment such as rivet guns is also reasonable, and the maintenance cost is low. Therefore, in some cases where the connection strength is not required or small batch production is carried out, the cost advantage of riveting is more obvious.

8. Applicable scenarios
Welding: Welding is suitable for the manufacture of electric wheelchair components that require high connection strength, rigidity and sealing, such as frames, seat frames, battery boxes, etc. These parts need to withstand large loads and long-term wear and tear. Welding can provide reliable connections to ensure the overall performance and safety of the wheelchair. In addition, welding is also suitable for the splicing of metal materials, such as the connection of steel pipes, steel plates, etc., and the manufacture of some parts that need to be sealed, such as fuel tanks, water tanks, etc.
Riveting: Riveting is suitable for some parts that do not require excessive connection strength or have certain requirements for the flexibility of the connection parts, such as the connection of wheelchair armrests, foot pedals, backrest adjustment mechanisms, etc. In these parts, riveting can easily realize the disassembly and replacement of parts, and can also meet certain usage strength requirements. In addition, for the connection of some thin plate structures or dissimilar metal materials, riveting is also a more suitable choice, because it does not require too high characteristics such as the melting point and thermal expansion coefficient of the material like welding.

9. Advantages and Disadvantages
Advantages of welding:
High strength: It can provide high connection strength, so that the structure of the wheelchair can withstand greater loads. It is suitable for parts that require high-strength load-bearing, such as frames, etc., to ensure the stability and safety of the wheelchair during use.
Good sealing: It can achieve the sealing of welds and effectively prevent the leakage of liquids and gases. For some parts that need to be waterproof and dustproof, such as battery boxes, motor housings, etc., the quality and performance of welding can meet the requirements and extend the service life of the parts.
High structural rigidity: The integrity of the welding connection is good, the structural rigidity is large, and it can reduce the vibration and deformation of the wheelchair during driving, improve the comfort of riding and the stability of control.
Strong material adaptability: It is suitable for the connection of a variety of metal materials. Whether it is steel, aluminum alloy or stainless steel, it can be welded by selecting appropriate welding methods and materials to meet the manufacturing needs of wheelchair parts of different materials.
Appearance beauty: Through subsequent grinding, polishing and other treatments, the welding part can achieve a better appearance quality, making the overall appearance of the wheelchair more neat and beautiful, in line with the design requirements of the product and the aesthetic standards of consumers.
Disadvantages of welding:
Complex equipment and high cost: It is necessary to be equipped with professional welding equipment, such as electric welders, argon arc welders, etc. These equipment are not only expensive, but also have certain requirements for power supply, gas and other supply conditions, which increases the production cost and the complexity of equipment maintenance. In some small-scale production enterprises or small-batch production workshops, it may be difficult to afford a higher equipment investment.
Complex and demanding operation: Welding is a technical operation that requires high skills and experience. Welders need to undergo special training and practice to master the correct welding methods and techniques to ensure welding quality and performance. If the welding operation is improper, weld defects such as pores, slag inclusions, and incomplete penetration are likely to occur, resulting in a decrease in connection strength and even safety hazards.
Welding deformation problem: During the welding process, due to the effect of high temperature, it is easy to cause deformation of the weldment, which will affect the dimensional accuracy and assembly accuracy of the wheelchair components. In order to control welding deformation, some measures need to be taken, such as pre-deformation, rigid fixation, etc., but this will also increase the complexity and cost of the production process.
Impact on material properties: The high temperature during welding may have a certain impact on the performance of the material, such as causing changes in the metallographic structure of the material, hardening, etc., thereby reducing the toughness and plasticity of the material and affecting the fatigue resistance and service life of the wheelchair components.
Non-detachable: Welding connection is a non-detachable connection method. Once welding is completed, if the parts need to be repaired, replaced or adjusted, it will be very difficult and may require cutting or destroying the weld, which not only increases the maintenance cost, but also may cause damage to the parts and reduce the reliability of the product.
Advantages of riveting:
Simple process and easy operation: The riveting process is relatively simple and does not require complex equipment and high temperature conditions. It only requires simple tools such as rivets and rivet guns to operate. Operators can master the riveting technology after simple training, which reduces the technical requirements and labor intensity of operators.
Reliable connection and good stability: Riveting can provide reliable connection. The connected parts have good stability and vibration resistance. They are not easy to loosen or fall off due to impact and vibration. They are suitable for use in the process of electric wheelchairs, which are often subject to bumps and vibrations, to ensure the firmness of the connection of parts.
Strong adaptability to material thickness: Riveting can play a good role in thinner metal sheets or materials that are difficult to weld, such as the connection between some non-metallic materials and metal materials. In some parts of electric wheelchairs, such as the connection between decorative covers, backrest fabrics, etc. and metal brackets, riveting can easily achieve the connection between different materials and meet the design and functional requirements of the product.
Removability: Riveting is a mechanical connection. Compared with the non-removability of welding, riveting is removable to a certain extent. When the parts need to be repaired, replaced or adjusted, just remove the rivets to easily disassemble the parts, which reduces the cost and difficulty of repair and improves the maintainability of the product.
Low cost: The cost of equipment and materials required for riveting is relatively low, and the price of rivets is also relatively cheap. In the case of small-batch production or low requirements for connection strength, the use of riveting technology can effectively reduce production costs and improve the economic benefits of products.
Disadvantages of riveting:
Relatively low connection strength: Since riveting is achieved through friction and shear force between rivets and connected parts, its connection strength is generally lower than welding. Under heavy loads or long-term stress, rivets may become loose or sheared, resulting in connection failure. Therefore, riveting is not suitable for some key parts with extremely high connection strength requirements.
Poor sealing: Riveting cannot form a continuous sealed weld like welding, and gas or liquid leakage is prone to occur. In the connection of some parts that need to be sealed, such as fuel tanks, water tanks, etc., riveting is difficult to meet the sealing requirements, which may affect the performance and service life of the product.
Bulky structure: Riveting requires drilling holes on the connected parts and using a large number of rivets for fixing, which makes the structure of the connection part relatively bulky and increases the weight of the product. For some electric wheelchair designs that require lightweight, riveting may be subject to certain restrictions.
Low efficiency: Manual riveting is slow, especially when a large number of rivets need to be riveted, the production efficiency will be greatly affected. Compared with automatic welding , the efficiency of riveting is low, and it is difficult to meet the needs of large-scale production.High dependence on rivet quality: The quality of riveting depends largely on the quality and installation quality of the rivets. If the material of the rivet is poor, the size does not meet the requirements, or the operation is improper during the riveting process, such as insufficient position accuracy of the rivet hole and inappropriate rivet length, the riveting quality will be reduced, and even problems such as loose connection and falling off will occur, affecting the safety and reliability of the wheelchair.

10. Summary
Through the above detailed analysis of the welding and riveting processes of electric wheelchairs, it can be seen that there are significant differences between the two in terms of process principles, working principles, equipment materials, connection strength, appearance quality, production efficiency, cost factors, applicable scenarios, advantages and disadvantages. In the actual manufacturing process of electric wheelchairs, enterprises should reasonably choose welding or riveting processes based on various factors such as the specific structure of the product, usage requirements, production scale, cost budget, etc., and give full play to their respective advantages to ensure the quality and performance of electric wheelchairs, meet the needs of consumers, and improve the production efficiency and economic benefits of enterprises. For international wholesale buyers, understanding these differences will help them communicate more effectively with manufacturers, gain a deeper understanding of the product’s manufacturing process and quality control, and thus choose high-quality electric wheelchair products that meet their market needs.