What is the impact of welding process on the durability of electric wheelchairs?

What is the impact of welding process on the durability of electric wheelchairs?

In today’s society, with the development of science and technology and the improvement of people’s living standards, electric wheelchairs have become an indispensable part of the lives of many people with limited mobility. The durability of electric wheelchairs is not only related to the user’s experience and safety, but also directly affects its competitiveness and service life in the market. As one of the key links in the manufacturing process of electric wheelchairs, welding technology plays a vital role in the durability of electric wheelchairs.

1. The importance of welding technology in the manufacture of electric wheelchairs
Structural stability
Electric wheelchairs are usually composed of metal frames, and the quality of welding technology directly determines the structural stability of the metal frame. Good welding can make the various metal parts firmly connected together to form a strong and stable frame structure, thereby providing a solid foundation for the electric wheelchair, enabling it to withstand the weight of the user and various stresses and impact forces during daily use, such as the bumps generated when driving on uneven roads. For example, if the welding is not firm, the metal frame may become loose, deformed or even broken during use, resulting in the instability of the overall structure of the electric wheelchair, increasing the risk of users falling and getting injured, and seriously affecting its durability and safety.
Carrying capacity
Electric wheelchairs need to have a certain carrying capacity to meet the needs of users of different weights. High-quality welding processes can improve the strength and rigidity of the metal frame and enhance its stability when carrying heavy objects. On the contrary, electric wheelchairs with poor welding quality may have problems such as bending and twisting of the metal frame when carrying heavier users, which reduces the service life and reliability of the electric wheelchair.

2. Common welding processes and their impact on the durability of electric wheelchairs
Manual arc welding
Manual arc welding is a traditional welding method that uses the arc heat generated between the coated electrode and the workpiece for welding. This welding process has the characteristics of simple equipment, flexible operation, and strong adaptability. It is still widely used in some small electric wheelchair manufacturing companies or maintenance work. However, the welding quality of manual arc welding depends largely on the technical level and operating experience of the welder, and the welding process is easily affected by external environmental factors such as temperature, humidity, wind speed, etc. If the welder operates improperly or the environmental conditions are harsh, welding defects such as poor weld formation, slag inclusions, pores, and incomplete penetration may occur. These defects will reduce the strength and toughness of the weld, thereby affecting the durability of the metal frame of the electric wheelchair.
Gas shielded welding
Gas shielded welding is a welding method that uses inert gas (such as argon, helium, etc.) or active gas (such as carbon dioxide, etc.) as shielding gas, tungsten electrode or melting electrode as electrode, and arc heat to melt metal and form a weld. Compared with manual arc welding, gas shielded welding has the advantages of fast welding speed, small heat-affected zone, and high weld quality. In the manufacture of electric wheelchairs, the use of gas shielded welding can effectively reduce welding deformation, improve the strength and toughness of welded joints, make metal frames more firm and reliable, and enhance the durability of electric wheelchairs. In addition, gas shielded welding can achieve automated or semi-automated operation, reduce the impact of human factors on welding quality, and improve production efficiency and product quality stability.
Robot welding
With the development of automation technology, robot welding is increasingly used in the electric wheelchair manufacturing industry. Robot welding is a highly automated and precise welding technology that controls the movement of the robot through programming, so that the welding electrode or welding wire performs welding operations according to preset trajectories and parameters. Robot welding has significant advantages such as stable welding quality, good consistency, high precision, and fast speed. It can accurately control welding parameters such as welding current, voltage, speed, wire feeding speed, etc., to ensure that the welding quality of each weld reaches a consistent high level, thereby greatly improving the overall strength and durability of the metal frame of the electric wheelchair. At the same time, robot welding can avoid human operating errors, reduce the generation of welding defects, and improve the yield and reliability of the product. In the long-term use of electric wheelchairs welded by robots, the structural stability and bearing capacity of the metal frame can be better guaranteed, and can withstand repeated use and various complex road conditions.

3. Specific factors affecting the durability of electric wheelchairs by welding process
Weld strength
Weld strength is one of the important indicators to measure welding quality, which is directly related to the tensile, compressive, and shear mechanical properties of the metal frame of the electric wheelchair. High-quality welding technology can form welds with high strength and good toughness, so that metal parts can be firmly connected. When the electric wheelchair encounters bumps, collisions, etc. during driving, the high-strength weld can effectively withstand and disperse stress, prevent cracking and fracture of the metal frame, and extend the service life of the electric wheelchair. On the contrary, if the weld strength is insufficient, fatigue cracks are prone to occur at the weld during long-term use and are subjected to repeated stress, which will gradually expand and eventually lead to the failure of the metal frame, affecting the normal use of the electric wheelchair.
Welding deformation
During the welding process, metal parts will deform due to local heating and cooling. Excessive welding deformation will affect the geometric shape and dimensional accuracy of the metal frame of the electric wheelchair, resulting in problems such as poor matching of parts and assembly difficulties. In order to ensure the normal performance and appearance quality of the electric wheelchair, it is usually necessary to correct the deformed metal frame, which not only increases the production cost and manufacturing cycle, but also may affect the local strength and stiffness of the metal frame. The use of advanced welding technology and reasonable welding sequence can effectively control welding deformation, reduce subsequent correction work, improve the quality and stability of the metal frame, and thus enhance the durability of the electric wheelchair.
Welding defects
Welding defects are common problems that affect the quality of the metal frame of the electric wheelchair. Common welding defects include pores, slag inclusions, incomplete penetration, cracks, etc. Porosity is the hole formed by the gas in the molten pool that fails to escape before the metal solidifies during welding. It will reduce the strength and density of the weld, become a stress concentration site, and easily cause fatigue damage to the weld during use. Slag inclusion refers to the non-metallic inclusions remaining in the weld, which will destroy the continuity of the weld metal and reduce the mechanical properties of the weld. Incomplete penetration refers to the phenomenon that the root of the weld is not completely penetrated, which will reduce the effective cross-sectional area of ​​the weld and reduce the load-bearing capacity of the weld. Cracks are one of the most dangerous welding defects, which may cause sudden fracture of the weld and cause serious safety accidents. In the manufacture of electric wheelchairs, strictly controlling welding process parameters, strengthening quality inspection and control during welding, and timely discovering and handling welding defects are of great significance to improving the durability of the metal frame of electric wheelchairs.

4. How to improve the durability of electric wheelchairs by optimizing welding processes
Select appropriate welding methods and equipment
According to the structural characteristics, material properties and production scale of electric wheelchairs, select advanced and efficient welding methods and equipment. For example, for small electric wheelchair manufacturers or repair workshops, relatively simple and flexible welding methods such as manual arc welding or gas shielded welding can be used; while for large-scale production enterprises, highly automated welding equipment such as robot welding can be considered to improve welding quality and production efficiency. At the same time, ensure the good operating status and regular maintenance of welding equipment to ensure the accuracy and stability of welding parameters.
Strengthen welder training and technical level improvement
For manual welding operations, the technical level and operating experience of welders have a direct impact on welding quality. Enterprises should strengthen the training of welders so that they can master the correct welding operation methods, skills and process specifications, be familiar with the performance characteristics of different welding materials and equipment, and be able to flexibly adjust welding parameters according to actual conditions. Regularly organize welders to participate in skill competitions and training courses to continuously improve their technical level and quality awareness. In addition, establish a complete welder assessment system and incentive mechanism to encourage welders to continuously improve their own operating level and ensure the stability of welding quality.
Optimize welding process parameters
According to factors such as the type, thickness, and structural form of the electric wheelchair metal material, optimize welding process parameters such as welding current, voltage, speed, and welding sequence. Through experiments and accumulation of practical experience, the optimal range of welding process parameters is determined, and parameter fluctuations during welding are strictly controlled. The use of advanced welding process control technologies, such as welding parameter monitoring systems and automated welding equipment, can accurately control welding parameters, ensure the consistency and stability of welding quality, and thus improve the durability of the metal frame of electric wheelchairs.
Strengthen welding quality inspection and control
Establish a complete welding quality inspection system, and use a variety of inspection methods and means, such as appearance inspection, non-destructive testing (ultrasonic testing, radiographic testing, magnetic particle testing, etc.), mechanical properties testing, etc., to conduct comprehensive quality inspection and evaluation of welded joints. During the welding process, welding defects are discovered and handled in a timely manner, and unqualified welds must be repaired or scrapped to ensure that the quality of each weld meets the design requirements and quality standards. At the same time, statistical analysis of welding quality data is carried out to find out the root causes and laws of quality problems, continuously improve welding processes and quality control measures, and improve the overall level of welding quality.

5. Case analysis
After adopting the robot welding process, the durability of a certain electric wheelchair manufacturer has been significantly improved. Before using robot welding, the company mainly used manual arc welding to weld the metal frame of electric wheelchairs. Due to the uneven technical level of welders and unstable factors in the welding process, the weld quality of some products was problematic, such as poor weld formation, pores, and incomplete penetration. After using the electric wheelchair for a period of time, the metal frame became loose and deformed, affecting the product’s service life and user satisfaction. After introducing the robot welding system, the company strictly followed the robot welding process requirements, accurately controlled the welding parameters, optimized the welding sequence, and effectively reduced the generation of welding defects. After quality inspection and actual use tracking, it was found that the strength of the metal frame of the electric wheelchair welded by the robot increased by about 20%, the deformation decreased by about 30%, the overall durability and reliability of the product were significantly improved, the user complaint rate dropped significantly, and the market competitiveness was significantly enhanced.

6. Conclusion
The welding process plays a vital role in the manufacturing process of electric wheelchairs. It is directly related to the structural stability, load-bearing capacity and durability of the electric wheelchair. By selecting appropriate welding methods and equipment, strengthening welder training and technical level improvement, optimizing welding process parameters, and strengthening welding quality inspection and control, the welding quality of electric wheelchairs can be effectively improved, their durability can be enhanced, and a safer, more reliable and comfortable means of travel can be provided for people with limited mobility. In the future development of electric wheelchair manufacturing, with the continuous innovation and application of welding technology, it is believed that the durability and performance of electric wheelchairs will be further improved to meet people’s demand for high-quality electric wheelchairs.