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Shelving Production Line
Rack Beam Automatic Welding Machine
Rack Beam Automatic Welding Machine
Rack Beam Automatic Welding Machine
Rack Beam Automatic Welding Machine
Rack Beam Automatic Welding Machine
Rack Beam Automatic Welding Machine

Rack Beam Automatic Welding Machine

The Rack Beam Automatic Welding Machine is designed for the automated welding of connectors and end fittings for rack beams. Utilizing automatic positioning and welding control technologies, the equipment ensures consistent weld quality and minimizes human error, making it ideal for automated production lines in large-scale rack manufacturing enterprises.

Rack Beam Automatic Welding Machine — Professional manufacturer, fully automatic high-efficiency welding, intelligent and flexible production.

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I. Equipment Overview

The Rack Beam Automatic Welding Machine is a complete production line system designed specifically for the automated welding of connectors (end plates/hooks) to both ends of warehouse rack beams. These connectors serve as the metal interface between the beam and the upright; the quality of the weld directly determines the structural integrity of the connection and the overall load-bearing safety of the racking system.

The welding line comprises several units: a main unit (an automatic dual-station welding machine for beam connectors), a Chaifu industrial robot, a beam transport conveyor, a fully automated control system, and a finished beam stacking rack. The entire line achieves full automation across the process—including automatic loading of beams and connectors, positioning, welding, and unloading. The main unit features a dual-station design paired with the precision welding capabilities of the Chaifu robot; this allows for single-clamping processing and continuous multi-angle welding of connectors at both ends, significantly enhancing both welding efficiency and quality.

The equipment is compatible with various materials, including cold-rolled sheet, galvanized sheet, and high-strength steel, accommodating beam lengths of 1200–4000 mm and thicknesses of 0.8–4.0 mm. It supports the welding of diverse beam profiles—such as box beams, P-beams, and C-beams—making it a core piece of equipment for warehouse rack manufacturers seeking to upgrade to automated production.


II. Equipment Components and Functions

(1) Main Unit — Dual-Station Automatic Crossbeam Welding Machine with Automatic Hanger Loading (One Unit)
The main unit is the core of the entire welding line, featuring a dual-station layout and an automatic hanger loading design. The welding stations operate in a cyclic, alternating manner: while one station performs welding, the other handles the clamping and positioning of the crossbeam and hangers. Its eight-axis welding capability allows for the simultaneous welding of four to eight seams connecting the crossbeam ends and hangers in a single cycle.
Dual-station cyclic operation: Welding and clamping occur simultaneously, enabling continuous, long-duration welding and eliminating downtime caused by waiting.
Single clamping, alternating front/back welding: Multi-angle welding is completed with a single clamping setup, effectively controlling deformation.
Simultaneous welding of four to eight seams at both ends: Significantly reduces operational complexity and boosts production efficiency.
Automated loading and positioning: Coordinates the crossbeam positioning mechanism, hanger loading mechanism, and welding mechanism to achieve automatic hanger loading and precise positioning.

(2) Chaifu Industrial Robot
The welding line utilizes a Chaifu industrial robot as the welding execution unit. Chaifu robots are characterized by high precision, stability, and durability, making them widely applicable in fields such as arc welding, spot welding, and plasma cutting.
High-precision welding: Chaifu robots offer high precision and stability, ensuring reliable weld quality.
Intelligent welding: Paired with an intelligent control system, the robot can autonomously learn welding paths and parameters, eliminating the need for tedious manual teaching.
Efficient coordination: With high movement speeds and short cycle times, the robot works in tandem with the dual-station main unit to achieve efficient, continuous welding.
Multi-scenario adaptability: Chaifu offers a comprehensive range of industrial robots—from light-duty to heavy-duty models—capable of meeting the welding requirements for crossbeams of various specifications.

(3) Crossbeam Conveyor Line
The crossbeam conveyor line serves as the material transport channel connecting the various stations, enabling the fully automated flow of crossbeams through the entire process—from loading and welding to unloading. Automatic Sorting and Conveying: Sorts individual beam bodies and transports them to the pick-up station.
Seamless Integration: Coordinates with the main machine, robots, and stacking racks to ensure materials arrive exactly when needed.
Continuous Efficiency: An 18-meter-long conveyor line works in tandem with upstream and downstream equipment, ensuring a smooth and highly efficient workflow.

(4) Fully Automated Production Line System
The fully automated production line system serves as the "brain" of the entire welding line, coordinating and controlling the synchronized operation of all unit equipment.
Fully Automated PLC Control: Achieves end-to-end automation, covering everything from loading and welding to unloading.
Intelligent Scheduling: Monitors equipment status in real-time and automatically manages production pacing.
One-Touch Parameter Recall: Welding parameters for different beam specifications can be preset and stored, allowing for instant switching.
Automatic Fault Diagnosis: Triggers alarms upon detecting anomalies, facilitating rapid troubleshooting and maintenance.

(5) Finished Beam Stacking Rack
The finished beam stacking rack is the final material-collection unit of the welding line, designed for the automatic stacking and neat arrangement of finished beams following the welding process.
Automatic Reception: Automatically receives finished beams after welding.
Automatic Stacking: Automatically stacks and arranges beams neatly and orderly according to preset programs.
Reduced Manual Labor: Significantly lowers the physical strain associated with manual handling.


III. Core Advantages

(1) Fully automated continuous operation for multiplied efficiency
The entire line operates automatically from start to finish, covering the automatic loading of beams and connectors, positioning, welding, and the unloading and palletizing of finished products. A dual-station alternating design allows welding and clamping to occur simultaneously, enabling prolonged continuous welding. Production efficiency is increased several-fold compared to traditional manual welding or single-station operations. Four to eight welds across both ends are completed in a single pass, drastically reducing welding time.

(2) High welding precision ensuring rack safety
The welding precision of the connector directly determines the structural integrity of the connection between the beam and the upright. The system utilizes high-precision positioning mechanisms and robotic welding to ensure accurate connector placement and consistent weld quality. With single-clamping and alternating front-and-back welding, the workpiece does not require repositioning, effectively minimizing deformation. The welds are aesthetically pleasing and consistently reliable, effectively resolving the quality inconsistency issues associated with manual labor.

(3) Significant labor savings and reduced overall costs
Traditional beam welding relies on a large workforce of welders, resulting in low efficiency and inconsistent quality. This automated welding line operates continuously, requiring only 1–2 operators for monitoring. Compared to traditional multi-station, multi-operator setups, labor costs are reduced by over 70%. Furthermore, replacing manual labor with robots eliminates worker exposure to high temperatures, arc light, and welding fumes, thereby protecting their health and well-being.

(4) Flexible production and multi-purpose capability
By simply changing positioning/clamping fixtures and adjusting welding parameters, a single machine can handle the welding needs of various rack beam specifications. It supports the welding of various beam types, such as box beams (interlocking beams), P-beams, and C-beams. It accommodates beam lengths from 1200mm to 4000mm and thicknesses from 0.8mm to 4.0mm. It is particularly well-suited for rapid production switching between orders involving diverse product types and specifications.

(5) Intelligent control and ease of operation
The fully automated production line is coordinated by a central PLC control system. Parameter settings are intuitive and convenient; welding parameters for different specifications can be preset and stored, allowing for instant switching with a single command. Automatic fault diagnosis and alarm functions facilitate rapid troubleshooting and maintenance. Significantly lowers operator skill requirements; general operators can start working after only short-term training.

(6) Rugged, durable, stable, and reliable
The main unit features a high-precision drive and positioning system, ensuring stability and reliability during long-term, heavy-load operation.
Chaifu Robotics possesses core industrial robot technologies, delivering high precision, high stability, and a long service life.
The entire line supports continuous, long-term operation with high stability and a low failure rate.
Key components utilize high-quality materials and precision manufacturing processes.


IV. Technical Parameters

Item Parameter
Applicable Workpieces: Rack beams (box beams, P-beams, C-beams, etc.)
Applicable Materials: Cold-rolled sheet, galvanized sheet, high-strength steel
Beam Length: 1200–4000 mm (customizable)
Material Thickness: 0.8–4.0 mm (customizable)
Main Unit Workstations: Dual-station alternating cycle
Welding Capability: 8-point welding (4 to 8 weld seams at both ends completed in one pass)
Robot Configuration: Chaifu Industrial Robot
Control System: Fully automatic PLC control
Operators: 1–2 persons


V. Production Process

Cross-beam loading (conveyor line) → Automatic fin loading (fin loading mechanism on the main unit) → Automatic positioning of cross-beam and fins (dual-station clamping) → Automatic robotic welding (welding of eight seams in a single pass) → Dual-station alternation (welding and clamping performed simultaneously) → Automatic unloading of finished products (stacking rack) → Finished product palletizing


VI. Application Areas

The automated welding line for rack beams is widely used in the following scenarios:

Heavy-duty storage racks (beam-type racks): Welding the connectors (end plates) at both ends of the beam is a critical step in production; welding quality directly determines the strength of the connection between the beam and the upright, as well as the rack's overall load-bearing safety.
E-commerce logistics centers: Standardized, high-volume welding production of beams ensures rapid delivery and long-term safe operation of the racking systems.
Intelligent automated warehouses: Automated storage systems impose strict precision requirements on rack components; high-precision welding ensures the accurate connection of beams to uprights.
Medium-duty shelving: Precise welding of connectors ensures a stable connection between beams and uprights, guaranteeing reliable load-bearing performance.
Drive-in/Drive-through racks: High-quality beam welding ensures the overall stability of the rack structure and its resistance to lateral forces.
Cold chain storage: Welding of high-strength steel beams, suitable for low-temperature and high-humidity environments.


VII. Service Support

Solution Design: Customized welding line design and layout planning based on customer product drawings, production capacity requirements, and factory conditions.
Custom Manufacturing: Support for non-standard customization, with full control over the entire process—from fixture design to integrated line manufacturing.
Installation & Commissioning: On-site installation, commissioning, and operator training provided by engineers to ensure rapid production startup.
After-Sales Support: Long-term technical consultation and spare parts supply; engineers hold all necessary visas and are available for on-site service worldwide at any time.
Continuous Optimization: Equipment modification and capacity upgrade services available to adapt to changing production needs.


VIII. Why Choose Us

Nearly 20 Years of Manufacturing Experience: Mature technology, refined processes, and reliable quality
Full-Line Integration Capabilities: Covers the entire workflow—including feeding, welding, conveying, and stacking—for a one-stop delivery solution
Robot + Dual-Station Technology: High-precision welding combined with dual-station cyclic operation ensures both efficiency and quality
Direct Manufacturer: No middlemen, offering excellent value for money
Global Service Network: Engineers hold all necessary visas, ensuring rapid response

Equipment Composition:

  1. Two sets of cantilever automatic palletizers, including a 7-meter moving platform
  2. One set of automatic turnover special welding machine – movable and telescopic (equipped with two Megmeet 350DR welding machines)
  3. Full-automatic production line system
  4. Column finished product palletizer frame
  5. 18-meter column assembly line

No. Name Qty (Set) Brand Remarks
1 Planetary Reducer 11 Zhuolan Planetary Reducer 130F
2 RV Reducer 2 Qinchuan RV Reducer 50C
2 Touch Screen 1 Xinjie Brand TG765
3 Industrial PLC 1 Xinjie Brand 60T-E
4 Servo Motor 14 Delta
5 Servo Drive 14 Delta
7 Welding Power Source 2 Megmeet 350DR
8 Air Cylinder Several Airtac 63*150
9 Solenoid Valve Several Airtac 4V210-08
10 Bearing Several NSK
12 Safety Device 2 Customized

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About
Wuxi Yanwu Xinhui Technology Co., Ltd.

Established in 2012, Wuxi Yanwu Machinery Co., Ltd., is a professional manufacturer specializing in the R&D, design, manufacturing, and servicing of cold roll forming equipment. The company is dedicated to providing global customers with integrated solutions for automated cold roll forming production lines.

Our main products include cable tray forming machines, racking forming machines, C/Z purlin machines, solar mounting bracket forming machines, floor deck machines, door frame machines, automotive profile equipment, and cut-to-length/slitting lines.

These products are widely used in the construction, electrical power, logistics and warehousing, automotive manufacturing, new energy, and infrastructure sectors.

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