"100-Ton Workpiece "Snaps Together Instantly!" Qianhao Electric Permanent Magnet Fixture Solves Three Major Pain Points in Heavy-Duty Welding and Intelligent Manufacturing"
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2025.08.07
[Hunan · Changsha] In the field of heavy machinery manufacturing, welding and transporting steel structural components—often weighing several tons—has long relied on slings and manual positioning, resulting in low efficiency and significant safety risks. Qianhao Magnetic Electric has recently developed the latest "Pan Shi Series" Electro-Permanent Magnetic Welding Fixture , redefining production line logic with groundbreaking magnetic technology—when this "smart magnet" is attached to the end of a robotic arm, the three critical processes of workpiece adhesion, sorting and positioning, and welding clamping are seamlessly integrated into a fully automated, unmanned workflow for the first time.
I. The Magnetic Revolution: One Fixture Unlocks Three Key Scenarios
On traditional welding lines, workpieces must go through three separate processes: handling, sorting, and fixing—while Qianhao's electric permanent magnet fixture leverages "Electrified Excitation / De-energized Permanent Magnetism" Feature: First-ever single-device multi-function integration achieved
Adsorption and Transport : It firmly grips 100-ton workpieces within 10 seconds, effortlessly handling tilting and flipping—while consuming 90% less energy than electromagnets.
Smart Sorting : Precisely separating stacked steel plates via magnetic pole partitioning control (with collaborative positioning from the ShibiT 3D vision system)
Welding Retention : After power failure, it continues to output a strong magnetic force of 16 kN/cm², resists high-temperature spatter, and completely eliminates welding deformation.
Technical Director Li Ming Conducts On-Site Comparative Testing “Previously, the welding fixture’s hydraulic system occupied 15㎡ of space, but now it has been completely replaced by a single magnetic plate measuring approximately 30cm square, reducing the changeover time from 2 hours to just 3 minutes.”
II. Headquarter Alliance: Building a Magnetic Smart Manufacturing Loop
Qianhao Magnetic Electric's explosive growth stems from its deep partnership with industry giants:
✅ Co-building an Intelligent Welding Island with FANUC
On the production line of a leading engineering machinery company, FANUC robotic arms equipped with Qianhao fixtures form a "magnetic welding" unit, enabling fully automated processes of lifting, positioning, and welding—resulting in workpiece positioning accuracy as precise as ±0.05mm.
✅ Together, Visionbit cracks the sorting and palletizing code.
Addressing the challenging issue of disorganized stacking for irregularly shaped parts, Qianhao Magnetic Plates, combined with the VisionBit AI Sorting System, have successfully boosted the sorting efficiency of automotive axle housings by 300% through dynamically adjusting magnetic suction points—while achieving palletizing accuracy that exceeds the national Grade II standard.
III. Real-World Evidence: A Double Whammy of Cost and Efficiency
At XCMG Group's excavator undercarriage production line, the Qianhao Solution is delivering remarkable benefits:
| Metrics | Traditional Model | Qianhao Magnetic-Electric Solution | Improvement幅度 |
|---|---|---|---|
| Single-item throughput time | 42 minutes | 8 minutes | ⬆️425% |
| Clamping Energy Consumption | Hydraulic pump 11 kW/h | Pulse power supply: 0.5 kW/h | ⬇️95% |
| Workplace injury rate | An average of 3.2 incidents per year | Starting from 0 | 100% eliminate |
IV. Industry Outlook: The Rise of the Magnetic Intelligent Manufacturing Ecosystem
“Electric permanent magnet technology is replicating the ‘electric revolution’ in the heavy industry sector,” noted Wang Haifeng, CTO of Qianhao. “Over the next three years, we will open up our magnetic control interface protocol, enabling fixtures to become integral components of intelligent production lines.” Magnetic Middleware 。”
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