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Project Introduction: Dual‑Head Energy‑Storage Welding Machine for Hot‑End Automotive Oxygen Sensors

Aug 19,2026

Automotive hot‑end oxygen sensors are core components for engine closed‑loop fuel injection control, exhaust‑gas detection and air‑fuel‑ratio adjustment. The oxygen‑sensor base is mostly a precision thin‑walled stainless‑steel part, and its welding position lies in the high‑temperature hot‑end zone of the exhaust system. Conventional welding equipment delivers large heat input and long heating duration, which may damage internal sensor elements, deform bases, oxidize weld seams and leave welding spatter residues. These defects further trigger abnormal sensor signals, exhaust leakage and shortened service life of components. The Haifei dual‑head energy‑storage welding machine for hot‑end oxygen sensors is custom‑developed for sensor‑base welding conditions. It adopts a dual‑head synchronous energy‑storage welding structure. With instant energy release, low heat‑input and spatter‑free forming technology, it realizes synchronous and uniform fusion on both sides of workpieces. Welding heat‑affected zones are small, which effectively protects sensor internal elements.

I Customer Background & Production Pain Points

The customer specializes in processing automotive oxygen sensors, NOx sensors and exhaust‑sensor base assemblies.

Pain points of original welding processes:

1.Conventional single‑head welding requires welding in separate passes. Long heating duration and continuous heat accumulation easily damage internal sensor elements, leading to sensor‑signal drift and degraded component performance.

2.Traditional welding generates heavy spatter and slag. Residues may adhere to sensing zones or pipeline interiors, impairing signal accuracy and exhaust flow.

3.Sequential single‑head welding causes uneven heating on two sides of workpieces. Bases tend to deform and suffer poor flatness, resulting in poor assembly fitting and unsatisfactory air‑tightness in later stages.

4.Unstable energy output of conventional equipment easily produces micro‑pores, cold joints and uneven penetration in weld seams. Welds are prone to gas leakage and cracking under high‑temperature and vibration conditions.

5.Conventional processes lack thermal‑control systems. Parameter adjustment relies heavily on operator experience; parameters are hard to be fixed and production data cannot be traced.

II Customer Requirements

1.Adopt dual‑head synchronous‑welding structure to complete bilateral fusion in one clamping cycle, mitigate uneven heating caused by multi‑pass welding and improve weld quality & production efficiency.

2.Equip capacitive energy‑storage instant‑welding system to shorten heating time, reduce heat input, lessen thermal impact on sensor internal elements and stabilize sensing performance.

3.Optimize welding forming process to reduce spatter & slag residues and obtain clean weld seams.

4.Improve weld quality, minimize pores and cold‑joint defects, and boost weld air‑tightness and structural stability.

5.Standardize welding parameters, support parameter storage & switching for multiple product specifications, and enable storable and traceable production data.

III Custom R&D Solutions

Targeting customer requirements, the specialized R&D team iteratively optimized schemes considering oxygen‑sensor welding difficulties:

1.Process Verification: Carry out multiple groups of welding tests for thin‑walled stainless‑steel bases of hot‑end oxygen sensors of various specifications; optimize core parameters including dual‑head synchronous pressure, energy‑storage energy, discharge duration and pressure‑hold cooling.

2.Equipment Selection: Deploy Haifei dual‑head energy‑storage welding machine for hot‑end oxygen sensors. Balanced bilateral pressure & energy output guarantees even workpiece heating and relieves excessive temperature difference and uneven deformation caused by multi‑pass welding. Equipped with capacitive energy‑storage welding power source, it completes fusion instantly within short time, featuring small heat‑affected zones and effective protection for internal sensor elements.

3.Structural Design: Dual‑heads run synchronously and smoothly with precise positioning and stable long‑term operation. Custom exclusive positioning tooling delivers unified benchmarks and accurate alignment to ensure symmetric and neat weld forming.

4.Core Advantages

Low Thermal Loss: Stable temperature control, well‑protected components.

Fine Forming: Low deformation, excellent air‑tightness.

High Productivity: Less spatter, reliable performance.

IV Delivery, After‑Sales & Customer Feedback

Pre‑acceptance and on‑site equipment inspection were completed. Continuous trial operation yields stable welding pass rate. After commissioning, all original production pain points are fully resolved. Timely, professional and thoughtful after‑sales service wins high customer recognition.

V Haifei Corporate Mission

Meeting customers’ customized welding demands is Haifei’s core mission. We adhere to the philosophy “Create Value for Customers”. Everything starts from your practical welding requirements: whether you need standalone automatic machines, integrated workstations or complete production lines, please share your demands, and Haifei will conduct targeted R&D and customization for you.