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Special‑Purpose Servo Silver‑Contact Welding Machine

Aug 21,2026

Silver contacts serve as critical conductive contact carriers for electrical apparatus make‑and‑break operations. As dissimilar‑metal welded assemblies, silver contacts are formed by fusing silver‑alloy contacts to copper bases. Under long‑term working conditions of frequent make‑and‑break, arc erosion and alternating current, defects such as cold joints, uneven fusion, bonding gaps and partial detachment may occur. These defects can easily cause electrical apparatus overheating, poor contact, switch sticking and premature component ageing. Conventional cylinder‑driven welding machines suffer from delayed pressure output, limited positioning accuracy and poor pressing stability, which readily result in contact crushing, deformation, offset and weak welding, leading to unstable conductivity of finished parts and inconsistent service life of equipment.

Developed for relay and contactor silver‑contact welding applications, the Haifei special‑purpose servo silver‑contact welding machine adopts servo electric‑cylinder closed‑loop pressure and position control system. It achieves flexible pressing and constant‑condition fusion. Silver contacts bond tightly to copper bases with flat contact surfaces and stable electrical conductivity, effectively improving make‑and‑break reliability and service life of low‑voltage electrical switches.

I Customer Background and Pain Points

The customer engages in manufacturing various relays, contactors and low‑voltage electrical switch components.

Pain points of original welding processes:

1.Conventional cylinder welding machines produce prominent pressing impact and insufficient positioning accuracy, easily causing crushing, offset and deformation damage to silver contacts.

2.Pneumatic pressing features rigid response and large pressure fluctuation. Silver contacts fail to fit closely against copper bases, giving rise to uneven weld nuggets and residual welding gaps. This causes excessive equipment operating temperature, unstable contact performance and contact erosion‑induced detachment after long‑term service.

3.Conventional welding shows poor matching between heat input and pressure, easily bringing about local cold joints, pseudo‑welds and weak welds.

4.Processes are hard to be solidified, and production data cannot be traced.

II Customer Requirements

1.Adopt servo electric‑cylinder precision pressing system to realize fully‑closed‑loop programmable control over pressure, position and speed. Pressing shall be flexible, stable and impact‑free to reduce crushing, deformation and offset of silver contacts.

2.Optimize dissimilar‑metal fusion process to improve fusion compactness between contacts and copper bases, stabilize electrical conductivity and control operating temperature rise.

3.Properly match heat input and pressing sequence to mitigate cold joints and uneven fusion.

4.Support parameter storage and switching for multi‑specification contact products; process data shall be storable and traceable.

III Custom‑Developed Solutions

Targeting customer requirements, the dedicated R&D team carried out repeated scheme tuning considering silver‑contact welding challenges including easy‑to‑crush features and difficult alignment.

1.Process verification: Conduct multiple groups of welding tests for silver contacts and copper bases of different specifications. Optimize key parameters including servo descending speed, bonding pressure, pressure‑holding profile, welding energy and cooling setting.

2.Equipment selection: Deploy special‑purpose servo silver‑contact welding machine equipped with servo electric‑cylinder drive system for smooth operation, reducing contact deformation, scratching and offset.

3.Fixture design: Custom‑built dedicated positioning tooling for silver contacts effectively reduces workpiece displacement and bonding gaps.

4.Core Advantages

Low‑deformation: stable pressure control, minimal deformation.

Superior performance: sound fusion, stable electrical conduction.

Efficient and reliable: stable operation, wide adaptability.

IV Delivery, After‑Sales Service and Customer Feedback

Pre‑acceptance and equipment inspection were completed. Continuous trial operation maintains stable welding pass rate. After commissioning, all original welding‑related production pain points are fully resolved. Timely, professional and thoughtful after‑sales service earns positive customer feedback.

V Haifei’s Mission of Meeting Customized Customer Demands

Haifei adheres to the philosophy of “Creating Value for Customers”. All work starts from customer requirements. What are your specific welding requirements? Do you need automation, integration or complete production‑line solutions? Please inform us, and Haifei will carry out targeted equipment R&D and customization for you.