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Project Introduction: Dual‑Head Medium‑Frequency Welder

Sep 08,2026

For bolt and nut welding of auto‑parts, conventional single‑head welders require repeated clamping and sequential single‑point welding. Workpieces are heated successively, which easily causes sheet‑metal deformation, scattered weld‑spot strength and unqualified torque values.

The Haifei dual‑head medium‑frequency welder is designed for welding conditions of auto‑parts. It enables simultaneous welding on both sides of the workpiece. Bolts and nuts can be welded at two positions in one clamping cycle. Weld spots are firm and stable, suitable for welding of auto‑parts.

I Customer Background and Pain Points

One customer mainly manufactures automotive body structural components including reinforcement panels for ABC pillars, and performs projection‑welding of bolts and nuts.

Production pain points of the original welding process:

1.Sequential single‑head welding leads to uneven heating of workpieces. Sheet‑metal parts tend to twist and deform, resulting in poor alignment in subsequent assembly.

2.Positioning benchmarks shift in repeated clamping. Welding strength varies between the two points, readily generating cold joints and insufficient torque.

3.Conventional power‑frequency equipment has ordinary energy‑saving performance, leading to high energy‑consumption cost in continuous operation. Welding output becomes unstable under power‑grid fluctuation, causing spatter and surface indentation.

4.Sequential welding involves cumbersome procedures and low production rhythm. The equipment lacks complete parameter‑storage and traceability functions.

II Customer Requirements

1.Adopt dual‑head simultaneous‑welding structure to eliminate re‑clamping errors, balance heat input on both sides of workpieces and reduce sheet‑metal deformation.

2.Optimize stability of welding output to achieve full and uniform weld nuggets, improve torque and pull‑off resistance of weld spots and reduce welding defects.

3.Lower equipment operating energy consumption and support long‑time continuous stable operation.

4.Adapt to production of multi‑specification workpieces and support parameter storage and recall.

III Custom‑Developed Solutions

Targeting customer requirements, the dedicated R&D team repeatedly tuned and optimized schemes in view of welding difficulties of auto‑parts, to ensure deliverables fit customer demands. Details are as follows:

1.Process verification: Conduct multiple groups of welding‑process tests for sheet‑metals of different thicknesses and various‑specification bolts and nuts.

2.Equipment selection: Adopt Haifei dual‑head medium‑frequency welder. Dual welding heads can press down and weld synchronously. Two‑position welding of bolts and nuts is completed within one clamping setup. Current output is stable and controllable with concentrated heat input.

3.Structural design: The complete machine runs stably with good synchronization performance of dual heads. Accuracy remains stable after long‑term operation. Custom‑built exclusive positioning tooling reduces welding offset and dislocation. Tooling surfaces receive protective treatment to mitigate workpiece burning and indentation.

4.Core Advantages

Stable welding: uniform strength, good appearance.

Low deformation: even heating, easy assembly.

Efficient & stable: low energy consumption, quick production change‑over.

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 of the customer are fully resolved. Timely, professional and thoughtful after‑sales service earns positive customer comments.

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.

Wuxi Haifei Intelligent Equipment Co., Ltd. https://www.haifeiwelder.com/

Wuxi Haifei Intelligent Equipment Co., Ltd. has been focusing on the R&D and production of special‑purpose welding machines for 17 years. The company has obtained ISO9001 Quality Management System Certification, China Compulsory Certification (3C) and CE Certification. It is a National High‑tech Enterprise, a Specialized, Refined, Differential and Innovative Enterprise of Jiangsu Province, a Specialized, Refined, Differential and Innovative Enterprise of Wuxi, and a Gazelle Enterprise in the Southern Jiangsu National Self‑Dependent Innovation Demonstration Zone.

Should you be interested in our special‑purpose machines, please contact us: 400‑0510‑750