Using fully automatic CNC punching machines for sheet cutting, the mold clearance is precise to 0.1mm, and the hole position error is controlled within ± 0.02mm. For irregular openings, a laser cutting machine is introduced to achieve dynamic focal length compensation, ensuring that the perpendicularity of the cutting surface is ≤ 1 °. The bending process is completed by a CNC bending machine, and the rebound deformation is controlled by an angle compensation algorithm. The single bending angle error does not exceed 0.5 °, and the cumulative error of multiple bending is controlled within 1 °.

　　焊接與表面處理

　　Welding and surface treatment

　　焊接環(huán)節采用機器人自動(dòng)化焊接工作站，焊縫軌跡規劃基于三維模型離線(xiàn)編程，焊接速度穩定在800mm/min，熔深控制在3-5mm區間。關(guān)鍵承重部位實(shí)施雙面焊接，破壞性試驗顯示焊縫抗拉強度達母材85%以上。表面處理采用型前處理工藝，脫脂、表調、磷化三道工序后，磷化膜重達到2-3g/m2。靜電噴塑選用聚酯粉末涂料，膜厚控制在60-80μm，經(jīng)百格試驗附著(zhù)力達0級標準。

　　The welding process adopts a robot automated welding workstation, and the weld trajectory planning is based on offline programming of 3D models. The welding speed is stable at 800mm/min, and the penetration depth is controlled within the range of 3-5mm. Double sided welding is implemented in key load-bearing areas, and destructive tests show that the tensile strength of the weld seam reaches over 85% of the base metal. The surface treatment adopts an environmentally friendly pre-treatment process, which includes three steps of degreasing, surface adjustment, and phosphating. After that, the weight of the phosphating film reaches 2-3g/m2. Polyester powder coating is selected for electrostatic spraying, with a film thickness controlled at 60-80 μ m, and the adhesion strength reaches the 0 level standard after the hundred grid test.

　　裝配與調試

　　Assembly and Debugging

　　標準化裝配流程包含七個(gè)工位：進(jìn)行門(mén)板鉸鏈預裝配，通過(guò)扭矩扳手控制預緊力在12-15N·m；接著(zhù)安裝承重導軌，水平度偏差≤0.2mm/m；然后進(jìn)行密封條貼合，采用進(jìn)口雙面膠帶確保IP55防護等級；隨后進(jìn)行模塊化安裝，強電/弱電區域分隔間距符合IEC 60529標準；再進(jìn)行線(xiàn)纜管理，使用尼龍扎帶固定，彎曲半徑不小于線(xiàn)徑6倍；接著(zhù)進(jìn)行接地連續性測試，電阻值≤0.1Ω；進(jìn)行功能調試，模擬滿(mǎn)載工況運行24小時(shí)，溫控范圍需保持在-10℃60℃之間。

　　The standardized assembly process includes seven workstations: firstly, the door panel hinges are pre assembled, and the pre tightening force is controlled at 12-15N · m through a torque wrench; Next, install the load-bearing guide rail with a horizontal deviation of ≤ 0.2mm/m; Then, the sealing strip is attached and imported double-sided tape is used to ensure an IP55 protection level; Subsequently, modular installation will be carried out, and the separation distance between strong and weak electrical areas will comply with the IEC 60529 standard; Perform cable management again, fix with nylon zip ties, and the bending radius should not be less than 6 times the wire diameter; Next, conduct a grounding continuity test with a resistance value of ≤ 0.1 Ω; Finally, perform functional debugging and simulate full load operation for 24 hours. The temperature control range should be maintained between -10 ℃ and 60 ℃.

　　成品檢驗與包裝

　　Finished product inspection and packaging

　　成品檢驗包含23項檢測項目，包括：門(mén)板開(kāi)啟耐久性試驗達10000次無(wú)變形，鎖具防盜等級通過(guò)EN 1300 B級認證，抗震性能滿(mǎn)足IEC 60068-2-27標準。包裝環(huán)節采用蜂窩紙板，內部使用EPE緩沖材料，包裝箱跌落試驗從1.2米高度自由落體后，機柜變形量不超過(guò)2mm。

　　The finished product inspection includes 23 testing items, with a focus on the durability test of the door panel reaching 10000 times without deformation, the anti-theft level of the lock passing the EN 1300 B-level certification, and the seismic performance meeting the IEC 60068-2-27 standard. Environmentally friendly honeycomb cardboard is used in the packaging process, with EPE cushioning material used internally. After the packaging box falls freely from a height of 1.2 meters, the deformation of the cabinet does not exceed 2mm.

　　通過(guò)上述標準化流程，仿威圖機柜實(shí)現日產(chǎn)能200臺套，直通率達98.7%，關(guān)鍵尺寸CPK值保持在1.67以上。該體系既保證了大批量生產(chǎn)效率，又能通過(guò)模塊化設計滿(mǎn)足200余種定制配置需求，為工業(yè)自動(dòng)化領(lǐng)域提供可靠的基礎設施保障。

　　Through the above standardized process, the imitation Weitu cabinet achieves a daily production capacity of 200 sets, with a pass through rate of 98.7%, and the critical dimension CPK value remains above 1.67. This system not only ensures mass production efficiency, but also meets over 200 customized configuration requirements through modular design, providing reliable infrastructure support for the industrial automation field.