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Semi automatic welding machine

The semi automatic welding machine combines manual loading with fully automatic medium-frequency DC spot welding — 2.5 s per piece, one-key HMI changeover, Omron PLC, and a fume-extracted safety enclosure. Designed for internal metal components of electrical appliances, customized to your part drawings, and upgradeable to full automation. Delivery in 50 working days.

Spot welding · Semi‑automatic equipment

Semi Automatic Spot Welding Machine for Electrical Appliance Metal Components

A semi-automatic welding machine is used for welding inner parts of electrical devices in an ergonomic all-inclusive welding workstation. The process starts when component ① is delivered to the machine by a feeding system operator, where it will be isolated from all neighboring parts and placed onto the marking machine. Then the operator places raw part ② and clicks the start button. The machine performs its medium-frequency DC resistance welding and gets rid of the produced part every 2.5 seconds. The final parts are checked by the worker who makes sure they are suitable for use.

The key characteristics include one-click user interface change, welding recipes stored in Omron PLC, modern Guolong medium-frequency DC spot welding power source, and automatic safety device with smoke extraction system and doors locking mechanism. Fixture configuration, electrodes shape, and welding parameters are adjusted as per your drawings and specifications given for production, and system adjustments can be done.

Standard delivery: 50 working days | One‑key HMI changeover | 2.5s per piece

Semi automatic welding machine internal welding station

Internal welding station of the semi automatic welding machine (representative image)

What is a Semi Automatic Welding Machine?

A semi-automatic welding machine represents a kind of spot welding device where the operator does load the parts, yet the machine itself takes care of all the important welding processes. In contrast with the fully manual spot welder, in this case, the welding parameters, welding position, and pressure values are set by the machine, which ensures that each of the parts is stably welded. As opposed to the fully automated solution, this option does not require any elaborate parts feeding systems and is a relatively cheap and effective decision for cases when medium volume production is required, or the part feeding is complex. In this configuration, part 1 is being fed into the welding fixture with the help of a bowl while the operator loads part 2 and pushes the start button after the parts are adjusted; at this point, the lifting cylinder raises the parts up to the welding height whereupon the upper welding body applies pressure for the medium-frequency welding process that takes two and a half seconds; the completed parts are unloaded by the machine itself. The operator checks the quality of welding on the parts after that. The machines are custom made, which means that we will customize the fixture, feeding technology, as well as welding parameters according to the shape of the of part, location of welding spots, and production features.

2.5s per piece cycle
Approx. 1,440 pcs/hour from a single welding station operated by one worker.
Medium‑frequency DC welding
Guolong MF DC power source delivers precise current control and stable weld nuggets.
One‑key changeover
Welding recipes stored in the Omron PLC; switch variants with a single tap on the HMI.
Non‑standard custom design
Tailored to your part geometry, weld point layout, and production targets.

Technical Specifications

Semi‑automatic medium‑frequency DC resistance welding for internal metal components of electrical appliances. 2.5s per piece, one‑key HMI changeover, Omron PLC control.
Applicable components Internal metal components of electrical appliances (customized to part drawings)
Welding technology Medium‑frequency DC resistance welding (Guolong welding unit)
Welding stations 1 welding station
Production capacity 2.5 s per piece (approx. 1,440 pcs/hour)
Loading method Vibratory bowl feeding + manual loading by one operator
Changeover method One‑key switching via HMI (welding recipes stored per product type)
Quality assurance Weld parameters fixed by machine; weld quality ensured and verified by operator inspection
Control system Omron PLC with HMI touch screen
Power & air supply 380V ±10% 50Hz, 75kVA (15kW) | Compressed air ≥ 0.6MPa
Machine dimensions / operators L1200 × W1000 × H1800 mm | 1 operator
Delivery time 50 working days

Detailed Process Flow

The semi-automatic welding cycle follows this sequence (operator selects the product recipe via HMI before start):

  1. Automatic loading of Component ① – The vibratory bowl feeder loads Component ① into the machine automatically.
  2. Automatic material separation and positioning – Parts are separated and positioned on the welding fixture.
  3. Manual loading of Component ② – The operator places Component ② and presses the start button after correct placement.
  4. Automatic welding – The lifting cylinder raises the assembly to welding height and the upper electrode cylinder executes the medium-frequency DC weld with the preset recipe parameters.
  5. Automatic unloading – Welded parts are discharged automatically after welding is complete.

Core Technical Advantages (Custom Non‑Standard Design)

Consistent welds without full-automation cost

Electrode pressure, weld position, and parameters are machine-controlled, so weld quality no longer depends on operator skill — while manual loading keeps the investment significantly lower than a fully automatic welding line.

Medium‑frequency DC welding power

Compared with conventional AC welding, the Guolong medium-frequency DC unit provides faster current response and finer control over heat input, delivering stable weld nuggets with minimal spatter on small precision components.

One‑key product changeover

Welding recipes for each product variant are stored in the Omron PLC. Switching production is done with a single tap on the HMI — no mechanical adjustment, no parameter re-tuning — ideal for multi-variant production.

Safe operation with an upgrade path

The full enclosure with interlocked doors and top fume extraction keeps spatter and fumes away from the operator, and the platform supports a later upgrade to fully automatic loading as volume grows.

Trusted by industry leaders

ABB
DELIXI
EKF
KRIPAL
HPL
CHAC
Schneider
IEK GROUP
SUNIR
Bevone
Weg
HUYU
RAAD
WALTONE
HAVELLS
C&S electric

Applications and Integration

Electrical appliance component welding – Internal metal parts requiring precise, repeatable spot welds
Medium‑volume production – Where full automation is not yet cost-justified but weld consistency is required
Multi‑variant parts – Frequent product changeover handled by one-key HMI recipe switching
Custom OEM projects – Non-standard part geometries and weld point layouts, upgradeable to full automation

Custom Engineering & Delivery

1. Part analysis & fixture design Within 15 working days after first advance payment · sample parts required
2. Welding process validation Weld trials on your actual parts
3. Manufacturing 50 working days
4. Pre-FAT At Benlong factory with customer parts
5. Installation & commissioning On-site
6. Final SAT & training Acceptance report

Request a Custom Semi Automatic Welding Machine Quote

Provide your part drawings or samples as well as your weld point positions & production targets. Our engineers will create a semi-automatic welding machine design with the proper fixture, electrode & feeding arrangement compatible with your product.

Inquire Now

WhatsApp: +86 150 5837 0007 | Email: xsb@benlongkj.cn | English & Chinese support

Why Choose Benlong for Welding Automation?

  • 15+ years designing custom welding machines for low‑voltage electrical products
  • Semi-automatic architecture: automatic weld quality at a fraction of full-line cost
  • Medium-frequency DC welding power for precise heat control
  • One-key HMI changeover for multi-variant production
  • Enclosed, fume-extracted design for operator safety, upgradeable to full automation

Typical Custom System Includes

Semi-automatic welding equipment consisting of: · Vibratory bowl feeder with loading station; Step-feed track; Lifting & positioning cylinder; Upper electrode welding cylinder; Guolong medium-frequency DC welding power source; Omron PLC w/HMI; Discharge chute; Safety enclosure w/interlocked doors and fume extraction port; Installation commissioning; One-year warranty

Frequently Asked Questions

What does “semi-automatic” mean?

The operator only needs to place part 2 in the machine, and then just push the button: part 1 is automatically delivered from the vibrating feeder, and all operations are performed automatically, including the welding of parts and unloading of finished parts, every 2.5 seconds. The parameters are programmed into the PLC program, which ensures the same quality of welding regardless of the operator’s experience.

What parts can be welded by this machine?

The machine is designed for internal metal pieces used in electrical equipment (contacts, terminals, brackets, and similar small parts). The machine is custom-made; its fixtures and electrodes are designed based on drawings on customer’s parts. Please send us sample parts for evaluation.

How can the quality of welds be ensured?

The machine guarantees the position of the weld, as well as the current and electrode pressure used, which allows getting the same result every time. After the parts leave the machine, the operator checks the quality of the welds.

Is it possible to upgrade the machine to the fully automatic version later?

Yes, the machine can be upgraded to fully-automatic loading in the future. You may start with the semi-automatic version and upgrade the system later.

What is the schedule for design and delivery?

Please provide us with all necessary drawings and specifications (positions of welds, desired performance, supply capability of the factory). The design phase is done in 15 working days after a prepayment, while the manufacture phase takes another 50 days.

All specifications subject to final technical agreement. Benlong Automation – custom welding solutions for low‑voltage electrical products.

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WhatsApp
+86 150 5837 0007
Email
xsb@benlongkj.cn