Inhaltsverzeichnis
Überblick & Anwendungsfälle
Able Hardware manufactures custom-welded metal frames for OEM programs that value repeatable quality, predictable cost, and tight downstream fit-up. Frames leave our Suzhou factory production-ready with robotic MIG welding, upstream laser cutting, and CNC prep, and export-focused QA. Explore related welding services und surface finishing options.
Why this solution for production repeatability & cost control
Robotic MIG with validated parameters delivers consistent fillet size and penetration; engineered fixtures and bead sequencing control distortion; upstream laser cutting and CNC prep shorten total cycle time. The result is stable takt, fewer assembly reworks, and a reliable total landed cost across releases.
Typische Branchen & Anwendungen
- Material-handling frames, lift-assist structures, conveyor and automation bases
- Rolling frames, cart chassis, and modular fixtures for factory logistics
- Appliance and HVAC subframes, Klammern, and mounting structures
- Robotics cells, inspection stations, and equipment bases
Capabilities & Materialien
Frame types, tube sizes & thickness range
Primary materials: carbon steel tube and thick sheet stock; stainless available on request. Typical tube sizes: 20×20–100×100 mm, 1.5–6.0 mm wall for single-pass welding. Heavier sections use multi-pass sequences with controlled inter-pass temperatures (°C). Joint designs include fillet, lap, plug, and corner—selected to match load paths, access, and service environment.
Fixtures, distortion control & weld quality levels (ISO 5817)
Precision fixtures with functional datums lock critical faces; clamp strategy, tacks, and balanced sequencing minimize pull. Acceptance follows ISO 5817 Level B/C as specified. Weld symbols comply with ISO 2553; visual inspection aligns to ISO 17637.
Fertigungsoptionen
Process flow (laser cutting → welding → machining → finishing)
- Laser schneiden & prep: tube/sheet nesting, edge quality to ISO 9013, tabs/slots for self-location.
- Robotic MIG welding: stable arc, travel speed, and torch angle per WPS/PQR (ISO 15614-1 / AWS D1.1). Personnel qualified to ISO 9606-1; welding quality requirements align with ISO 3834 scope by contract.
- Straightening & light CNC: press straightening for global geometry; drilling/tapping and secondary machining for precision interfaces.
- Abschluss: Pulvermantel (RAL/Pantone equivalent), zinc plating per ASTM B633 or equivalent, or e-coat—selected for exposure class and geometry. See /services/finishing/.
Supported tolerances (ISO 13920 / ISO 2768) & hole patterns
General welded structures follow ISO 13920 (Class B/C by agreement). Machined features follow ISO 2768-m unless drawings call out tighter. Hole groups and slot arrays originate from laser/CNC data to preserve mounting alignment across batches and sites.
Toleranzen & GD&T
Datum strategy (A/B/C) for mounting faces & wheel plates
Functional A/B/C datums are established on primary mounting faces and wheel plates to control how the frame is located in assembly and inspection. This strategy improves interchangeability, reduces shim usage, and protects bearing/roller life.
Flatness, squareness, parallelism & hole position examples
Typical controls:
- Flatness on base members to maintain caster alignment
- Perpendicularity of uprights to base datum within agreed millimetres over height
- Parallelism between rails to protect belt or chain tracking
- Position of hole groups (z.B., ±0.2–0.5 mm to datums) for reliable module mounting Verification uses dedicated checking fixtures for in-process go/no-go and CMM for first-article and periodic audits. Thermal cut quality follows ISO 9013 to stabilize downstream accuracy.
Qualität & Testen
Was wir überprüfen (visual, NDT, CMM, PPAP basics) und Dokumentation
- Visuell: ISO 17637 with acceptance to ISO 5817 Level B/C
- NDT options: MT/PT for surface indications; UT/RT per ISO 17638/17640/17636 by risk profile or specification
- Dimensional: fixture gauges for critical features; CMM on datums and hole patterns for FA/PPAP and periodic checks
- Traceability: heat/batch certificates; COA with every shipment
- PPAP basics: agreed element list (z.B., PSW, FAI, process flow, PFMEA/control plan snapshots)
- Records: WPS/PQR, operator qualifications, and inspection reports maintained with the lot and mirrored in the packing list. See /quality/.
Oberflächen & Haltbarkeit
Pulvermantel, Zinkbeschichtung, E-Coat; color standards & corrosion targets
Finishes include powder coating with RAL/Pantone-matched colors, zinc plating per ASTM B633 equivalents for internal or moderate exposure, and e-coat for uniform coverage in complex geometries. Corrosion performance verification via ISO 9227 salt spray is available to agreed hour targets (z.B., 240–720 h depending on system and thickness). Masking, plug protection, and edge rounding are defined in the router to protect critical fits.
Verpackung & Versand
KD/nested options, labeling, and ISPM-15 export packing
Export-ready packing is engineered for safe handling and fast line-side use: KD or nested sets with edge and paint protection; barcoded labels tied to drawing revision; ISPM-15 pallets/crates; and stable stack geometry for optimized container loading. Learn more at /packaging-shipping/.
Preisgestaltung & Vorlaufzeit
MOQ, Beispielrichtlinie, Indikative Kostenfahrer (Keine harten Preise)
Typical flow: prototype → fixture approval → SOP; production via releases/blanket orders. MOQs reflect material thickness, fixture complexity, and finishing system. Cost drivers include tube size and wall, total weld length and positions, GD&T intensity, coating type and thickness, and packing density. Samples move on expedited queues for design validation; serial timing depends on release size and coating schedule.
Standards & Einhaltung
Relevante Standards/Zertifizierungen & Dokumentation bereitgestellt
- ISO 13920 (general welded structures)
- ISO 2768-m (machined features), ISO 9013 (thermal cut quality)
- ISO 15614-1 / AWS D1.1 (procedure qualification), ISO 9606-1 (operator qualification), ISO 3834 (welding quality requirements)
- ISO 2553 (weld symbols), ISO 17637 (visual), ISO 5817 (acceptance)
- ISO 17638/17640/17636 (MT/UT/RT), ISO 9227 (salt spray)
- ASTM B633 equivalents (zinc finishes)
FAQ
Q1: Which materials are supported?
Carbon steel tube and thick sheet stock are standard; stainless options suit higher corrosion environments.
Q2: What welding process is used?
Robotic MIG is standard for repeatability and throughput. Multi-pass sequences apply to heavier sections with controlled inter-pass temperatures.
Q3: What tolerances are typical?
ISO 13920 Class B/C for welded geometry unless otherwise agreed; machined features to ISO 2768-m or to print.
Q4: How are frames inspected?
Visual to ISO 17637 with acceptance to ISO 5817, dedicated fixtures for in-process checks, and CMM for FA/periodic audits. Optional MT/PT/UT/RT per specification.
Q5: What documents ship with the lot?
COA, heat/batch traceability, WPS/PQR, operator qualifications, Inspektionsberichte, and agreed PPAP elements.
Q6: What about MOQ and lead time?
MOQs track fixture complexity and finishing. Prototypes move quickly; serial releases follow the approved fixture and router.
Q7: How are shipments packed?
KD or nested with edge/coating protection, labeled to drawing revision, on ISPM-15 pallets/crates.
Q8: What drawings are needed for a quote?
3D/2D files with GD&T, material spec, Dicke, weld call-outs, finish system, and any critical hole groups; expected annual volume and release size help optimize pricing.
Aufruf zum Handeln
Upload drawings for a fast DFM review. Receive fixture concept, risk notes, and an optimized quotation. [Upload drawing / Get a quote].