(1) Pole Production Process:
(1) Cutting → Bending → (3) Welding → (4) Repairing & Sanding → (5) Shaping → (6) Head Straightening → (7) Mounting Bottom Plate → (8) Welding Bottom Plate → (9) Door Installation → (10) Welding Door Strip, Electrical Strip, Lock Base → (11) Fork Bending → (12) Galvanizing → (13) Powder Coating → (14) Final Inspection → (15) Shipment
(II) Process Requirements:
Cut-to-Length Shearing
1.1 Adjust the slant of the strip cutting machine and ensure it matches the required longitudinal cutting size before cutting.
1.2 Determine the steel plate placement, ensuring the size of the excess material to make it usable.
1. The 3 length dimensions are guaranteed when the product is opened. The width dimensions must be ≤±2mm. The tolerance for the lower rod dimensions is as follows: generally, a positive tolerance of 0-2mm is taken at the large end of each rod section. A negative tolerance of -2-0mm is applied at the small end. After the size adjustment, the cutting is completed automatically by the cutting strip machine.
1. 4 Equipment Aspect: Before cutting, inspect the operation of the roller cutting equipment, clear away debris on the track, and maintain the equipment in good running condition.
2. Bending
Bending is a critical process in the production of lighting poles, with the quality of bending directly affecting the pole's integrity. Once bent and shaped, it cannot be repaired. Specific attention points include:
2.1 Before Bending: First, remove the cuttings from the sheet material to ensure no cuttings damage the mold during bending.
2.2 Inspect the material's length, width, and straightness; the straightness should not exceed 1/1000. If the straightness does not meet the requirements, make corrections, especially ensuring the straightness of polygonal rods.
2.3 Adjust the large bending machine's bending depth and determine the placement of the sheet material.
2.4 Properly mark on the sheet material, tolerance: ≤±1mm
2.5 Proper alignment and bending to ensure the tube seam is minimal, with both edges not exceeding a 5mm height difference.
Welding
During welding, perform straight seam welding on the tube blanks after bending machine due to semi-automatic welding. It is mainly the responsibility of the welder to make timely adjustments to the loose welding position and base parameters. Ensure the straightness of the weld seam.
4. Patch and sand
Rework and polishing involve repairing defects on pipe blanks after automatic welding. Repair personnel should inspect each piece individually, weld any defects found, and then grind the welds, ensuring the finished surface is nearly identical to the automatic weld.
5.整形 - Plastic Surgery
The整形 process includes straightening the pole, rounding the ends of the billet, and sizing the diagonal dimensions of the polygon. General tolerance: ＜±2mm. The straightness error of the billet shall not exceed: ≤±1.5/1000.
6. Head-to-head
The straightening process involves flattening the ends of the bent billet to ensure the tube ends are perpendicular to the centerline, without any angles or unevenness. Additionally, the ends are then polished smooth.
7. Bottom Plate Installation
Spot-weld the bottom flange and web, the key is to ensure the bottom flange is perpendicular to the centerline of the lamp post, the web is perpendicular to the bottom flange, and parallel to the lamp post busbars.
8. Welded bottom flange and ribbed plate
Welding requirements refer to the welding process in accordance with national standards, ensuring the quality of the welds to be aesthetically pleasing, free from blowholes and slag inclusions.
9. Open the door
During this process, one must be bold yet meticulous. Firstly, carefully examine the drawings to determine the door's orientation, then position it according to the dimensions specified, including up-down, left-right, and the door frame size. Be meticulous during plasma cutting to ensure the cut is straight, and simultaneously, weld the cut door panel to the lamp post using electric welding.
10. Welded Door Strip, Electrical Strip, Lock Seat
During welding door strips, position the 40mm wide strips at an extension of 8-10mm, particularly ensuring they are flush against the lamp post during spot welding for a secure weld.
Welding electrical bars and locking seats, mainly, position according to the drawing, lock the seat in the middle of the door, with an error of ≤±2mm, maintain horizontal above, do not extend beyond the lamp post.
11. Bending Fork
The process of the bent fork is similar to the door opening process, requiring boldness with meticulousness. Firstly, pay attention to the door's direction; secondly, note the bending point; thirdly, control the fork angle and traction speed, ensuring they are consistent and guaranteeing a 100% yield of finished products.
12. Galvanized
12.1 Pre-Galvanized Inspection
Inspect the surface of the lamp post before galvanizing for any paint welds; if present, clean them.
12.2 Pickling
Perform necessary degreasing on the pole surface, soak in the degreasing tank for 15-30 minutes, then clean in the washing tank for at least two more thorough washes.
Surface treatment of the pole with an oxide layer cleaning, 20-40 minutes in hydrochloric acid to remove the oxide layer; if there are localized oxide layers, treat them with tools first and then acid wash for 15 minutes. Analyze the acid composition every 24 hours.
After pickling, it is essential to wash in the cleaning pool to remove acid ions from the surface of the lamp post, and the washing must be done more than twice.
12.3 Zinc Aid Agent
After the light pole is cleaned, immerse it in the zinc treatment pool, maintaining a temperature of 60-70℃ for 3 minutes. Analyze the zinc treatment additive every 4 hours.
12.4 Galvanized
After water cooling, to prevent white rust (zinc oxide) from forming on the galvanized surface, chrome acid treatment must be applied to the surface. During this process, a yellow passivation solution is produced on the surface, which can naturally fade upon rainfall.
13. Powder Coating
13.1 Polishing: Flatten the surface of the galvanized rod using a polishing sand wheel to ensure the lamp post surface is smooth and even.
13.2 Straightening and Shaping: Straighten and shape the polished lamp post and its mouth, ensuring the straightness of the lamp post reaches 1/1000. The diameter requirements are: small posts ≤ ±1mm, tall posts ≤ ±2mm.
13.3 Door Panel:
13.3.1 All door panels undergo a post-plating treatment, which includes zincing, missed plating, and zinc residue in the lock holes.
13.3.2 When drilling screw holes, ensure the electric drill is perpendicular to the door panel, with equal gaps around the door panel, and the door panel is flat.
After screwing in, the door panel must not be loose; it must be firmly secured to prevent detachment during transit.
13.4 Powder Coating: After the door is installed on the lamp post, it is coated with powder paint according to the production schedule requirements. Then, it is baked in an oven. The oven temperature and insulation time must be strictly adhered to according to the specifications of each type of powder paint to ensure the adhesion and smoothness of the lamp post, meeting quality requirements.
14. Factory Inspection
Factory inspection is conducted by the quality control personnel, who must inspect each item on the pole inspection checklist. Inspectors must record and archive their findings, and the inspection form must be signed by both the workshop supervisor and the quality control officer before shipment is allowed.
15. Packaging and shipment
15.1 Wrapping - Wrapped according to customer's requirements
15.2 Prior to shipment, the warehouse, in conjunction with the finance department, will handle all pre-shipment formalities. Settlement of product quantity, weight, and amount will be made according to the contract provisions.
