Automated Welding Enhances Hydraulic Support Manufacturing in China’s Coal Industry

Client Profile

In February 2025, Zhengzhou Coal Mining Machinery Group (ZMJ), China’s leading mining equipment manufacturer, sought to modernize their production of hydraulic support structures. Facing increasing demand for robust coal mining equipment, their traditional manual welding processes for 10mm+ thick steel components had become a critical bottleneck.

Production Challenges

• Material thickness: 10-30mm steel plates required extensive multi-pass welding
• Quality issues: Manual welding resulted in inconsistent penetration and frequent defects
• Labor constraints: Certified heavy plate welders were increasingly difficult to recruit
• Throughput limitations: Production couldn’t keep pace with mining industry demands

Technical Complexities

• Full penetration welds meeting MT/T 587 mining equipment standards
• Minimal distortion in large structural assemblies
• Consistent quality across high-volume production

Implemented Automation Solution

• Overhead-mounted robotic welding unit for optimal positioning
• Mobile base system allowing access to large structural components
• High-deposition welding equipment for thick plate applications
• Integrated seam tracking to accommodate part variations

Operational Improvements

• Quality enhancement: Weld defect rate reduced by 80%
• Productivity gain: Output increased by 4-5x compared to manual welding
• Consistency improvement: Achieved uniform weld profiles across all production

Strategic Business Impact

• Faster delivery times for critical mining equipment
• Improved competitiveness in international markets
• Enhanced ability to meet China’s mining safety standards

Industry Significance

• Solves specialized heavy fabrication challenges
• Addresses skilled labor shortages in traditional industries
• Enhances quality in safety-critical mining equipment

Sustainable Benefits

• Reduced energy consumption per welded component
• Improved working conditions for welding personnel
• Better utilization of raw materials

About Aixsen

At Aixsen, we deliver end-to-end industrial automation systems designed for demanding manufacturing environments.

We deliver precision laser cutting, robotic arc welding, and intelligent material handling solutions—designed as standalone systems or integrated lines, fully engineered around your specific process, quality requirements, and output targets.