High temperatures pose real challenges to automatic welding equipment. To ensure stable operation, extend service life, and guarantee safety, special attention should be paid to the following:

I. Protection and Cooling of Core Systems

1. Electronic Control System (The Core)

Forced ventilation & air conditioning: The electric control cabinet (including PLC, inverter, servo driver, etc.) is the “brain”. Ensure cooling fans work properly and clean filters daily (more dust in high temperatures). If possible, install industrial air conditioners or coolers for key cabinets to keep internal temperature within the allowable range (usually <40℃).

Avoid direct sunlight: Do not place control cabinets in direct sunlight or near high heat sources (such as freshly welded workpieces).
Temperature & humidity monitoring: Monitor readings of internal temperature and humidity sensors (if equipped), or check cabinet temperature manually regularly.

Humidity control: In hot and humid areas, prevent condensation inside cabinets. Use anti-moisture heaters or keep cabinets well-sealed.

2. Torch Cooling System

Coolant inspection and replacement:

*   Ensure sufficient coolant level in the tank, checked daily.

*   Use special high-boiling-point, anti-corrosion coolant recommended by the manufacturer (usually ethylene glycol mixture). Pure water has low boiling point and tends to boil and vaporize at high temperatures, causing cooling failure.

*   Test coolant freezing and boiling points regularly (shorten intervals in hot seasons) and replace if necessary. Replace cloudy or deteriorated coolant immediately.

Cooling circulation inspection:

*   Cooling circulation inspection:Check if the cooling pump operates normally before startup daily by listening and feeling water flow/pressure.

*   Inspect cooling hoses for bending, flattening, or leakage. Hoses may soften at high temperatures and must be secured to avoid friction.

*   Ensure unobstructed cooling channels inside the torch (normal return water flow and temperature).

Water temperature monitoring: Watch coolant return temperature. Stop immediately for inspection if temperature rises abnormally (close to or exceeding the set alarm value).

3. Lubrication of Mechanical Moving Parts

Use high-temperature lubricants: For ball screws, guide rails, bearings, gears, etc., use high-quality high-temperature-resistant grease or oil (usually >80℃ or higher). Ordinary lubricants tend to thin, leak or coke at high temperatures.

Shorten lubrication intervals: Lubricants are consumed and contaminated faster in high-temperature, high-dust environments.

Appropriately shorten maintenance cycles (refer to manuals and actual conditions).

Clean before lubrication: Remove old grease and dirt before applying new lubricant.

II. Electrical System and Safety

1. Cables and Wiring

Inspect insulation and aging: High temperatures accelerate aging, embrittlement of cable insulation. Regularly check power cables (welding output), control cables, air hoses and water pipes for damage, cracking or hardening.

Avoid overheating: Arrange cables neatly without tangling to ensure good heat dissipation. Prevent cables from touching high-temperature workpieces or the ground directly.

Tighten connections: Thermal expansion and contraction may occur at high temperatures. Regularly check and tighten all electrical terminals (especially high-current terminals) to avoid overheating or fire caused by poor contact. Operate with power off!

2. Reliable Grounding
Welding ground connections must be firm and clean. This is essential for equipment safety and welding quality. High temperatures accelerate oxidation at contact points, so inspections must be enhanced.

3. Overload Protection
Ensure overcurrent, overheating and other protection devices function normally. Equipment is more likely to operate at full load in high temperatures.

III. Gas Circuit and Wire Feed System

1. Gas Circuit Sealing

*   High temperatures may accelerate aging of O-rings at hose connections. Regularly check air hoses (especially shielding gas hoses) for leakage (using soap water or leak detector).

*   Prepare spare O-rings of common specifications.

2. Gas Cylinder / Supply System

*   Gas cylinders (especially CO₂) are strictly prohibited from exposure to direct sunlight! They must be placed in cool, ventilated areas or protected with sunshades. Exposure causes rapid pressure rise inside cylinders, which is extremely dangerous.

*   For busbar or pipeline gas supply, ensure supply pipes are also protected from direct sunlight and high-temperature baking.

3. Wire Feed System

*   Contact tip / wire liner: In high-temperature welding, contact tip wear may accelerate, so inspection and replacement frequency should be increased. Keep the inside of the wire liner clean. Lubricant on the welding wire may accumulate more easily at high temperatures.

*   Dry welding wire: Store welding wire in a dry environment (constant temperature and humidity cabinet recommended). Use opened wire as soon as possible. Welding wire easily absorbs moisture in hot and humid conditions, causing porosity. Use a welding wire drying oven if necessary.

*   Wire feed roller pressure: Check and adjust pressure. Excessive pressure may aggravate wire deformation or roller wear at high temperatures.

IV. Equipment Environment and Operation Adjustment

1. Improve Equipment Environment

*  Workshop ventilation: Strengthen overall ventilation to lower ambient temperature and remove welding fumes and heat. Use large industrial fans or negative pressure exhaust systems.

*  Equipment spacing: Maintain sufficient heat dissipation space between equipment and between equipment and heat sources.

*  Sunshade: Install sunshades or curtains if equipment is installed in direct sunlight (e.g., near windows).

2. Arrange Production Reasonably

*  Off-peak operation: If possible, schedule welding during cooler periods (early morning, evening).

*  Increase rest intervals: During continuous high-intensity welding, add proper “rest” time for equipment to cool down.

3. Fine-tune Welding Parameters

*   High temperatures may slightly change arc characteristics or affect molten pool behavior due to higher workpiece temperature. Welders/programmers should monitor and fine-tune voltage, current, wire feed speed, etc., if abnormalities occur (excessive spatter, poor formation). Adjust carefully and based on actual conditions.

V. Strengthen Maintenance

1.Increase inspection frequency: In hot seasons, increase daily and regular inspections, focusing on temperature, abnormal noise, odor, leakage, and alarms.

2.Strictly follow maintenance plans: Fully implement scheduled maintenance (daily, weekly, monthly) per manuals, especially critical in hot seasons.

3.Prepare spare parts: Stock vulnerable parts that fail easily in high temperatures, such as fans, filters, O-rings, thermal grease, high-temperature lubricants, etc.

4.Cleaning is critical: Thoroughly clean equipment after daily work, especially welding slag, dust and oil on control cabinet vents, heat sinks, fan blades, guide rails and screws. Dust accumulation is the main enemy of heat dissipation!

VI. Safety First

1.Fire prevention: High temperature + welding sparks + oil/dust increase fire risk. Ensure no flammables around equipment, and fire-fighting equipment is available and effective.

2.Heatstroke prevention: Provide operators with cooling drinks, ventilation facilities, and reasonable breaks to prevent heatstroke. Operator condition affects operation safety.

3.Personal protective equipment (PPE): Strictly wear welding helmets, protective gloves, flame-resistant work clothes, etc., even in high temperatures. Choose breathable materials.

Daily Maintenance Checklist for High-Temperature Conditions

*   Before startup: Check coolant level/quality, clean control cabinet filters, inspect cables and hoses, check cooling pump.

*   During operation: Monitor control cabinet temperature, coolant temperature, abnormal noise/odor/alarms; observe arc and weld quality.

*   After work: Thoroughly clean equipment (especially heat dissipation parts); check equipment status; replenish consumables if needed.

*   Periodically: Shorten intervals for lubrication, filter replacement, coolant testing; strengthen inspections of air tightness, grounding, terminal connections; check wearing parts (contact tips, etc.).