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Turnkey solutions for linear resistance welding machines

Thyristor resistance welding power and time controller
for linear welding machines

Thyristor resistance welding power and time controller for linear welding machines, Mikroprocesorowy Regulator Mocy i Czasu Zgrzewania dla zgrzewarek liniowych, tyrystorowe zasilanie transformatorów zgrzewalniczychpolish know how good priceWe present affordable, easy to use and reliable device for power supply of the welding transformers of linear resistance welding machines. We offer a complete solution containing a microprocessor controller and a power circuit with double thyristor module and a heat sink. The device is ideal for upgrading the electrical power circuit of single-phase linear resistance welding machines.

The presented device is the result of experience acquired during several decades of work on electronic circuits for resistance welders.

Characteristics of the device:

  • microprocessor controller with an intuitive menu in Polish and English,
  • individual resistance welding parameters for initial, middle and final part of the welding item,
  • resistance welding parametrs settings:
    • resistance welding power,
    • resistance welding time,
  • built-in resistance welding modes:
    • continuous,
    • with flexible configurable intervals with no current,
  • protection filters for thyristor module,
  • reduced noise emission to power supply network,
  • digital system for elimination of the DC component,
  • galvanic separated inputs and outputs for protection against damage.

We have made a number of successful modernization of linear resistance welding machines made by different manufacturers. The high quality of our thyristor resistance welding power and time controller is proved by our satisfied customers, who come back after years, to order modernization of next welding machines in their factories.

EXPERT ADVICE: Individual parameters for the three phases of welding

Offered thyristor resistance welding power and time controller for linear welding machines allows to set individual parameters for the three phases of welding - initial, middle and final. Typically, the initial and final phase of the resistance welding are a few millimeters long, while the middle phase comprises the remainder of the item. Possibility to set other welding currents in the initial phase and the final phase than in the middle has a number of advantages. It reduces shunt effect and in consequence makes it possible to obtain identical weld over the entire length (this is particularly important in the production of cans, where burn at the edges will result in leaking of the liquid from inside of a can). It allows to increase the strength of the welded seam on the edges of the item, which is important for further mechanical processing, where the material is subjected to large forces (e.g. production of air ducts).

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Linear welding machine control system

Linear welding machine control system, system sterowania zgrzewarką liniową, automatyzacja zgrzewarek liniowychWe offer comprehensive automation of linear welding machines producing air ducts, cans and many other kinds of items.

Offered control system is ideal for upgrading old linear resistance welding machines. It offers high reliability thanks to the use of modern branded automation components, as well as replacing unreliable electromechanical sensors with inductive sensors.

Characteristics of the linear welding machines control system:

  • modern system with a PLC,
  • ease of use,
  • control of pneumatically actuated electrode roller,
  • protection of staff thanks to the use of the safety relay,
  • installation of reliable non-contact inductive sensors,
  • protection of motors with motor breakers,
  • automatic mode of operation,
  • manual mode of operation,
  • the ability to turn off or turn on wire feed,
  • the ability to work with two wires (separately for upper and bottom roller),
  • the ability to work with the same wire for the upper and bottom rollers,
  • handling of emergency incidents,
  • optional: colour human-machine interface,
  • optional: variable-frequency drive (adjust of the motor speed).

CASE STUDY: The control system in the factory producing air ducts

Our control system was used to modernize the old type linear resistance welding machine in the factory producing air ducts. Thanks to the use of modern branded industrial automation components and eliminating unreliable electromechanical sensors, we increased reliability. The control system has been designed with ease of use in mind, so training of staff did not last long. The use of linear welding machine for the production of air ducts has a number of advantages over previously used spot welder. Obvious benefit is to accelerate the production process. Moreover, linear weld extending the full length of the item, so the seam has greater strength than welds made only on certain points with spot welder.

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