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Frequently Asked Questions
What is the price for such a welding system? The price of an Impulse Welder depends on the welding task and the material volume that has to be joined. The material volume determines the weld energy and the weld pressure. We offer standard machines with an energy capacity of 500 Joule to 56,000 Joule at price range of € 10.000,00 to € 300.000,00
How high are the operating costs? The machine only requires electrical energy, which will be approx. only 20 % of a resistance welding machine and compressed air (app.100PSI). Furthermore there is no requirement for water-cooling of the transformers or electrodes. Only the electrodes themselves, which have a very long lifetime if they are adjusted correctly, need to be overhauled or replaced according to the welding frequency used. Maintenance consists of lubricating the weld cylinder, replacement of set down springs and air filters.
How to justify the relatively high investment? The operating costs are very economical, as the electric energy consumption is low and no additional supplies such as gases, vacuum etc are needed. The machines operate at a low cycle time of 3 seconds/part (high throughput) and up depending on the load/ unload time required. The load/unload time depends on the parts and fixturing. We can offer manual to fully NC controlled automatic loading fixtures that are fully integrated to the welder. An additional cost saving factor is the quality of the weld that makes parts treatment after welding unnecessary in most cases which saves time and labour cost.
What is the lifetime of such a welding machine? There is only one moving part in the machine, which is the cylinder with the upper electrode. With good maintenance lifetime expectancy is 15 years and longer. One example is a certificate received from a customer, certifying, that an IMPULSA 12.000 was running for 13 years, and made about 50 million welds during 7 days a week and 3 shifts without interruption during this period.
What QC supervision is provided? The most reliable QC test is the measurement of the so-called Set Down Value (0.001mm). The set-down is the distance that the parts travel from the point where the weld pressure has been applied (cold status) and the energy discharge when the material heats up and is joined. In addition the weld current that flows between the 2 parts is also measured and recorded. The data are stored in the on board computer and can be retrieved at any time. A tolerance band can be established that will indicate in and out of tolerance parts and will stop the machine when bad parts are produced.
What is the welding frequency of such a system? The energy recharge time of the capacitors is 1 to 3 seconds, depending of the size of the machine. The recharge time defines the theoretical cycle time of the machine. However, the production cycle time will be depending on the time needed for loading, positioning and unloading of the parts to be welded. The real production frequency is therefore very much depending on the design of the welding fixture. Practically achieved production rates are about 3 to 15 seconds per weld, depending of the size of the parts and the size of the machine. Can the machines be integrated into automatic production lines? Our machines of all sizes can be integrated into automatic production lines. I/O devices for the machine processor and computer allow the full integration of the welder to outside controllers and safety devices including full NC control. The welding parameters are stored within the onboard computer and can be downloaded.
Which materials are suitable for capacitor discharge welding? All current-conductive metals are suitable in general. However, the contents of different materials in an alloy will influence the quality of a weld. We can only make definitive recommendations after we know the part form, size and material composition of the parts to be welded. What will be the maximum size of the parts to be welded?
The volume of the welding zone decides the energy requirement. Also the
strength and leak tightness requirements of the weld have to be
considered. The current that flows through the intersection between the
parts will heat the welding zone. The maximum current, which can be
produced is approx. 600.000 A.
How to prepare the parts to be welded? Capacitor discharge welding is basically a form of resistance welding. It requires projections on the parts to be joined. In order to maintain good weld quality, it is important that the parts to be joined are mechanically accurate with minimum tolerance variation and that the material compositions are consistent. Note: The machine can only maintain weld quality in regard to dimensional positioning and weld strength that is within the tolerance range of the parts.
Wie teuer ist eine solche Schweissanlage? Die Menge des zu verschweissenden Materials entscheidet über die Anlagengrösse. Je mehr Energie man benötigt, um so höher die Grundinvestition. Eine Aussage zu treffen, ohne die Schweissaufgabe zu kennen, macht somit keinen Sinn. Die Preise für die Grundmaschinen bewegen sich von € 10.000,- bis € 300.000,-
pulse welding gmbh, Am Hasselt 20c, DE 24576 Bad Bramstedt, info@pulsewelding.de |