CNC/Full automatic stud welding system Series V

The fully automatic series V stud welding machines warrant a maximum of precision and reliability through their robust construction and the use of high-value components. The available working areas as well as numerous possible option enable the customer-specific design of the machines.

• working area X/Y: 1000 x 2000 mm, 1250 x 2500 mm or 1500 x 3000 mm (Other dimensions upon request as special production.)
  The entire working area can be reached by each welding head.
• welding range
  stud diameter 3-8 mm, stud length 6-50 mm (Other diameters and lengths as well as special welding elements upon request as special production.)
• max. number of stud welding heads: 4
  (The machine concept is designed for four working stations. If a milling unit is used at the most three stud welding heads can be mounted.)
• max. operating speed of the X-/Y-axis: 30 m/min
• positioning accuracy of the welded studs: +/- 0,2 mm
• Fast and easy programming by operating software i1stud.
  i1stud enables - besides programming directly on the machine - entering the welding coordinates on an external PC. Thus idle times by programming on the machine can be avoided.
  optional: operating software i3stud (inkl. DXF data converter) with operating terminal with industrial panel PC
  (DXF data import: The customer-specific DXF-data are automatically converted and transfered to the controller. Visualization of the program sequence.)
• ample program memory
• mobile operating panel
• very easy operation
• welding parameter monitoring and documentation (by stud welding units PRO-D/PRO-C)
  - recording of welding current, welding time and arc voltage for each weld
  - recording of stud travel (lift, piston runtime, immersion depth) for each weld [only when an automatic welding head with travel measuring system is used]
  - comparison of the recorded welding parameters (actual values) to the parameters of a reference weld (set values) (tolerances adjustable)
  - in case of variances to the reference weld a warning is displayed or the unit is locked for further welds until the release by the operator (functionality can be switched off)
  - storage of the last ten welding parameter sets
  - optional (also retrofitable): welding parameter memory for the storage of 24500 welding parameter sets (storage with date and time) with USB-interface for data transmission (welding parameter sets) to a PC
  - optional (also retrofitable): PRO-xDataLog
  The software PRO-xDataLog enables - besides reading out the welding parameter memory - the real-time transmission (Live Logging) of the welding parameter sets recorded by the stud welding unit to a PC that is connected to the stud welding unit. Immediately after each weld the welding parameter set (with date and time) that is recorded by the unit is written into a file on the connected PC. There the data can be analyzed (e.g. by MS Excel) and stored.
• automatic stud feeding
• very good accessibility of the machine
• flexible positioning of the pneumatic clamps on the machine table
• short set-up and retooling times
• quick change system for welding heads
• free zero points (zero point shift)
• re-weld function with program continuation
• optional protection devices:
  - light curtain
  - safety fence
• high processing speed due to dynamic servo motors
• premium axes with high-precision guides and threaded spindle or belt drive warrant a maximum of precision and reliability
• inside slide mountings with cover bands avoid damages to the drive caused by welding spatters, smoke and dust
• very robust and warp resistant welded steel machine frame
• machine table made from aluminium T-grooved plates with laminated fabric plates for electrical insulation and as wear protection
• stop bars (150 mm behind the X- and the Y-zero point) facilitate the setting up of the variable stop positions
• pneumatic working lift/welding head 80 mm (mechanic adjusting range through precision crank handle 40 mm)
• The machines are suitable for all stud welding methods.
  The following stud welding units and automatic stud welding heads can be used:
  PRO-C 1000/1500 = stud welding units for capacitor discharge stud welding (contact and gap method)
  PRO-D 1200/1600 = stud welding units for drawn arc and short cycle stud welding
  KHA-200F with integrated travel measuring system = automatic stud welding head for capacitor discharge (gap and contact method), drawn arc and short cycle stud welding
  KKA-200F = automatic stud welding head for capacitor discharge stud welding (contact method)
• connection values
  electrical (mains supply, mains fuse external): 400 V/50 Hz, 16A
  pneumatical: ≥ 6 bar, unoiled, dry, clean

OPTIONS:

• servo motor-driven Z-axis 300 mm for the exact and fast positioning on different levels
• fluid spraying device for targeted wetting of the welding point before welding for each welding head
• milling unit with exhaust device for targeted removal of problematic surface layers at the welding point
• pneumatic single stud feeding, manual stud insertion (e.g. for feeding special studs (special geometries, overlong studs))
• stud switch for feeding studs with the same diameter but different lengths into one welding head
• pneumatic mass clamps standard
• pneumatic mass clamps aperture angle 90°
• mechanic mass clamps mounted on welding head
• pneumatic mass clamps mounted on welding head
• workpiece downholder for each welding head
• shielding gas module for each welding head
• multidirectional balls table