Basic Configuration of Resistance Welder and Role of Each Part

Resistance welder sandwiches an object to be welded by the welding electrodes,
andapplies electric current while applying a pressure.

Photo:Basic Configuration of Resistance Welder and Role of Each Part.

Resistance Welding Model, Temperature Distribution at the Welding

Image:Resistance Welding Model, Temperature Distribution at the Welding

Welding Power Supply: Control Method

An appropriate welding power supply must be selected based on the material or shape of the object to be welded and the required welding quality.There are five different types in our welding power supplies based on the type of control of the welding current, and each type is selected in a way to best demonstrate its characteristic in welding.

Basic System Welding Current Wave Form Feature
Inverter Type
Photo:Inverter Type Basic System
Image:Inverter Type Welding Current Wave Form AC current is rectified into DC current. Because of high frequency, heat efficiency is good and suitable to precision welding. Furthermore, stable welding quality can be expected because of the electric current and voltage feedback control. As high speed repetitive welding can be made, it is suitable for use in automated systems.
Transistor Type
Photo:Transistor Type Basic System
Image:Transistor Type Welding Current Wave Form Electric current is directly controlled by a transistor. Because the control speed is fast and the waveform can be controlled, it is suitable to ultra high precision welding of very small components or extremely ne wires. Stable welding quality can be obtained by the electric current and voltage feedback control.
Hybrid (DC + Inverter) Type
Photo:Hybrid Type Type Basic System
Image:Hybrid Type Welding Current Wave Form Polarity of a large current is switched in high speed by a power transistor. It is called hybrid type because it has a high speed feature of DC and polarity switching feature of AC power supplies. It is suitable for welding of battery tabs where different types of metal are series welded.
Capacitor(DC)Type
Photo:Capacitor(DC)Type Type Basic System
Image:Capacitor(DC)Type Welding Current Wave Form Electric is charged into a capacitor and discharged at once. Because a large current can be applied, it is used for material which has good heat dissipation characteristic and difficult to weld, such as aluminum or copper. Furthermore, because of the short welding duration, heat impact is minimized, and as a result, it is suitable for welding of small components.
Single Phase(AC)Type
Photo:Single Phase(AC)Type Type Basic System
Image:Single Phase(AC)Type Welding Current Wave Form Welding current is controlled by a thyristor. Because the welding duration can be made long, it has a broad application, and it is suitable to a material which is relatively easy to weld, such as iron.

Welding Power Supply: Welding Current Capacity

After the consideration for control method, select a suitable welding power supply having the appropriate current carrying capacity depending on the size and thickness of the object to be welded.

Image:Welding Power Supply: Welding Current Capacity

Welding Head & Electrode

How the electrode contacts the object to be welded (how to apply the current) is determined by the shape or structure of the object. Furthermore, shape and material of the electrode and the applied pressure are also important factors in resistance welding.

Photo:Welding Head & Electrode

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