Apart from electrical energy, which usually corresponds to only about 20% of the usual amount of resistance welding, no other consumables are needed. Even cooling of the welding transformer and / or the electrodes can normally be dispensed with.

Only the electrodes, which in any case have extremely long service lives when the machine is correctly adjusted, must be reworked or replaced depending on the load.

The amount of material to be welded determines the size of the system. The more energy you need, the higher the basic investment. Making a statement without knowing the welding task does not make sense.

The running costs are extremely low, since very little energy is consumed, no high grid connection values ​​are required, consumables are eliminated and the machine can operate at a very high cycle rate.

In addition, in most cases, both a pre-treatment and aftertreatment of the parts to be welded can be relinquished with. That means less staff!

Since there are hardly any moving parts on such a device apart from the movable top electrode, a service life of over 10 years is quite common.

As an example, we have a letter of thanks from one of our customers confirming that they have made more than 50 million good parts in 13 years with a CDWM12000 machine. The machine has run in 3-shift operation 7 days a week, without failure.

The recharge time of the capacitors after welding is 1-3 s depending on the size of the machine. This time also defines the theoretical cycle time. However, in most cases, the actual cycle time is determined by the times spent feeding, positioning, and unloading the parts. The production speed of the system thus depends essentially on the device. Depending on the size of the machine, a clock rate of between 15 and 30 welds per minute for initial calculations can be assumed as the value that can be realized in practice.

Apart from an assembly control, which monitors the presence of the parts to be welded, the so-called “Einsinkweg” is measured at each individual weld. This is the way to go when the softened metal is compressed during welding. Together with an additional current measurement at the welding point and the control that both values are in a previously defined tolerance field, a clear distinction can be made between good and bad parts.

The machine has an automatic interface to which a higher-level system can be connected. With the welding parameters stored in the block for an individual welding task and a suitable device, the system is naturally suitable for integration into a fully automatic production line.

Basically all conductive metals, although the material composition of the parts to be welded and the material combinations – if the parts are not made of the same material, significantly affect the welding result. Conductivity, melting behavior, degree of hardness and the proportion of non-metallic substances are only some of the parameters that play a role. A clear statement can only be made after a detailed report of the material composition of the substances to be welded.

The amount of material to be welded determines the energy requirement, so today’s limit is reached when a peak current of about 600,000 A is no longer sufficient for an acceptable welding result. Of course, the requirements for the welded joint determine the maximum size. For rotationally symmetric parts, the following guideline values apply for easily weldable material and using ring humps:

Normal stressed connection: approx. 100mm diameter

Liquid and gas-tight connection: approx. 80mm diameter.

Since pulse welding is a hump welding method, the type and size of the hump(s) must be specified. In addition, care must be taken, that the parts have as possible as no fluctuations in their geometric dimensions but also in their material compositions. With this method, it is possible to maintain the tolerances of the parts to be welded largely after the welding.