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Series V Stud welding CNC

Technical Data

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 three 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 30M/min
Positioning accuracy of welded studs +/-0.2mm
Fast and easy programming using i1stud software 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 (via PRO-C/PRO-D stud welding units - recording of weld current, weld time and arc voltage for each weld
- recording of stud travel (Lift, piston runtime, immersion depth) for each weld (only when an automatic weld 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
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 servo motors  
premium axes with high-precision guides and threaded spindle maximum precision and reliability
inside slide mountings with sealing bands avoid damage 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 (behind the X and the Y zero point) facilitate the setting up of the variable stop positions
pneumatic working lift/welding head 80mm Mechanical adjustment range through precision crank handle 40mm
The machine is 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 electrical (mains supply, mains fuse external): 230/240V/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 the 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°
  • mechanical mass clamps mounted on welding head
  • pneumatic mass clamps mounted on welding head
  • workpiece downholder for the welding head
  • shielding gas module for the welding head
  • multidirectional balls table