Resistance welding is very common in industry. It is robust and is very suitable for automation. Correctly, the process is called resistance pressure welding. The heat required for welding two parts is generated by means of resistance heating using electric current. The welding current required for this is between a few hundred amperes and several hundred kilo amperes, depending on the component size and application. The welding current is transferred to the components by electrodes. These are pressed onto the components to be welded. The pressing force prevents the electrodes from lifting off and an arc. The trick is to control and regulate the welding current and the force with which the components to be welded are pressed against each other at the welding spot in such a way that a welded joint of the desired quality is created.
HIE welding controls do just that.
Spot Welding
Spot welding is the most widely used resistance welding process. The best-known applications can be found in car body construction. In modern vehicles there are up to 5000 welding spots in a car body. Spot welding is also used in many other products that use thin sheet metal. Modern high-strength steels, surface coatings and lightweight materials, such as aluminium, place high demands on the welding equipment.
HIE welding controls control, regulate and monitor the quality-determining process parameters in such a way that a welding spot of the required quality is created.
Projection welding
In Projection welding, the current concentration does not take place via the electrode shape, as in spot or roller seam welding, but via the design of the contact point between the components to be joined. Most of them are hump-shaped. Hence the name of the procedure. A typical application is the welding of nuts. Annular components can be welded with a current pulse in one go without distortion. Welding currents of several 10,000 kA are not uncommon for projection welding. The welding current is introduced within a few milliseconds. The hump melts when the welding current begins. The electrodes must be quickly adjusted so that there are no splashes.
HIE welding controls not only control, regulate and monitor the current pulse, but also simultaneously record the electrode movement and the electrode force. Important process parameters for the quality assessment of a projection weld.
Seam welding
Seam welding is practically a series of individual welding spots. It is used when welding thin sheets. The work pieces to be welded are passed between two counter-rotating disc-shaped copper electrodes. At the contact point, the welding current flows through the work pieces to be welded in concentrated form. At the same time, the individual work pieces are pressed together. This creates a continuous sequence of welding spots. The rotation speed of the rollers is adjustable. Depending on the requirements, quilting seams or sealing seams can be created. Washing machine drums, dishwashers, sinks, fuel tanks, chimney pipes and much more is produced with this very easily automated welding process.
HIE welding controls take over the control, regulation and monitoring of all quality-determining process parameters.
Direct conductive heating
In the case of direct conductive heating, a high current is conducted directly through the work piece to be heated. The physical is the same as with resistance welding, except that the temperature is usually well below the melting temperature. Pre- and post-treatment of welded components are typical areas of application. The heating takes place evenly over the entire cross-section of the component through which the electrical current flows. This is not so easily possible with other heating methods.
With HIE welding controls, heat inputl can be controlled, regulated and monitored very precisely via the current.
Special applications
In addition to the standard procedures, there are a large number of variants and combinations. HIE welding controls are modular. We can cover almost any combination of processes. Do you have a special application? We show you what is possible.
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