Product Specification

Ac Dc Projection Resistance Welding Machine Copper Wire Spot Aluminum Welding

Product Overview

This stationary projection resistance welding unit is engineered for manufacturers who require dependable joining of low-carbon steel, stainless steel, coated sheets, and select non-ferrous materials. It performs spot welding of thin-gauge panels, projection welding of fasteners such as nuts and bolts onto flat surfaces, and secure attachment of wire mesh to structural components, making it a flexible asset on a mixed-production floor.

The system follows a fixed-machine, moving-workpiece layout that simplifies material handling and supports integration into semi-automated cells. With forced water cooling, programmable weld schedules, and a robust pressurization frame, this equipment reduces cycle time while keeping nugget quality consistent across high-volume runs. When configured for copper wire applications, it enables repeated, low-resistance joints that hold up under continuous production demands.

Key Technical Advantages

Stable Pressurization with Auxiliary Stroke

The electrode descends in a two-stage motion that closes contact gently before applying full force. This reduces electrode bounce, keeps current path stable, and delivers more uniform nuggets even when welding copper wire or multiple stacked layers.

High-Permeability Transformer Core

Silicon steel laminations with high magnetic permeability, combined with an internal water-circulation jacket, allow sustained output at a 50% duty cycle. The design supports heavy continuous use without thermal derating, which is critical for high-conductivity materials like aluminum and copper.

Microcomputer-Controlled Program Memory

Up to 16 weld schedules can be stored and recalled instantly. Operators switch between stainless steel, coated stock, and copper wire joints without manual recalibration, cutting setup time and reducing operator-dependent variation.

Rigid Frame for Continuous Duty

The welded steel body keeps electrode alignment stable over long shifts, preventing side deflection under electrode force up to 15,000 N. This mechanical rigidity preserves joint geometry on thicker projection welding tasks.

Wide Model Range for Capacity Scaling

Four rated-power options from 100 to 250 KVA let a facility match the unit to its actual workload. Smaller shops avoid over-specifying, while larger plants can push weld capacity up to 6.0 + 6.0 mm mild steel with the 250 KVA frame.

Applications

Working Principle

Technical Specifications

After-Sales and Support

• 12-Month Warranty — Full coverage on the main frame, transformer, and electrical control system against manufacturing defects, with rapid spare-part dispatch from our warehouse.
• Application Engineering Consultation — Our team reviews your sample material, joint geometry, and production rate to recommend electrode contours and the correct program settings before you order.
• Remote Troubleshooting — Video-based diagnostics through WhatsApp or email to help your maintenance staff solve electrical or pneumatic issues without a site visit.
• Spare-Part Kit Included — Every machine ships with common consumables and wear items so commissioning and early operation are not interrupted by local sourcing delays.
• English Documentation Pack — Operation manual, hydraulic/pneumatic diagrams, and electrical schematics in English are provided with the equipment to simplify local maintenance.

Frequently Asked Questions

Can this machine weld copper wire to a copper terminal reliably?

Yes. When configured as a copper wire welding machine, the transformer and electrode pressure are tuned to deliver the higher current and shorter weld time that copper requires. The water-cooled secondary circuit prevents overheating during repeated copper-to-copper joints, and the programmable controller holds the heat balance consistent across a production batch.

What is the difference between the auxiliary stroke and the main working stroke?

The auxiliary stroke brings the electrode down rapidly to just above the part surface without impact, then the machine switches to the slower main stroke that applies the full welding force. This two-phase pressurization avoids electrode bounce and hammering, which is especially important when setting a nut or stud onto a sheet for projection welding.

Will power fluctuation affect weld quality on a 3-phase 380V supply?

The microcomputer controller monitors weld current timing, but the unit is designed for a stable 3-phase supply. For plants with frequent voltage swings, we recommend adding a line stabilizer to keep the KVA output consistent. The controller's programmable current step allows compensation for minor fluctuations.

Which model should I choose for welding 2mm aluminum sheets?

For sheet metal up to about 2mm on aluminum or its alloys, the DN(B)-160 offers sufficient short-circuit current (35 KA) with a manageable electrode force of 6000 N. If your application also includes thicker steel sections or projection-welded fasteners above 2mm, consider the DN(B)-200 for additional headroom.

Can the machine be integrated into an automated production line?

Yes. The fixed-machine, moving-workpiece layout plus external control signals permits integration with rotary index tables, pneumatic slides, or robotic part handling. We can supply a PLC interface option to trigger welding via external input and provide feedback on cycle completion.

Request Your Welding Solution

Original Product Images For Review