2.5+2.5mm Modular Multi-Functionality Heavy Duty Spot Welder Intermediate Frequency Inverter DC Spot Welding Device for Iron Hardware

Product Description

 

Product Description

 

PDKJ, BORN FOR METAL WELDIN

High Power ▪ Intermediate Frequency ▪ DC output current

Intermediate Frequency Inverter DC Spot (Convex) Welder
DTB-80  DTB-160  DTB-240  DTB-280  DTB-340  DTB-450

Energy saving, power saving, high efficiency, low operating cost, and high welding quality.

Product overview: The medium frequency inverter DC spot welding machine converts the power frequency (50Hz) AC to the medium frequency (1000Hz) DC output. The time resolution is higher than that of the power frequency, the control accuracy is also improved, and the output current is not affected by the change of the secondary output circuit. It has high thermal efficiency, large output power rate and better welding quality. Compared with the traditional power frequency welding machine, inverter medium frequency DC welding will be efficient and energy-saving. It is a technological revolution breakthrough in the field of resistance welding.
 

Welding Advantages of PDKJ Intermediate Frequency Inverter DC Spot Welder

1. Easy to operate
No skill training required, easy to operate, and easy to master for beginners.

2. Design life 20 years
It is designed for the lifespan of 20 years, with over 100000 hours of intensive work and aging testing in industrial laboratories.

3. Good quality
The surface of the welding spot has few oxidation and deformation, even without any marks, and the welding is firm and has good quality.

4.Widely used
Metal cabinets, automotive components, fasteners, electronic components, instruments and meters, battery spot welding, hardware spot welding, electrical switches, terminal wires, wire mesh, mesh baskets, etc.

5. Fast welding speed
High power, fast dotting speed, short time consumption, high welding efficiency.

6.  Customized
Can be customized fixtures, electrode arms, electrode holders, and electrode heads of different sizes for different product work-pieces, and can customize highly automated welding equipment and production lines.

 

Question 1: What should be considered when using a medium-frequency inverter DC spot welder for welding enclosures?

When employing a medium-frequency inverter DC spot welder for welding enclosures, the following factors should be taken into account:

• Material Compatibility: Ensure that the welder is suitable for the specific alloy composition and thickness of the enclosure material, as different aluminum alloys may require distinct welding parameters.
• Preparation: Thoroughly clean and degrease the surfaces to be welded, removing any oxide layers or contaminants that could compromise weld quality. Proper edge preparation, such as chamfering or V-grooving, may also be necessary.

• Question 2: What welding process is typically used for enclosures?

  The most commonly employed welding processes for enclosures include:

• Tungsten Inert Gas (TIG) Welding: Provides excellent control over heat input, making it suitable for thin and delicate aluminum components, as well as for producing aesthetically pleasing, high-quality welds.
• Gas Metal Arc Welding (GMAW/MIG): Offers higher deposition rates and is more suitable for thicker materials or higher-volume production, particularly when using pulse welding modes for better control over heat input and spatter reduction.
• Friction Stir Welding (FSW): A solid-state joining process ideal for large, thick-section aluminum enclosures, as it produces strong, defect-free joints with minimal distortion and no need for filler material.

 

Product Parameters

Parameters of PDKJ Intermediate Frequency Inverter DC Spot Welder (1)
 

parameter	DTB-160	DTB-240	DTB-280
Rated capacity	160KVA	240KVA	280KVA
Input power	3 φ 380V	3 φ 380V	3 φ 380V
short-circuit current	35KA	50KA	65KA
Load duration	20%	20%	20%
control mode	Primary / secondary constant current	Primary / secondary constant current	Primary / secondary constant current
Inverter frequency	1000HZ	1000HZ	1000HZ
Arm extension size	500 × 350mm	500 × 350mm	500 × 350mm
press	6000N	12000N	12000N
Electrode stroke	80mm	100mm	100mm
Cooling water flow	12L/min	14L/min	14L/min
Welding capacity /Al. plate	2.5+2.5mm	3.0+3.0mm	3.5+3.5mm
Welding capacity / carbon steel	3.0+3.0mm	4.0+4.0mm	4.5+4.5mm
Electrode arm size	φ 59x173mm	φ 74x195mm	φ 74x195mm
Electrode holder size	φ 24.6 × 180mm	φ 31.6 × 250mm	φ 31.6 × 250mm
Electrode head size	φ 16x50mm	φ 20x60mm	φ 20x60mm
weight	384kg	733kg	820kg
Overall dimension	1180*750*1830mm	1205*870*2140mm	1205*870*2140mm

Detailed Photos

Characteristics of PDKJ Intermediate Frequency Inverter DC Spot Welder 
 

1. PDKJ MFDC Controller
The intermediate frequency welding controller and current closed-loop control can control the actual welding current at high speed. The output current is DC, and the current is smooth, the inductance reactance is zero. The working frequency is 1000Hz, and the time control accuracy is 1ms. The welding program can achieve multiple welding functions such as preheating, welding, and tempering to achieve complex welding functions. Humanized design, can save multiple welding presets.
 

2.LCD touch screen
The interface is simple and beautiful, and the operation is simple. Multi language switching between Chinese and English, with clear welding parameters at a glance. Cooperate with preset functions to achieve fast welding.
 

3. Water cooling circulation system
Transparent and intuitive water flow meter for easy observation and adjustment of cooling water flow. PDKJ customized anti-corrosion and anti-aging soft water pipes have a long service life and prevent water leakage accidents. Stable and appropriate temperature can improve welding quality and speed.
 

4. Thickened and stable body design
The body is designed with a high-strength thickened steel plate mechanical structure, which is stable and rigid, ensuring that the body does not vibrate during welding, and large welded work-pieces do not shake. The high-strength corrosion-resistant nano coating body can ensure machine quality and ultra long service life. And it won the Red Dot, known as the "beautiful spot welder".
 

5. Pure copper transformer
The transformer of PDKJ is made of pure copper for both primary and secondary poles, with a high conductivity magnetic core and high-quality epoxy resin poured inside. It has good insulation performance and stable performance, and is packaged in a stainless steel shell, with a compact and beautiful appearance. The rectifier component adopts high-power ABB diodes, with stable performance and high efficiency, making it the most reliable heart of PDKJ spot welding machine.
 

6. Precision and flexible welding platform
The welding platform adopts high conductivity brass material with the copper content of  85%, integrated electrode voltage mechanism, short gas path, compact structure, fast reaction speed, and more convenient installation and maintenance. The stroke between electrodes is adjustable, which can greatly improve the welding speed. Internally, it adopts water-cooled circulation for heat dissipation, and can quickly replace welding fixtures and electrode heads.
 

7. R&D Pneumatic system
The seventh generation pressure stabilizing cylinder developed specifically for welding has fast response speed, high pressure resistance, and long service life, meeting the needs of high-speed welding. The cylinder directional valve adopts SMC/Airtag triple body, with fast response speed and large flow rate, meeting the requirements of high-speed management.
 

8. Safe and reliable circuit system
The body comes with an LS air switch, and the circuit design fully complies with the humidity breakdown voltage standard for electrical equipment air gaps. The body is equipped with an emergency stop button. All electrical designs strictly comply with safety standards from China, the European Union, and North America.
 

 
Cooling component of spot welding machine
 

Stainless steel water tank and water pump (optional)

Large capacity water tank, stainless steel shell for heat dissipation, combined with high-power water pump, using room temperature water circulation cooling. This standard cooling component can meet welding operations with general strength. Maintaining the spot welding machine at the optimal working temperature can improve welding quality and accuracy, and extend the service life of the machine. It's recommended to use spot projection welding machine with power less than 160KVA  for optional.

When the temperature is below 0ºC, please use antifreeze.
 

 

Industrial grade chiller (optional)

1.Vertical top air outlet design, easy installation and maintenance.
2.High quality brand refrigeration components, with a control accuracy of ± 1.0 ºC to ± 3.0 ºC;
3.Stainless steel multi-stage centrifugal pump and stainless steel water tank, PVC connection material, no worry of rust;
4.Multiple alarm protection functions and providing passive signal output;
5.Independently developed and produced bilingual intelligent temperature controllers in Chinese and English, with various settings and fault prompt functions, making operation simple and convenient;
6.The pure water filtration protection device ensures the safe operation of the equipment;

This advanced cooling component can meet ultra-high strength welding work. Maintaining the spot welding machine at the optimal working temperature can improve welding quality and accuracy, and extend the service life of the machine. It's recommended to use 170KVA spot projection welding machine for optional.

When the temperature is below 0 ºC, please use antifreeze.

 

Welding Automation and Non-standard Customized welding equipment

Since its establishment 18 years ago, PDKJ has designed and completed numerous cases of welding automation and production lines. It is a leading enterprise in automation technology in Dongguan, focusing on automatic welding in the fields of laser welding and Electric resistance welding. More than 3000 high-end users around the world have witnessed the common use.

  

Part of classic automation cases of PDKJ:

Anzhao Oil Heater Production Line, BYD Copper Wire Terminal Welding Machine, Leite Automobile Radiator Aluminum Parts Spot Welding Machine, Feng's Wire Mesh Welding Machine, Hettich Slide Rail Welding Machine, Qixin Side Furnace Medium Frequency Welding Machine, Huayangtong Door Plate Code Reinforcement Welding Machine, CRRC Copper Wire Welding Machine, Chongqing Linglong Small Chassis Automation Welding Machine, Nanjing Qiangli Laser Automation Production Line, etc.

Usage on site

Q1: What should be considered when using a vertical spot welder to weld enclosures?

Answer: When using a vertical spot welder for welding enclosures, consider the following:

• Joint design: Optimize the joint configuration (e.g., lap, butt, or T-joint) and geometry to facilitate efficient heat transfer and minimize distortion.
• Welding parameters: Precisely set the welding current, time, and force based on the material properties, thickness, and joint design.

Q2: What welding processes are suitable for welding enclosures?

Answer: Suitable welding processes for welding enclosures include:

• Seam welding (SW): A continuous version of RSW, used for longer, linear welds on enclosures, providing high-speed, automated joining.
• Projection welding (PW): Uses specially formed projections on one or both parts to concentrate the welding current, creating strong, consistent welds with minimal heat-affected zones.

Packaging & Shipping

Our team

Patent certificate

FAQ

1,What precautions should be taken during transportation and installation of the spot welding machine?

Answer: During transportation, please ensure that the spot welding machine is properly packaged and secured to prevent collisions or damage during transit. During installation, please follow the instructions in the product manual to ensure the correct installation location and wiring of the equipment. If necessary, we can provide installation guidance and technical support to ensure the equipment's normal use.

2,Does the spot welding machine have an energy-saving mode or sleep function?

Answer: Yes, some advanced models of spot welding machines are equipped with energy-saving mode or sleep function. When the equipment is idle or not in use for a long time, the energy-saving mode can automatically reduce the power consumption of the equipment to achieve energy saving. The sleep function can automatically enter a low-power state after a period of idle time, further reducing energy consumption. These functions help reduce energy waste and operating costs.


3,Does the spot welding machine require cooling during the welding process?

Answer: Yes, during continuous high-intensity welding, the spot welding machine generates a certain amount of heat. To ensure equipment stability and prolong its service life, it is typically equipped with a cooling system. The cooling system can effectively reduce equipment temperature through methods such as circulating cooling water or fan cooling.

4,How to maintain and upkeep the spot welding machine after prolonged use?

Answer: After prolonged use, the spot welding machine requires regular maintenance and upkeep to ensure normal operation and prolong its lifespan. Firstly, clean the exterior and interior of the equipment regularly to remove dust and dirt. Secondly, check the wear condition of the welding electrodes and replace severely worn electrodes promptly. Additionally, inspect the power lines and control systems for proper operation, and repair any abnormalities promptly. Simultaneously, lubricate and fasten the equipment regularly to ensure stability and accuracy.

5,
How does the spot welding machine adapt to the welding requirements of different materials?

Answer: The spot welding machine can adapt to the welding requirements of different materials by adjusting welding parameters and selecting appropriate welding electrodes. Since different materials have different thermal conductivity, melting points, etc., parameter adjustments need to be made according to the material characteristics. Our spot welding machine has flexible parameter setting functions, allowing customization adjustments based on the specific requirements of customers to meet the welding requirements of different materials.


6,What should I do if my machine is damaged during the warranty period?
Answer: First, our engineers will assist you in diagnosing the issue through online guidance. If any parts are damaged during the warranty period, we will ship the parts to you for replacement free of charge. If you are unable to resolve the issue by replacing new parts, we will dispatch engineers to your factory to assist in repairing the machine.
For foreign users, we prioritize solving problems for you through remote phone and video calls. Over the past decade, almost all issues have been successfully resolved through remote phone and video calls. If part replacement is necessary, it will be done through express delivery, with remote guidance for installation.
If the problem still cannot be resolved, we will negotiate and dispatch after-sales engineers to your location for repairs.

7,What are the dimensions and weight of the spot welding machine? Is it convenient for transportation and installation?

Answer: The dimensions and weight of the spot welding machine vary depending on the model. During the design and production process, we fully consider the convenience of equipment transportation and installation. The equipment has a compact structure and is lightweight, making it easy for you to transport and install. Furthermore, we provide detailed installation guides and technical support to ensure you can easily complete the installation process.


8,How is quality inspection carried out after welding on the spot welding machine?

Answer: Quality inspection after welding on the spot welding machine mainly includes visual inspection, destructive testing, and non-destructive testing. Visual inspection mainly observes the appearance quality of the weld, such as whether the weld is smooth and free of cracks, etc. Destructive testing involves mechanical property tests such as tensile and bending tests conducted on samples to evaluate the strength of the weld. Non-destructive testing includes methods such as X-ray inspection and ultrasonic testing to detect defects inside the weld. Select appropriate testing methods for quality inspection based on specific requirements and industry standards.