160kVA Precise Control Automated Spot Welder Intermediate Frequency Inverter DC Spot Welding Device for Aluminum Automobile Manufacturing

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.

 

 

Product Parameters

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

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

Packaging & Shipping

Our team

Patent certificate

FAQ

1,How are the electrodes of the spot welding machine maintained and replaced during the welding process?

Answer: The electrodes of the spot welding machine gradually wear during use, so they need to be checked and maintained regularly. When electrode wear is severe, new electrodes should be replaced promptly. When replacing electrodes, choose suitable electrode materials and specifications and follow the correct installation and adjustment procedures outlined in the equipment manual. Additionally, regular cleaning and polishing of electrodes can extend their service life.

2,Does the spot welding machine have energy-saving features?

Answer: Yes, our spot welding machine has energy-saving features. The equipment automatically enters a low-power mode when idle or not in use, reducing energy consumption. Additionally, we utilize an efficient power management system to ensure optimal energy utilization during the welding process.

3,How to control noise generated during the welding process of the spot welding machine?

Answer: Noise generated during the welding process of the spot welding machine mainly comes from the contact between the electrode and the workpiece and the vibration generated when the current passes through. To control noise, the following measures can be taken: Firstly, choose welding equipment and power supply systems with low noise to reduce noise generation sources. Secondly, arrange the work area reasonably, placing the welding equipment in a place with good sound insulation to reduce noise transmission. Additionally, operators can wear noise-canceling earplugs or earmuffs to protect hearing health.

4,How is the accuracy and stability of the spot welding machine ensured?

Answer: Our spot welding machine adopts advanced control systems and precise mechanical transmission mechanisms to ensure welding process accuracy and stability. During the manufacturing process, we strictly adhere to quality control standards and conduct rigorous quality inspections to ensure the equipment's stability and reliability.

5,What should be paid attention to when the spot welding machine welds thin sheet materials?

Answer: When welding thin sheet materials, the spot welding machine needs to pay special attention to controlling the welding pressure and welding time to avoid over-welding, which may cause material deformation or burn-through. It is recommended to use smaller welding currents and shorter welding times, and adjust the welding pressure appropriately to achieve good welding results.

6,Does the spot welding machine support counting function?

Answer: Yes, our advanced models of spot welding machines support real-time counting function, allowing users to better calculate the length of work and whether workpieces are missed welds.

7,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.

8,How is the welding speed of the spot welding machine adjusted?

Answer: The welding speed of the spot welding machine can be adjusted by adjusting welding parameters and control systems. By increasing or decreasing parameters such as welding current, welding time, and welding pressure, you can control the welding speed to adapt to different welding requirements.