Energy Efficient Welding of Nuts and Bolts, No Problem with it!

Recently, a famous automobile company approached us with the need to upgrade its welding production line. The main issues encountered in the welding process of this automobile company were as follows:

1. The welding quality of the nuts and bolts is unstable, resulted high product defect rate;

2. The original process utilizes AC welding technology, which is energy intensive and requires a secondary wire return process;

3. The original production line used imported brands, resulted high equipment purchase costs.

In response to the above issues, Heron has developed a comprehensive range of metal joining solutions, introducing the MFDC resistance welding process to replace the original process. This enhancement improves the stability of the welding quality and minimizes the heat-affected zone, thereby resulting in a more beautiful appearance of finished product. Additionally, the implementation of the new process reduces energy consumption during production, leading to significant cost savings in energy input. Furthermore, it reduces the need for secondary processing procedures and enhances production efficiency. 

The proposal utilizes Heron's self-developed MFDC resistance welding standard spot and projection welder. The MFDC resistance welder employs MFDC technology. MFDC resistance welding utilizes a three-phase input power supply, resulting in a significant reduction in size and reactive power loss compared to AC transformers. It also features a rapid rise in current function, stable current output, high precision of constant current, high heating intensity, and good projection welding effect. The 40KA welding current can reach the set value within 3ms, making it particularly suitable for the projection welding processes. 

Our welders have power ratings from 110KVA to 880KVA, maximum short-circuit currents from 24KA to 110KA, an effective weld throat depth of 950mm, and a weld pressure range of 10,000 to 24,000N at 6bar gas. While single stroke cylinders are standard, our welders are also compatible with optional dual cylinders and servo-electric cylinders.

In addition to the automotive industry, our welders find wide applications in the low-voltage electrical industry, compressor industry, motor industry, hardware, and home appliances industry. It is suitable for spot welding, and projection welding, and provides stable weld quality with a beautiful exterior of finished products for non-ferrous metals, high-temperature alloys, low-carbon steel, stainless steel, high-strength steel, galvanized steel, aluminum alloys, and other materials.