PMS DALEX INDUSTRIAL MACHINES CLASS PMS. DALEX Schweißmaschinen GmbH & Co. KG. made in Germany

Transcription

1 PMS DALEX INDUSTRIAL MACHINES CLASS PMS made in Germany DALEX Schweißmaschinen GmbH & Co. KG

2 DALEX INDUSTRIAL WELDING MACHINES The industrial manufacturing requires highest when it concerns capability, quality and reliability of welding machines in use. The DALEX PMS line enables a range of machines to the industry which consistently proves its capability in a wide range of industrial applications. SPECIFICATION The modularity of the PMS line fi nd its application as spot-, projection- and roll seam welding machines in industrial series production. Rated power from 16 up to 630 kva (alternating current), from 60 up to 1200 kva (3-phase-direct current) from 80 up to 1000 kva (medium frequency); Electrode force from 20 up to dan (0,2 150 kn); Maximum welding current up to 300 ka; Modifi cations for individual applications; Optimum cost-performance ratio; Wide range of accessories; Optimum quality and durability; Exclusive high-grade components of well-known brands manufacturers; High-performance transformer self manufactured without thermal problems for shift operation; High performance, robust and modern engineering. MODELS OF PMS A = Spot welding machine with spot welding fitting and foot switch for sport welding B = Combined Spot-Projection welding machine with changeable fittings and key-operated switch for preselection of operation mode. Operation optional by foot switch or 2-hands safety start desk for spot- and projection welding C = Projection welding machine with projection fitting and 2-hands safety start desk for projection welding NL = Longitudinal Seam welding machine with longitudinal welding heads and foot switch NQ = Transversal Seam welding machine with transversal welding heads and foot switch NQ 1 = Transversal seam welding machine with top drive gear NQ 2 = Transversal seam welding machine with bottom drive gear NQ 3 = Transversal Seam welding machine with top and bottom drive gear - 2 -

3 CLASS PMS MODELS OF CYLINDERS SINGLE-STROKE CYLINDER EH Standard equipment for every machine is the single-stroke cylinder. The range of electrode force as well as the stroke are corresponding with the type of machine and the electrical capability. DOUBLE-STROKE CYLINDER DH The piston for the work clearance stroke is fl oating positioned. The operation mode long-stroke can be used on demand. DOUBLE-STROKE CYLINDER WITH ADJUSTMENT-STROKE DHZ The piston for the work clearance stroke is fl oating positioned. The required work clearance stroke can be adjusted by spindle. The operation mode long-stroke can be activated optionally by a switch selector. DOUBLE-STROKE CYLINDER WITH ADJUSTMENT-STROKE AND SEQUENCE SWITCH DHZF The piston for the work clearance stroke is fl oating positioned. The required work clearance stroke can be adjusted continuously by spindle. On this cylinder the reach of the desired position of the work clearance stroke is electrically detected and is used to switch automatically into the work stroke. Likewise a absolutely hit-free and bounce-free placing of the electrode can be achieved. SERVO-MOTOR DRIVEN MODEL SII dan SII dan SII dan - 3 -

4 RANGE OF STANDARD MACHINE PMS 10-6 T PMS 11-6 PMS 10-6 PMS or 100 Nominal Power at 50% duty cycle (kva) 100, 160 or 200 Nominal Power at 50% duty cycle (kva) 16 or 32 Nominal Power at 50% duty cycle (kva) 80 Nominal Power at 50% duty cycle (kva) Throat Length 200, 350 or 550 Throat Length 250, 350, 550 or 750 Throat Length 250, 350, 550, 750 or 1050 Throat Length 250, 350, 550, 750 or 1050 Electrode force (dan) or Electrode force (dan) , or Electrode force (dan) , or Electrode force (dan) , or Stroke max. 65 Stroke max. 65 Stroke max. 90 Stroke max. 100 PMS 16-6 PMS 32-6 PMS 12-6 PMS 36-6 Nominal Power at 50% duty cycle (kva) 200 or 250 Nominal Power at 50% duty cycle (kva) 100, 160 or 200 Nominal Power at 50% duty cycle (kva) 100, 160 or 200 Nominal Power at 50% duty cycle(kva) 160, 200 or 250 Throat Length 350, 550, 750 or1050 Throat Length 350, 550, 750 or 1050 Throat Length 250, 350 or 550 Throat Length 175 or 250 Electrode force (dan) , , or Electrode force (dan) , , , Electrode force (dan) , , , Electrode force (dan) , , , Stroke max. 120 Stroke max. 100 Stroke max. 100 Stroke max. 120 Illustrated machines are in standard frequency. All machines are available in three-phase or medium frequency direct current - 4 -

5 OPTIONAL FEATURES 4-RANGE SELECTOR SWITCH for coarse adjustment of the welding performance installed in attached cabinet MAIN SWITCH according to VDE installed in attached cabinet. FLOW CONTROL INSTRUMENT (water control switch) installed in water feed ARM SUPPORT TURBE ARM for bottom spot fitting TUBE ARM FITTING with special wide working length of the spot fitting FITLER-SOUND ABSORBER for oil-free outgoing air installed at air exit PENDULUM ELECTRODE HOLDER as top fitting BAR ELECTRODE HOLDER as bottom fitting ADJUSTMENT DEVICE with ratchet for height adjustment of bottom fitting HYDRAULIC WELDING UNIT (Compensating element) Side flexible conductors to improve the current partition as well as rubber spring for optimized followup and to compensate tolerances of work piece PROJECTED ELECTRODE HOLDER PRESSURELESS LOWER of the top fitting by manual valve installed at cylinder VISE ELECTRODE for conductive clamping and manual operation, air-operated available ELECTRODE FORCE SWITCH electronic operated BAR ELECTRODE with current partition for mounting on top and bottom platen RETURN STROKE MONITORING electrical operated PRESSURE COMPENSATOR for projection welding tools to be mounted of the top platen PROGRAM SELECTOR SWITCH for preselection of the welding program FLANGED ELECTRODE HOLDER to be used on a projection welding machine for spot welding POSITION ENCODER electrical operated

6 COMPARISON OF DIFFERENT KINDS OF CURRENT For an objective comparison one needs identical welding applications which demands certain welding current. A good quality spot welding of an aluminium sheet with a thickness of 4 + 4mm requires a welding current of approx. 57 ka. The different impedances in the secondary circuit of welding machines and connection related factors defines the size of the required mains transformer. SINGLE-PHASE ALTERNATING CURRENT THREE-PHASE DIRECT CURRENT DOUBLE CONNECTION (G3) MEDIUM FREQUENCY DIRECT CURRENT The following example is based of 350 mm throat length: kind of current welding current primary current no-load voltage mains cross section fuse protection connected mains power single-phase alternating current 57 ka 850 A 12,5 V AC 150 mm 315 A 550 kva three-phase direct current 57 ka 500 A 6,7 V DC 25 mm 100 A 260 kva medium frequency DC 57 ka 500 A 7,0 V DC 25 mm A 260 kva ADVANTAGES OF DIRECT CURRENT MACHINES UNIFORM CURRENT PARTITION IN ELECTRODES AND WORK PIECE The current partition in electrodes and work pieces is related only to the ohmic resistance of the material which results in a relatively uniform current partition. This effect is especially interesting with several spot welding joints on projection and cross-wire application. LOW TREND-TO-ALLOY OF THE ELECTRODES Continuous flow of current because of no zero crossing of the current curve results in low specific load of the electrodes.in general the effect is reduced alloying of the electrodes and the service life will be increased. SHORT WELDING DURATION WITH REDUCED HEAT AFFECTED ZONE The feed of heat into the weld by welding with direct current is higher than welding with alternating current of the same duration, because the current curve is not sinus-formed and shows no zero crossings. Work piece and electrodes are thermally lower loaded and the heat affected zones keep small. GOOD CONDITIONS FOR MAINS CONNECTION The load for the mains supply is symmetrical for all three phases of the supply network. Low cost of installation and mains transformer, mains connection and main switch. BIG POWER FACTOR SMALL LOSSES Compared to alternating current machines with a low power factor, a power factor of 0,9 (cos phi) is achieved. The inductive losses in the secondary circuit are practically zero. LOW ENERGY CONSUMPTION Because of the eliminated inductivity in the secondary circuit an optimized transmission ratio of primary to secondary is achieved. A lower need of energy from supply network is the result. HIGH WELDING CURRENT WITH LOWER SECONDARY VOLTAGE Low secondary voltage enables a high welding current with adequate dimensions of the secondary circuit on machines with long throat because of the eliminated inductive resistance. This kind of machines weld more softly and spatter formation is avoided

7 TECHNICS OF MEDIUM FREQUENCY The DALEX MF-technics offers essential elements towards effi cient series production. This welding technology is the answer to increasing demands of quality, productivity and capacity of resistance welding. METHOD In an special inverter the three-phase power supply is rectifi ed and converted to alternating two phase current of 1000 Hz. A compact, close coupled transformer is primary fed with this current, which is rectified again on secondary side. The result is a welding current which can be regulated fast and precise because of the 1000 Hz. ADVANTAGE direct current in high quality minimal inductive loss energy saving regulation and time adjusting in ms fast upslope long life of electrodes compact and lightweight transformer high quality of welding spot wide range welding application symmetrical load of supply network low trend of spatter formation MEDIUM FREQUENCY TRANSFORMATOR nominal capacity at 20 % duty cycle (kva) 80 up to 90 nominal capacity at 20 % duty cycle (kva) 130 up to 180 nominal capacity at 20 % duty cycle (kva) 250 up to 300 nominal capacity at 20 % duty cycle (kva) 500 nominal capacity at 20 % duty cycle (kva) 700 up to 1000 no-load direct voltage (V) 6.3 up to 8.3 no-load direct voltage (V) 7.0 up to 10.2 no-load direct voltage (V) 10.2 up to 16.0 no-load direct voltage (V) 11.8 no-load direct voltage (V) 8.4 up to 15.9 weight (kg) 17 weight (kg) 26,5 weight (kg) 33 weight (kg) 54,5 weight (kg) 167 number of diodes (pieces) 2 number of diodes (pieces) 4 or 6 number of diodes (pieces) 4 or 6 number of diodes (pieces) 6 number of diodes (pieces) 10 PLANNED USE short-time welding (f. e. annular projections), partially as replacement of capacitor discharge welding machines welding of galvanized sheets joining of different materials as well as nonferrous metals welding of coated materials DALEX MEDIUM FREQUENCY TRANSFORMERS ARE REMARKABLE FOR low self-impedance low need of cooling water series connection of all cooling circuits secondary voltage suppressor wiring beginning with size MF 180 diodes are tightened max. as a pair high capability with small size LIFE OF ELECTRODES - MF DIRECT CURRENT / ALTERNATING CURRENT COMPARISON OF WELDING CURRENT CURVES - 7 -

8 DALEX-SERVOTRONIC SERVOTRONIC - PRODUCT RANGE THE WORKS Our developers have provided the DALEX S-class with a new design featuring 3 power stages. SII dan SII dan SII dan In this process, great importance was attached to optimal compatibility with the system construction kits for PMS series spot, projection and seam welding machines. GENTLE POWER WITH BRAINS Less is more goes the old saying. What this means for spot, projection or seam welding is illustrated by the second generation of DALEX servomotor welding machines. Instead of simply flattening the projections before the actual welding process, as would be the case with conventional pneumatic systems, the geometry of the projections is kept completely intact with a DALEX SERVOTRONIC. Pneumatic Servo technology DIAGRAM: PRE-WELDING PROJECTION GEOMETRY SCHEMATIC: DYNAMIC CHARACTERISTICS OF A SERVO-MOTOR DALEX PROJECTION WELDING MACHINE WITH SERVOTRONIC Process safety and welding quality are drastically increased. The success factors: Die-to-die blow-free welding electrode touch-down on the component Constantly adjusted preliminary force for defined press-on of components to be welded (projection geometry remains intact) Welding current build-up synchronized with welding force build-up with an also constantly adjusted end force Optimal process operation reproducibility with typical welding cycles of 20 ms to 150 ms - 8 -

9 DALEX SERVOTRONIC EXAMPLE: SLIDING SELECTOR SHAFT The component geometry of the sliding selector shaft within the welding area,the shape of the annular projection DALEX robotwelding station with 2 projection machines with servomotor drive at the welding stud, and the material properties of both weld elements placethe highest demands on the welding technology. The SERVOTRONIC developed by DALEX now provides an optimal solution for this challenge. APPLICATIONS: WELD NUTS/LOCK PLATES Especially with safety-relevant elements, the quality of the weld (welding projection) is a decisive factor for a component s lifetime. In the final analysis this is the point where, particularly in car manufacturing, questions of stability, solidity and hence also of the vehicle s and human safety are settled. DALEX SERVOTRONIC dynamically readjusts the welding parameters by virtue of an intelligent control technology and ensures optimal lens formation in resistance welding to a high degree. With the SERVOTRONIC, DALEX welds an enormous variety of material pairings. Avoidance of spatters inside the thread when nut welding is solvable. Welding to measure is controllable with the SERVOTRONIC. DALEX-CNC-coordinate welding system in medium frequency technology with servomotor drive - 9 -

10 MODIFIED PMS CLASS CUSTOM-MADE SOLUTIONS FOR INDUSTRIAL DEMANDS The DALEX concept of modifications of high-capable standard machines in response to individual demands is a well proved and secured base for industrial welding with high productivity and economic efficiency. The machines are used in the various branches such as automotive manufacturing, utility and agricultural manufacturing, aircraft construction, wire grating manufacturing, luminous advertising, household appliances, electrical engineering, furniture manufacturers as well as window and door manufacturers. For complex welding applications the series of DALEX machines type PMS can be fast and cost efficient modified thanks to their modular design. For reproducible welding results they can be completed by special tools designed for the intended application

11 MODIFIED PMS CLASS - EXAMPLES OF USE DALEX Medium Frequency Projection Welding Machine PMS 14-6 MF with special tools projection welding of wire console DALEX Spot Welding Machine PMS 11-6 with special fittings stepp-spot welding of sink basin DALEX Three-Phases Direct Current Machine PMS 11-6 G3 with special fittings spot welding of luminous aluminium letters DALEX 3-Cylinder Projection welding machine PMS 36-4 MF in medium frequency technics projection welding of parts for automotive manufacturing

12 MODIFIED PMS CLASS - EXAMPLES OF USE DALEX Transversal Roller Seam Welding Machine PMS 14-6 with special fittings roller seam welding of chimney pipe DALEX Medium Frequency Projection Welding Machine PMS 32-6 MF with special tool projection welding of fuel distributor DALEX Double Head Projection Welding Machine PMS 32-6 with special tool projection welding of reinforcement of hinges DALEX Bench Spot Welding Machine PMS 10-6 T spot welding of copper stranded wire on mains terminal

13 MODIFIED PMS CLASS - EXAMPLES OF USE DALEX Projection Welding Machine PMS 36-6 with special tools SCHWEISSAUFGABE projection welding of lock case on door frame DALEX Medium Frequency Projection Welding Machine PMS 36-6 MF with special tool projection welding of cylindrical tubes DALEX Three-Phase Direct Current Projection Welding Machine PMS 38-6 G3 projection welding of diffuser on compressor housing DALEX Projection Welding Machine PMS 32-6 with automatic nut feeding device projection welding of nuts on sheet metal parts

14 MODIFIED PMS CLASS - EXAMPLES OF USE DALEX Transversal Seam Welding Machine PMS 16-6 seam welding of lye drums DALEX Double-Head Projection Welding Machine PMS 32-6 projection welding of barrel clamping ring DALEX Roller Seam Welding Machine PMS 11-6 with special tools seam welding of filtering bag fabrics DALEX Double-Head Projection Welding Machine PMS 36-6 with special projection tool projection welding of case of a lock on lock plate

15 MODIFIED PMS CLASS - EXAMPLES OF USE DALEX Transversal Roller Seam Welding machine PMS 11-6 with special fittings seam welding of filter screen DALEX Projection Welding Machine PMS 36-6 with special tools projection welding of fire-extinguisher case DALEX Medium Frequency Projection Welding Machine PMS 36-6 MF with special fitting projection welding of adapter on flue gas part DALEX-Projection Welding Machine PMS 32-6 with special fitting projection welding of fine screen parts You will find further examples of application at

16 Stand 11/2012 DALEX Schweißmaschinen GmbH & Co. KG Koblenzer Strasse 43 D Wissen Tel. +49 (0) Fax +49 (0) Internet: kontakt@dalex.de made in Germany