An Introduction to Automated Resistance Welder

Posted on Apr 30, 2021

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Automated Resistance Welder

The automated resistance welder is also known as ERW machines, which stands for electric resistance welding machine. In automated resistance welders, which come in various types and sizes, the interface of the metal parts will be melted and joined together.

What Is an Automated Resistance Welder Used for?

An automated resistance welder is a welding machine that is used to permanently join multiple metal parts through a thermo-electric process utilizing electric current and regulated pressure. There are robotic, semi-automated, and fully automated resistance welding machines today, which automatically transfer the proper amount of current through the welding joint where heat is generated. The weld time and the pressure,  which is applied to the weld joint, are both accurately controlled in an automated resistance welder.

The automated resistance welder is also known as ERW machines, which stands for electric resistance welding machine. In automated resistance welders, which come in various types and sizes, the interface of the metal parts will be melted and joined together. Some common types of resistance welding methods include spot welding, seam welding, projection welding, flash welding, upset welding, and so on. The automatic ERW operations are widely used to help manufacture steel pipes, automotive and aerospace parts, and many more industrial production lines and assembly lines. 


Why Do You Need an Automated Resistance Welder?

The automated resistance welders can provide a rapid production cycle and continuous accuracy. With automation and robotic technology in modern resistance welding machines, the metal joining process can be critically and simply controlled to optimize the consistent quality and efficiency of production. Also, to complete the metal fabrication in these welders, there is no need for inserting any extra filler materials to form the bonds between the parts, making automated resistance welding machines more cost-efficient.

In addition to saving time and cost of fillers, the automated resistance welders are versatile, making the welding machine a popular solutions for a large range of applications from fusing cross wires, automobile parts to light bulb filaments. For materials such as sheet metal, the automatic spot welder will be an excellent choice for mechanists. Another strength of automated resistance welders that enhances the flexibility of the equipment is the ability to handle three or more material thickness at one time, welding the product effectively and precisely.

:: Read more: Automated Resistance Welder: An Evolution


Electric Resistance Welding Process (ERW)

In the electric resistance welding process, the automated resistance welder utilizes electrodes that are typically made from copper-based alloys to transfer the electric current through the interface of the metal pieces. Copper is used due to the ideal heat conductivity and low electrical resistance, which makes the weld heat tending to work on the materials instead of the electrode itself. Every time the weld cycle is finished, the copper electrode is cooled down mostly via water that passes through the conductive tools in an automated resistance welder.

As the energy is concentrated on the weld joint on the surfaces of the metal pieces, the material melts due to heat. In the automated resistance welder, under the control, a precise amount of pressure is also added to the weld joint, forming the force to join the metal pieces effectively. Applying a great density of current to the weld joint like flash welding can melt the material and form a high-quality weld rapidly. The material, mostly sheet metals, typically has a permanent and strong connection once the molten joint cools down and solidifies.


Different Types of Automatic Resistance Welders

With the development of automated welding machines and electric resistance welding technologies, there are many ERW equipment in the market serving different metal joining applications. For instance, there are automatic spot welding machines, seam welding machines, flash welding machines, projection welding machines, and so on. They can be distinct from the geometry of the weld and how the welding machine applied pressure onto the joint.


● Spot Welding Machine:

Spot welding machines are the most common automatic resistance welding equipment used to join multiple sheet metals via the heating process. On the “spot” where the metals are melted, pressure is applied under accurate control. As an ideal solution for high volume welding production, the classic electric resistance welding method is widely used in the automotive, aerospace, medical manufacturing, electronics, and rail industry. Especially in the automotive industry, the equipment is widely utilized for over a century.


● Seam Welding Machine:

Actually, the automatic seam welding machine is one type of resistance spot welders, which utilize a “wheel-shaped electrode” to convey current and force onto the weld joint. The obvious difference between seam welding and general spot welding is that the metal parts spin between the electrodes as the electric current passes through in the seam welding machine. The automated resistance welder can accurately supply a precise amount of predetermined weld current and control the weld time, making it a great solution for overlapping welds, welded seam, and individual spot weld at required intervals.


● Projection Welding Machine:

Similar to the previous type, the projection welding machine uses heat generated due to the electric resistance to current as well as applying controlled pressure to form the weld. The ERW process utilizes projections, embossments, or intersections to concentrate the thermal energy at the weld joint. Every time there is sufficient resistance generated on the weld joint, the projections will then collapse, forming the weld nugget. Projection welding machines are widely used for plate materials, cross-wire joining applications which are suitable for material intersection welding methods.


● Flash Welding Machine:

Flash welding machine is the automated resistance welder that utilizes flashing action. A significantly great density of electric current is used in flash welding,  which is concentrated on very tiny contacting points of sheet metals. Once the flashing action begins, the additional force will also be applied to the weld joint, and all the moving parts work together at a predetermined high speed under control. The strong advantage of the flash welder is the short upset time where the impurities and oxides in the base materials are pressed out to create a high-quality weld during the process that the sheet metals are forced together.


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