Capacitor discharge projection welding machine is the fastest form of resistance projecting welding which uses capacitors to deliver power to parts. As capacitors are charged with substantial amounts of energy, the energy is released into the parts rapidly within milliseconds.
Capacitor discharge projection welding machines are essentially a resistance welding process. During this process, the capacitors are charged with pre-set voltage, and then discharged via a pulse transformer. This enables very high current to pass through in a very short time which leads to exceptional projection welding quality.
The power requirement is often negligible compared with other resistance welding process since the capacitor discharge projection welding machine requires power only for discharging the bank of capacitors. This results in the saving of power usage as well as the connected loads. Since the weld time is very short (typically 3 to 12 milliseconds), water cool for the electrodes is not required and the heating or blackening of welded components are negligible.
The resistance projecting welding technology is ideal for projections welding, thin sheet spot welding and dissimilar metal welding. For those who place high regard in aesthetics, power saving and consistency in projecting welding should employ this technology.
As a matter of fact, capacitor discharge technology has been around for a while, and with safety concerns and technological advancement being taken into consideration, it not hard to see why conventional resistance welding is being improved significantly. Here are two of three core reasons that led the capacitor discharge projecting welding system to take off:
● Heat-affected zones are virtually eliminated: Capacitor discharge projection welding machines deliver a laser, welded-like joint, which means that the metallurgy characteristics of steel remain virtually the same as it did prior to the capacitor discharge welding process. Similar to the laser weld, capacitor discharge weld conveys a joint that largely limited surface spatter and deformation, but is also less expensive than a laser weld.
● Robust power supply is not required: In most cases, you do not need a large draw on a power distribution network when using a capacitor discharge projection welding machine. But this can be a problem in some areas (e.g., rural community). In some respects, a capacitor discharging projecting weld can be run under the same electrical power as a residential electric dryer, and this can be cost-effective for manufacturers who have to rearrange the electrical configuration and the floor layout of the workshop. Moreover, some manufacturers find themselves having to interlock their resistance welders because of the lack of adequate AC power at their location. This can in turn limits the strain on the power distribution network, and a capacitor discharge projecting welding can eliminate this kind of electrical coordination.
● Long-lasting Electrodes: Because the energy (even at high level) delivered in the capacitor discharge projecting welding is concentrated for such a short time, the wear on the electrode is less compared with the conventional resistance welding process. As a result, electrodes can last for 10 times as long depending on the applications, meaning parts can be machined quickly afterwards. And because the electrical discharge is so rapid, the part does not overheat upon completing the welding. The user wearing proper gloves should have no issue handling the part comfortably. He should be able to hand it as if he was handling sheet metal. Nevertheless, keep in mind that certain materials like stainless steel can retain heat due to the higher resistance compared to other metals like mild steel.
As mentioned previously, resistance projection welding has been improved so much over the years that their use has been extended across industries in many applications. Some of the common applications include: shock absorber components, oil filters, oil port to cylinder tube welding, projection nut welding, projection bolt welding, window regulators, automobile components, leak proof welds, switch gear, fabricated stainless steel impellers, auto electrical, diamond tools, hydraulics, batteries, heavy duty transformers, name plate welding, silver contact welding, sheet metal parts, brake shoes, sheet metal furniture parts, dissimilar metal parts, relays, ball to rod welding, etc.
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