collector welding "hot staking"

This method is used for contact points which are accessible only from one side, where the contact electrode approaches - single-sided and from the top - close to the welding electrode. The loose leads are positioned over each other in a slot which has been slit into the collector. This method is applied in serial production of small-power motors using mechanised or automated welding machines and belongs to the field of resistance welding of enamelled wires.

resistance welding of contacts

In resistance welding of contacts, in general, dissimilar materials are to be joined. To this end, copper and brass alloys are used as insulators, however, depending on the application, also steel sheets with different metal coatings are used. The contacts normally consist of a material with a good conductivity (copper, silver, gold, etc.) which is, on the one hand, advantageous for the functioning of the produced parts but which, however, puts demands on the welding technique. Moreover, the contacts are normally produced with so-called high-speed machines with very high clock rates. The welding power sources which are used for this process must fulfil the following demands: high welding currents, dependent on contact geometry and material high duty cycle controlled, very short welding times integratable into different machine concepts online monitoring The high-frequency inverters of the SPATZH6000 series are particularly suitable for this application as they meet all the above-mentioned demands. The individually settable limit value- and alarm management of these power sources guarantee the steady, good quality standards of the produced parts

Resistance Welding of Lamps

Very thin foils made of exotic materials are welded with ultrafine wires and wire spirals which are hardly visible. Every single welded joint must be of good quality, since every single welding point is decisive for the function and lifetime of the lamp. Here, also extremely "smooth" welding currents are required in order to prevent preliminary damage of these susceptible materials through current surges. For cross wire welds inside the lamps, tight tolerances during wire penetration are requested. The above-mentioned demands are reliably fulfilled with the high-frequency inverter of the SPATZ series. The standard equipment comprises also the measurement inputs for current, voltage, force and displacement signals which allow reliable inline control of the process data