DT Series Spot Projection Resistance Welding Machine 50~150KVA

DT Series Spot Projection Resistance Welding Machine 

The DT Series Pneumatic Spot Projection Resistance Welding Machine represents a state-of-the-art advancement in precision resistance welding technology, specifically engineered for demanding projection welding applications. With power configurations spanning 50KVA to 150KVA, this specialized projection spot welder is designed to deliver consistent, high-strength welds on pre-formed projections, embossed features, and complex joint configurations. Ideal for automotive assemblies, electrical components, industrial hardware, and fabricated metal products, the DT Series integrates robust pneumatic control, intelligent welding management, and exceptional durability to meet the rigorous standards of modern manufacturing.

Product Overview:

The DT Series Projection Resistance Welder operates by concentrating electrical current through engineered projections on one workpiece surface. When pressed under precisely controlled pneumatic force against a mating surface and subjected to accurately timed current, these projections collapse uniformly to form reliable, repeatable weld nuggets. Unlike conventional spot welding, projection welding enables simultaneous multi-point welds and accommodates complex part geometries with superior alignment control. The DT Series is built with precision-guided mechanics, programmable force sequences, and adaptive current regulation to ensure optimal projection welding results across varied materials and design specifications.

Machine Structure & Key Components:

• Reinforced Steel Frame with Precision Guidance System – Provides exceptional stability and maintains exact alignment between upper and lower electrodes, crucial for accurate projection welding.
• Programmable Pneumatic Actuation System – Delivers adjustable multi-stage force control, including fast approach, welding force, and post-weld hold, ensuring proper projection collapse without part deformation.
• Specialized Electrode & Platen Configuration – Features flat or customized lower platens and upper electrodes designed to distribute force evenly across multiple projections.
• High-Capacity Welding Transformer – Available in single or three-phase 380V input, rated for 50% duty cycle to support continuous high-volume production.
• SUN18B Intelligent Microprocessor Controller – Advanced control system featuring dual current settings, dual weld time, upslope control, and pulsation functions specifically optimized for projection welding applications, with digital display for precise parameter monitoring.
• Solid-State SCR Power Module – Ensures reliable and precise current delivery for controlled projection collapse and consistent nugget formation.
• Customizable Tooling & Fixturing – Enables precise alignment of projections with electrode surfaces, accommodating a wide range of part sizes and geometries.
• Two-Stage Foot Pedal Control – Allows operators to initiate welding cycles and manage force application with enhanced accuracy and responsiveness.
• Integrated Cooling System – Maintains optimal operating temperatures for critical components, including transformer, SCR assembly, and electrode holders, during prolonged use.

Technical Parameters:

Key Features & Advantages:

• SUN18B Intelligent Projection Welding Controller – Advanced microprocessor system specifically configured for projection welding with dual current control, dual time settings, upslope functions, and pulsation capabilities for optimal projection collapse and weld quality.
• Digital Precision Control – Phase shift current adjustment from 01% to 99% provides exceptional control over welding heat input, essential for consistent projection welding results.
• Advanced Force Control & Profiling – Programmable force stages allow fine-tuned control of approach, welding, and hold pressures to optimize projection collapse and weld integrity.
• Simultaneous Multi-Point Welding Capability – Engineered to perform multiple projection welds in a single cycle, significantly improving throughput and consistency.
• Dual Current & Time Settings – Allows programming of two different welding schedules for complex parts or different projection configurations on the same workpiece.
• Broad Material Compatibility – Suitable for low-carbon steels, stainless steels, coated metals, and dissimilar thickness combinations commonly used in projection welding.
• High Production Efficiency – Simultaneous welding of multiple projections reduces cycle times and increases output compared to traditional sequential spot welding.
• Enhanced Process Control – Upslope function helps prevent initial splatter while pulsation capability improves heat distribution for better projection collapse.

Welding Samples:

Applications:

The DT Series Projection Welding Machine is essential for industries requiring high-precision, high-strength localized joints:

• Automotive Manufacturing: Welding of brackets, mounts, hinges, seat frames, and reinforcement panels with embossed projections.
• Electrical & Electronics: Assembly of contact points, switch components, connector pins, terminal blocks, and busbar configurations.
• Industrial Hardware: Attachment of nuts, bolts, studs, and threaded inserts to plates or housings.
• Appliance Production: Joining of handles, hinges, brackets, and structural supports in household and commercial appliances.
• Sheet Metal Fabrication: Welding of stamped or embossed components in enclosures, panels, and assemblies.
• Wire & Mesh Products: Cross-wire welding for grids, racks, and fencing applications.
• Industrial Equipment: Fabrication of guards, frames, machinery panels, and structural components with projection-based joints.

Why Choose the DT Series Projection Welding Machine?

• Intelligent Welding Control System – SUN18B microprocessor controller provides advanced programming capabilities specifically designed for projection welding requirements, including dual current settings and precise timing control.
• Superior Weld Consistency – Digital phase shift current control ensures accurate heat input for uniform projection collapse and reliable nugget formation across all weld points.
• Increased Productivity – Capability to perform multiple welds simultaneously drastically reduces cycle times and boosts manufacturing efficiency.
• Advanced Process Optimization – Upslope and pulsation functions allow fine-tuning of the welding process for different materials and projection designs, reducing defects and improving quality.
• Versatile and Adaptable – Accommodates a wide range of projection designs, material types, and part configurations through intelligent control and customizable tooling.

For manufacturers seeking to optimize their welding processes with the benefits of projection technology and advanced microprocessor control, the DT Series 50-150KVA Pneumatic Spot Projection Resistance Welding Machine with SUN18B Controller delivers the precision, performance, and intelligent control needed to excel in today's competitive industrial landscape.