DN Series Customized Resistance Spot Welding Machine For Cable Reels

DN Series Customized Resistance Spot Welding Machine for Cable Reels with Dual Welding Torches

The DN Series Customized Resistance Spot Welding Machine for Cable Reels with Dual Welding Torches is a specialized, high-performance welding system engineered specifically for the efficient and symmetrical manufacturing of cable reel (I-beam wheel) assemblies. Available in power configurations from 25KVA to 150KVA, this innovative dual-torch welding system features two independent welding guns operating simultaneously from opposite sides of the workpiece. This unique bilateral configuration dramatically reduces cycle times by performing symmetrical welds in a single operation, ensuring perfect alignment and balanced structural integrity for cable reels. Designed to meet the stringent requirements of reel and spool production, this system combines the proven reliability of the DN Series platform with custom-tailored automation for maximum productivity.

Product Overview:

The DN Series Dual-Torch Cable Reel Welder is a turnkey production solution built upon the robust DN Series resistance welding platform, enhanced with a symmetrical dual-welding-head design specifically for cable reel fabrication. The system positions the reel component within a custom fixture, where two independently controlled welding torches simultaneously approach from opposite sides to perform perfectly aligned spot welds. This bilateral welding approach not only halves the production time compared to single-torch systems but also eliminates thermal distortion by applying balanced heat input. Governed by dual SUN18B Intelligent Microprocessor Controllers (one for each torch), the system ensures synchronized yet independently adjustable welding parameters for each side, guaranteeing consistent, high-strength welds on both flanges of the I-beam wheel.

Machine Structure & Key Components:

• Heavy-Duty DN Series Welded Steel Frame – Reinforced structure designed to accommodate the forces and mechanisms of dual opposing welding heads while maintaining precision alignment.
• Custom Cable Reel Fixturing System – Precision-engineered fixtures and clamps designed specifically for I-beam reel components, ensuring secure and repeatable positioning for bilateral welding.
• Dual Independent Welding Torch Systems – Two complete welding gun assemblies (horizontal or C-type) mounted on opposing sides of the workpiece on precision linear slides, allowing for adjustable throat depth and electrode alignment.
• Dual High-Capacity Welding Transformers – Each welding torch is powered by its own DN Series transformer (rated per model: 25, 35, 50, 75, 100, or 150KVA), ensuring independent and充足 power delivery.
• Dual SUN18B Intelligent Welding Controllers – Two independent microprocessor controllers, one for each welding torch. This allows for synchronized cycle initiation while maintaining separate, optimized welding schedules (current, time, upslope, pulsation) for each side if required by the workpiece.
• Centralized Pneumatic Pressure System – A single air supply with precision regulators and solenoid valves controls the electrode force for both torches simultaneously, ensuring balanced pressure.
• Synchronized Motion Control System – Ensures both welding torches advance, contact, retract, and sequence in perfect coordination, controlled via the main operator interface.
• Integrated Safety Enclosure – Full perimeter guarding with dual-hand or foot pedal initiation and light curtains to ensure operator safety during the simultaneous bilateral welding process.
• Unified Operator Control Panel – A central HMI (Human-Machine Interface) allows the operator to set parameters, monitor both weld processes, and control the entire cycle from one location.

Technical Parameters:

Key Features & Advantages:

• Dual-Torch, Simultaneous Bilateral Welding – Two welding heads operate at once, doubling productivity and ensuring symmetrical heat application, which minimizes workpiece distortion and improves structural balance.
• Dual Independent SUN18B Control – Each torch has its own advanced controller, allowing for perfectly synchronized cycles with the flexibility to fine-tune parameters (dual current, dual time, upslope) independently for each side if needed.
• Perfect for I-Beam Reel (Cable Reel) Geometry – The opposing torch design is ideal for welding flanges to the hub or performing symmetrical welds on both sides of the reel's web, a common requirement in reel manufacturing.
• Halved Cycle Time – Performing two welds simultaneously effectively cuts the welding time per reel by approximately 50% compared to single-head machines, significantly increasing throughput.
• Enhanced Weld Quality & Consistency – Symmetrical force and heat input from both sides prevent warping and ensure uniform weld nugget formation on both connection points.
• Proven DN Series Core Technology – Leverages the ruggedness, reliability, and performance of the standard DN Series welder, ensuring low maintenance and consistent operation.
• Custom-Engineered Fixturing – Fixtures are tailored to specific cable reel dimensions, ensuring fast loading, accurate positioning, and repeatable weld location for every part.
• Flexible Configuration – The distance between the two torches can often be adjusted to accommodate different reel diameters within a specified range.

General Specifications:

• Power Supply: 380V, 2-Phases (for models ≥50KVA), 50/60Hz
• Control System: Dual SUN18B Intelligent Microprocessor Controllers
• Welding Process: Dual-sided, synchronous resistance spot welding
• Electrode Force: Adjustable, up to model-specific maximum
• Cooling: Integrated water cooling system for transformers and electrodes
• Operation Mode: Semi-automatic (manual load, auto weld) or Fully Automatic with auto feed (optional)

Welding Samples:

Applications:

This specialized DN Series system is exclusively engineered for manufacturing and repairing:

• Cable Reels & I-Beam Wheels: Welding side flanges to the central hub or performing symmetrical stitch welds along the web.
• Wire Spools: Assembly of metal spools for welding wire, fencing wire, and other continuous cable products.
• Hose Reels: Fabrication of reels for industrial hoses and cables.
• Other Symmetrical Fabrications: Any cylindrical or disc-shaped component requiring simultaneous, opposing spot welds for balance and efficiency.

Why Choose the DN Series Dual-Torch Reel Welder?

• Unmatched Productivity for Reel Welding: The dual-head design is the most efficient method for welding symmetrical components like cable reels, offering the fastest possible cycle times.
• Superior Product Quality: Simultaneous welding from both sides ensures balanced thermal input, resulting in less distortion and more dimensionally stable finished reels.
• Turnkey Customized Solution: The machine is delivered as a complete system with custom fixtures for your specific reel design, ready for production.
• Precision and Control: Dual independent SUN18B controllers offer unparalleled control over each weld, allowing for optimization and consistency.
• Reduced Operational Costs: Doubling the weld output per cycle reduces energy consumption per weld, labor time, and floor space requirements compared to two single-head machines.

For manufacturers of cable reels, wire spools, and similar symmetrical components seeking to maximize output, improve quality, and gain a significant competitive advantage, the DN Series Customized Resistance Spot Welding Machine with Dual Welding Torches provides a powerful, precise, and purpose-built production solution.