DTM Series Medium Frequency (MFDC) Projection Resistance Welding Machine

DTM Series Medium Frequency (MFDC) Projection Resistance Welding Machine
 
The DTM Series Medium Frequency (MFDC) Projection Resistance Welding Machine represents the cutting edge of resistance welding technology, engineered for superior control, energy efficiency, and weld quality in demanding projection welding applications. Utilizing advanced 1000Hz Medium Frequency Direct Current (MFDC) technology and controlled by the sophisticated SMF1-800 Inverter Welding Controller, the DTM Series delivers unprecedented precision for welding pre-formed projections, nuts, studs, and complex assemblies. With power configurations optimized for industrial applications, this system is ideal for automotive, aerospace, and precision manufacturing where consistent, high-integrity welds are non-negotiable.
 

Product Overview:

 
The DTM Series MFDC Projection Welder operates on the principle of converting three-phase AC input to stable, precisely controlled medium frequency DC output (1000Hz). This advanced power delivery, managed by the SMF1-800 inverter controller, enables exceptional control over the welding current waveform. When applied to projection welding, this technology ensures rapid, concentrated heat generation precisely at the projection points, resulting in cleaner, stronger welds with minimal thermal distortion and spatter. The system is specifically designed for applications requiring multiple simultaneous projection welds, high repeatability, and integration into automated production lines.
 

Machine Structure & Key Components:

• Heavy-Duty Reinforced Steel Frame – Precision-engineered for stability and alignment under high dynamic forces, with integrated vibration damping.
• Medium Frequency DC Inverter Power Source – Core MFDC technology converting 3-phase AC to 1000Hz DC, providing fast response and precise current control.
• SMF1-800 Intelligent Inverter Welding Controller – Advanced digital controller featuring touchscreen interface, programmable welding schedules, real-time monitoring, and adaptive feedback control.
• Precision Servo or Programmable Pneumatic Force System – Offers accurate and repeatable electrode force control with multi-stage force profiling.
• Dual-Sided Square-Box Secondary Circuit – Low-impedance, water-cooled copper secondary system ensuring efficient power delivery to the welding electrodes.
• Customizable Projection Welding Fixtures – Application-specific tooling and precision alignment systems for optimal part positioning.
• Integrated Water Cooling System – High-efficiency cooling for transformers, inverters, and secondary components.
• Safety Enclosure with Light Curtains – Complete operator protection with integrated safety interlocks.
• Data Communication Interfaces – Ethernet, Profibus, or DeviceNet connectivity for seamless integration into smart factory environments.

Key Features & Advantages of Medium Frequency (MFDC) Technology:

 
Superior Power Control & Efficiency:

• Precise Current Regulation: MFDC provides near-perfect square wave current output with extremely fast response time (<1ms), enabling accurate control of heat input.
• Higher Power Factor (≥0.95): Significantly reduces energy consumption compared to traditional AC welders (typically 0.6-0.7 PF), lowering operating costs by 30-40%.
• Balanced Three-Phase Load: Eliminates single-phase loading issues, reducing demand charges and improving facility power quality.

 
Enhanced Weld Quality & Consistency:

• Stable, Concentrated Heat Generation: DC current minimizes magnetic blow effect and provides deeper penetration with less surface heating.
• Reduced Spatter & Deformation: Precise current control prevents excessive melting and minimizes workpiece distortion.
• Excellent for Coated Materials: Ideal for welding galvanized, aluminized, and pre-painted materials with minimal coating damage.

 
Advanced Process Capabilities:

• Multiple Pulse Welding: SMF1-800 controller enables complex multi-pulse welding schedules for challenging materials and applications.
• Constant Current & Constant Voltage Modes: Adaptive control strategies for optimal weld quality under varying conditions.
• Real-Time Process Monitoring: Continuous monitoring of current, voltage, resistance, and energy with SPC data logging.

 
Operational Advantages:

• Reduced Electrode Wear: Lower RMS current and concentrated heat reduce electrode sticking and dressing frequency.
• Faster Welding Cycles: Higher frequency allows shorter weld times, increasing production throughput.
• Quieter Operation: Eliminates the loud "hum" associated with AC transformers.
• Compact Design: Smaller transformer size due to higher operating frequency.

Technical Parameters

 
 
General Specifications:
 
Operating Frequency: 1000Hz Medium Frequency DC
Input Voltage: 3-Phase 380-480V, 50/60Hz
Response Time: <1ms
Power Factor: ≥0.95
Cooling Requirement: Water, 15-25°C, 8-12L/min
Communication: Ethernet, Profibus, DeviceNet (optional)
 

Applications:

 
The DTM Series MFDC Projection Welder excels in high-precision applications:
Automotive Manufacturing: Seat frames, door hinges, brake components, suspension parts
Aerospace Components: Structural brackets, engine mounts, control linkages
Electrical Equipment: Busbars, switchgear, transformer components
Industrial Hardware: Fasteners, brackets, hydraulic components
Appliance Manufacturing: Compressor mounts, structural frames, hinges
Precision Engineering: Medical device components, instrumentation parts
 

Why Choose DTM Series MFDC Projection Welder?

 
Unmatched Weld Quality: MFDC technology provides superior control for consistent, high-integrity projection welds with minimal defects.
Significant Energy Savings: ≥0.95 power factor reduces energy consumption by 30-40% compared to conventional AC systems.
Increased Productivity: Faster weld cycles and reduced maintenance downtime boost overall equipment effectiveness (OEE).
Advanced Process Control: SMF1-800 controller enables sophisticated welding strategies for challenging applications.
Future-Proof Technology: Network-ready design integrates seamlessly into Industry 4.0 and smart factory environments.
Reduced Total Cost of Ownership: Lower energy costs, reduced electrode consumption, and minimal maintenance deliver excellent ROI.
 
For manufacturers seeking to advance their welding capabilities with state-of-the-art MFDC technology, the DTM Series Medium Frequency Projection Resistance Welding Machine delivers unparalleled performance, efficiency, and control. Contact our engineering team to discover how MFDC technology can transform your projection welding operations.
 
 
Welding Sample: