Mechelonic Engineers’ spot welding machines are a testament to the company’s commitment to quality and innovation. These machines are designed to deliver precise and reliable welds, ensuring that the products produced meet the highest standards of quality and durability. With input power specifications ranging from 10 KVA to 20 KVA, the machines are suitable for a wide range of applications, including automotive, aerospace, and electronics manufacturing.
Mechelonic Engineers’ spot welding machines are equipped with advanced features such as multiple welding schedules, programmable parameters, and real-time monitoring. These features allow for greater control and precision during the welding process, resulting in consistent and high-quality welds. The spot welding equipment is ideal for high-speed production in industries such as metal fabrication, offering both traditional and advanced welding technologies.
The company’s spot welding machines are also designed with ease of use and maintenance in mind. The machines are simple to operate, and their modular design makes maintenance and repairs easy and cost-effective.
Mechelonic Engineers’ spot welding machines are a reliable and cost-effective solution for any industry that requires precision welding. With their advanced features and commitment to quality, these machines are sure to deliver consistent and high-quality results for years to come.
A spot welding machine is a specialized type of welding equipment used to join two metal pieces by applying heat and pressure to a small, localized area known as a spot. This process, known as resistance spot welding, utilizes electrical resistance to generate the necessary heat to fuse the materials together. The spot welding machine is a staple in various industries, including automotive, manufacturing, and construction, due to its efficiency and reliability. By focusing the heat and pressure on a specific spot, these machines ensure strong and durable welds, making them indispensable in the production of high-quality metal products.
There are several types of spot welding machines available, each designed to meet specific needs and applications:
Pedestal Type Spot Welding Machine: Mounted on a pedestal, this stationary machine is ideal for heavy-duty applications, providing stability and precision.
Hand Spot Welding Machine: Portable and easy to carry, this machine is perfect for small-scale applications and on-site repairs.
Projection Spot Welding Machine: Utilizes a projection welding technique to join metal pieces, suitable for applications requiring precise welds.
Seam Welding Machine: Designed to weld along a seam, this machine is used for creating continuous, leak-proof joints.
Butt Welding Machine: Joins two metal pieces at a butt joint, commonly used in wire and rod welding.
Regulator Type ARC Welding Machine: Employs an ARC welding process, ideal for various metal fabrication tasks.
Stud Type ARC Welding Machine: Uses ARC welding to attach studs to metal surfaces, often used in construction and manufacturing.
Portable Welding Machine: Compact and mobile, this machine is suitable for small-scale and on-the-go welding tasks.
Inverter Mosfet ARC Welding Machine: Utilizes an inverter-based ARC welding process, offering efficiency and precision.
Inverter IGBT ARC Welding Machine: Another inverter-based ARC welding machine, known for its reliability and performance.
Mig(CO2) Welding Machine: Uses a MIG welding process with CO2 shielding gas, ideal for welding thicker materials.
Tig Welding Machine: Employs a TIG welding process, known for producing high-quality, precise welds.
Plasma Cut Machine: Uses plasma cutting technology to cut through metal with high precision and speed.
High performance Welding Machines built for durability:
Machine Type - Pneumatically operated pneumatic welding machine
Adjustable force - Permits high quality welding
Rugged industrial design - Improves productivity, minimizes repair costs and ensures long life.
Welding Transformer - Confirms to IS:4804 part 1 and RWMA standards, water cooled, with class ‘F’ insulation
Weld Control - The machine is equipped with a weld controller in which user can set the weld current precisely in steps of 1 cycle, having precise weld current control with help of phase control of thyristors. User can have a choice of controls, with constant current (Mup) or constant power output (C-Mos).
The machine operates at a copper voltage of 380 volts, which is crucial for its performance and compatibility with copper materials.
Electrodes/Dies & toolings - The machine can be supplied, optionally at extra cost, with custom built electrodes/dies with suitable jigs and fixtures for holding, guiding the work piece.
| Model | S+NG 16 | S+NG 20 | S+NG 25 | S+NG 30 |
|---|---|---|---|---|
| Max Sh Current @300TD | 16 KA | 20 KA | 25 KA | 30 KA |
| Welf Force KgF@5.6KC/Cyl dia | 450/100 | 625/125 | 1000/150 | 1000/150 |
| Throat Clearance | 200 mm | 200 mm | 200 mm | 200 mm |
| Max. Weldability (class 'B') | 2+2 mm | 3+3 mm | 3+3 mm | 3+3 mm |
| Machine size in mm | 450 x 1730 | 630 x 1800 | ||
| Depth (mm) | 700 mm + Throat | 725 mm + Throat | ||
| Machine weight in Kg | 400 | 450 | 700 | 750 |
| Installed power @415V 50Hz | 125 KW | 225 KW | 250 KW | 320 KW |
| Throat depth available | 300/450/600/900 | 450/600/750/900/1050 | ||
Press type air operated Spot Welders are designed for extraordinary versatility and are available with different styles of welding head arrangements. Additionally, the pedal operated spot welder is highly adaptable for various industrial and commercial applications, offering powerful capabilities for different materials and project types.
These air operated welders are designed for high-speed production work to meet the needs of a vast number of metal fabrication shops. Automatic feed mechanism with X-Y axis and Rotary movements with PLC could be supplied for fast production. A variety of electrodes and toolings can be fitted to render them suitable for spot welding, simple projection welding, electro-brazing, hot riveting, electro-forging, and upsetting.
The resistance welding process is highly effective in metal fabrication, utilizing pressure and electrical current to create strong welds through the resistance offered by the materials being joined.
Fully solid state electronic controls (Microprocessor based or CMOS based) are available for using with machine in order to obtain consistent and accurate weld results on a wide range of materials at a high-speed automatic operation.
These machines are designed and manufactured conforming to the Indian Standard Specification No.IS:4804 Part I and III or as per guidelines of JISC-9303 by a team of highly experienced engineers in welding technology.
Standard Ratings: 25, 35, 50 and 75 KVA @ 50% duty cycle.
Type: Air operated stationary press type Spot welders with pneumatic cylinder mounted directly.
Construction: Robust construction, streamlined appearance with maximum resistance to deflection.
Transformer enclosed in the main frame and pneumatic accessories mounted on the side of the machine and upper and lower arms mounted directly on to the body. Operating control station mounted on the machine clearly visible and within easy reach of the operator.
Standard Throat Depths: 300, 450, 600, 750 and 900 mm (Machine with other throats also available on request). Welding Transformer: Transformer conforms to IS: 4804 Part-I and RWMA Standards, water cooled, class 'F' insulation with thermoswitch protection for overloading.
Current Control: Welding current adjustable from 50 to 100% by means of a tap change links.
Cooling System: Transformer, Electrode holders, welding electrodes are water cooled.
Electrodes / Dies Toolings: One Pair of Morse Taper 2 straight Electrodes supplied as standard with the machine. Machine can be provided with custom-designed spot welding electrodes or welding dies to suit various sizes and shapes of work pieces, and suitable jigs and fixtures for holding, guiding and indexing of the work-piece as required at extra cost.
Electrode Control System: Upper electrode actuated by a heavy duty 2-way cushioned pneumatic cylinder controlled by an electrically operated 4-way solenoid valve. Compressed air at 1.5 Kg/cm.sq. - 5.6 kg/cm.sq. (20 to 80 psi) acting on the pneumatic cylinder provides electrode force. Machine provided with air filter, air lubricator, air pressure regulating valve, air pressure gauge.
High Lift Facility (Optional at Extra Cost): "High Lift" (retractable upper electrode) facility shall be provided by means of special cylinder. A hard/foot operated air valve causes the upper electrode to lift to the top most position for easy introduction of the job into the throat of the machine.
Dual Pressure System (Optional at Extra Cost): Dual pressure system shall be provided by means of two sets' of regulating and controlling devices and the necessary air circuits. Working in conjunction with special control units, this facility would enable application of a higher force on the job being welded at any point during the weld cycle.
Controls: Appropriate Control will be incorporated with the machine as per requirement.
| MODEL | T+NG 15 | T+NG 22 |
|---|---|---|
| SEC. CURRENT IN KA | 12 | 20 |
| CYLINDER DIA IN MM | 65 | 80 |
| FORCE @ 5 BAR KgF | 165 | 250 |
| THROAT DEPTH IN MM | 200 | |
| THROAT GAP IN MM | 250 | |
| OVERALL SIZE (APPROX.) (L X W X H) | 900 X 1200 X 1560 | |
MODEL : DC-SS
CAPACITY : 75 to 600 KVA at 50% Duty Cycle.
THROAT DEPTH :400 - 2500 MM
Press type air-operated Spot Welders are designed for heavy duty production work. These machines are used for welding ferrous and non-ferrous metal fabrication to aerospace weld standards. This machine is specially ideal for welding Aircraft components, Rail Coach building and components which call for very large throats. The machine is also highly effective in welding mild steel, accommodating different thicknesses and types of steel, including uncoated and galvanized options.
It is advisable to go for DC machines whenever Motor Generator sets are employed for power.
The machines are supplied with Microprocessor based control to obtain consistent and accurate weld results. Adequate steel voltage is crucial for the effective performance of the welding machine, ensuring it meets the necessary specifications for various applications.
| Machine Model DC-SS | 75 | 100 | 150 | 200 | 300 | 400 | 500 | 600 |
| Rating KVA @ 50% Duty Cycle | 75 | 100 | 150 | 200 | 300 | 400 | 500 | 600 |
| Max. Short circuit current K. Amps.: | 35 | 45 | 55 | 65 | 80 | 100 | 120 | 140 |
| Electrode Force: | Will be provided as per the Job Demand | |||||||
High performance weld heads built for durability:
Low inertia, fast follow-up designs
Improve weld consistency, reduce metal expulsion, and improve weld appearance
Adjustable force firing
Permits high quality welding since welding force is independent of electrode stroke length
Pneumatic or manual actuation
Configurable according to requirements
Rugged industrial design
Improves productivity, minimizes repair costs and ensures long.
All are precision, low inertia, force-fired designs, with a narrow vertical profile. They are ideal for both production line and bench applications and can operate at very high speeds
Precision Control
Thin design of the Weld Heads add consistency and control to complex welding applications.
Their low inertia designs ensure the fast dynamic response required for the electrodes to follow the minute expansion and contraction of the weld joint as it heats and cools.
A differential motion force-firing system initiates the welding control at the precise moment when the pre-set electrode force is applied to the work pieces.
| Force | 15 Kgf (min) - 45 Kgf (max) |
| Current | 2500 Amps max |
| Throat Depth | 200mm |
| Throat Gap | 80mm |
Note: Other values of force & current can also be given depending on requirement.
A spot welding machine typically consists of several key components, each playing a crucial role in the welding process:
Electrodes: These metal pieces apply pressure and heat to the workpieces, ensuring a strong weld.
Welding Gun: The handheld device that positions the electrodes on the workpieces, allowing for precise application.
Power Source: Provides the electrical power needed to generate the heat and pressure required for welding.
Control Panel: Allows the operator to control various parameters of the welding process, such as heat and pressure settings.
Cooling System: Prevents overheating of the electrodes and other components, ensuring consistent performance and safety.
Spot welding machines are widely used across various industries due to their efficiency and reliability:
Automotive: Essential in the manufacture of vehicles, spot welding machines join metal parts to create strong, durable structures.
Manufacturing: Used in the production of appliances, machinery, and other metal products, ensuring high-quality welds.
Construction: Vital in building and bridge construction, spot welding machines join metal components to form robust structures.
Aerospace: Employed in the manufacture of aircraft and spacecraft, where precision and strength are paramount.
Spot welding machines are equipped with several safety features to ensure safe operation:
Insulation: Prevents electrical shock by insulating the machine’s components.
Grounding: Ensures the machine is properly grounded to avoid electrical hazards.
Interlocks: Prevent the electrodes from being applied unless the machine is correctly set up, enhancing safety.
Safety Switches: Automatically turn off the power if the machine is not properly set up or if there is an issue with the welding process.
Cooling System: Prevents overheating, reducing the risk of electrical shock and ensuring consistent performance.
By incorporating these safety features, spot welding machines provide a secure and efficient welding solution for various industrial applications.
Regular maintenance is crucial to ensure the optimal performance and longevity of your spot welding machine. Here are some essential tips to help you maintain your machine:
Cleanliness: Regularly clean the machine and its components to prevent dust and debris from accumulating. Use a soft brush or cloth to wipe down the welding machine, ensuring that all parts are free from contaminants that could affect performance.
Lubrication: Lubricate the moving parts of the machine, such as the electrodes and the arm, to prevent wear and tear. Proper lubrication ensures smooth operation and extends the lifespan of the components.
Electrode Maintenance: Regularly inspect and replace the electrodes as needed. Worn-out electrodes can significantly affect the quality of the welds, so it’s important to keep them in good condition.
Check the Power Source: Ensure that the power source is stable and within the recommended range. Fluctuations in input power can lead to inconsistent welds and potential damage to the machine.
Check the Welding Current: Regularly check the welding current to ensure it is within the recommended range. Consistent welding current is essential for producing high-quality welds.
PTroubleshooting is an essential part of maintaining your spot welding machine. Here are some common issues and their solutions:
Poor Weld Quality: If you notice poor weld quality, check the condition of the electrodes, the welding current, and the power source. Worn or misaligned electrodes, unstable welding current, or an inconsistent power source can all contribute to subpar welds. Adjust or replace components as needed.
Machine Not Turning On: If the machine does not turn on, check the power source, circuit breaker, and fuses. Ensure that the machine is properly plugged in and that the power cord is not damaged. Sometimes, a simple reset of the circuit breaker can resolve the issue.
Electrode Not Moving: If the electrode is not moving, check the alignment of the electrode arm and ensure that it is properly positioned. Lubricate the moving parts if necessary to facilitate smooth operation.
Welding Current Not Stable: If the welding current is not stable, check the power source to ensure it is stable. Fluctuations in the power supply can cause instability in the welding current. Adjust the welding current settings as needed to achieve consistent performance.
Spot welding machines are an essential tool in various industries, including automotive, manufacturing, and construction. By understanding the basics of spot welding, selecting the right machine, and following regular maintenance and troubleshooting tips, you can ensure optimal performance and longevity of your machine. Remember to always follow safety guidelines and manufacturer instructions when operating a spot welding machine. With proper care and attention, your spot welding equipment will continue to deliver high-quality results, enhancing your production capacity and ensuring the durability of your welded products.
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