Resistance Welding in the Small Parts Section

In resistance welding for small parts, components made of steel or various non-ferrous metals are joined together using suitable joining methods such as spot welding, coated wire welding, compacting or resistance soldering.

The challenge of joining the most diverse geometries such as projection, wire or fork in a process-safe manner requires high-precision current, force, path and temperature profiles from the weld timer, as well as extensive switch-off and further switching options in the individual welding pulses and useful monitoring options.

With the modular SPATZ+ series, MATUSCHEK offers product solutions in the small parts section that meet the highest process requirements and can be optimised to meet specific customer needs.

In combination with the LSK precision welding heads, even small and very small components can be welded in confined spaces and thus represent the solution for countless joining tasks in electronics and medical technology.

To achieve higher currents of up to 100 kA and more, the SPATZ+ weld timers can be cascaded (master/slave). In this way, even more solid parts made of copper or aluminium can be welded, as in the field of electromobility.

Fully automated systems with field bus and Ethernet for superordinate weld timer, programming and analysis (Industry 4.0) are just as feasible with SPATZ+ controllers as sophisticated manual workstations.

Resistance Welding in Medical Technology

In medical technology, a welded joint must last a lifetime. Pacemakers, defibrillators, stents and device sensors do not allow the welded joint to fail. Here, welding heads with the precision of a scalpel and welding controllers are needed that can produce a safe welding spot and provide a reliable diagnosis.

Suitable weld timers for medical technology:

Suitable welding pincers for medical technology:

Examples for resistance welding in medical technology

Resistance Welding of Contacts

Contacts are produced in very large quantities. Whether welded or soldered, despite high cycle rates, high thermal stress and progressive wear, the connection must be firm at all times. SPATZ+ series controllers adapted to the task in hand not only create a firm connection, but also offer a wide range of monitoring functions to reliably detect poor welds. By means of a trend display in the software, it is also possible to recognize early on if something goes wrong.

Suitable weld timers for the welding of contacts:

Suitable welding heads for the welding of contacts:

Examples for the welding of contacts

Resistance Welding of Light Bulbs

Wafer-thin foils made of exotic material are to be welded with finest wires and barely visible wire coils. And every welded joint must be good. Because each individual weld determines the function and service life of the bulb.

Extremely "smooth" welding currents are also required here in order not to pre-damage these sensitive materials with current peaks. In the case of cross-wire connections within the bulbs, a narrow tolerance is also required for the penetration of the wires.

All these requirements can be reliably met with the high-frequency inverters of the SPATZ+ series. The measuring inputs for current, voltage, force and displacement signals, which are part of the standard equipment, enable reliable inline control of the process data.

Suitable weld timers for the welding of light bulbs:

Suitable welding heads for the welding of light bulbs:

Examples for the welding of light bulbs

Resistance Welding of Assemblies / Hybrid Components

Hybrid components combine different materials and geometries. For the welding process, this often presents a particular challenge, as the welding point is often not optimally accessible. In addition to precise welding control systems with special monitoring functions, heads and welding guns that know the position are also required.

In combination with our high-frequency inverters, our electromotive heads and guns are ideal for this purpose. Not only can they quickly adjust to the next welding spot by recording the path, but they also offer very fast repositioning behavior, as is known from very good follow-up behavior, thanks to the linear drive.

Suitable weld timers for the welding of hybrid components:

Suitable welding heads for the welding of hybrid components:

Examples for the welding of hybrid components

Resistance Welding of Collectors (Hot Staking)

This method is used for contact points accessible from one side, where the contact electrode is placed close to the welding electrode on one side from above.

The ends of the winding wires are placed one above the other in a slot which is sawed into the collector. This process is used in the series production of small motors on mechanized or automated welding machines and is part of resistance welding of enamel-insulated wires.

Suitable weld timers for the welding of collectors:

Suitable welding heads for the welding of collectors:

  • All ServoSPATZ+ actuators
Examples for the welding of collectors

Resistance Welding of Lead Batteries

The requirements for resistance welding of the connectors within a lead acid battery are very special. On the one hand, it is particularly important to prevent welding spatter, as relatively large quantities of liquid lead fly around in the production plant and the battery becomes unusable as a result. On the other hand, so-called "cold spots" must also be safely avoided, as these can lead to the destruction of the battery in later use.

The medium-frequency systems of the SPATZ+ series have proven themselves both for new systems and for subsequent integration into old systems. The standard equipment of these power sources includes limit value and alarm management, integrated weld data memories, options for process data analysis, various control strategies, freely configurable current profiles and much more.

Suitable weld timers for the welding of lead batteries:

Suitable extension cards for the welding of lead batteries:

Examples for the welding of lead batteries

Resistance Welding in Electric Mobility

Copper and aluminium are two highly conductive materials that need to conduct a lot of electricity for mobility, but need even more electricity for a permanent connection.

Hot crimping on the Hairpin Stators requires strong welding systems and flexible program structures in order to map the individual steps of the joining process.

Resistance soldering of thick, compacted copper strands requires a control system with endurance and temperature control matched to the melting point of the solder.

Suitable weld timers for welding in electric mobility:

Suitable welding heads for welding in electric mobility:

Examples for the welding in electric mobility
WELD TIMER

Here you will find the product solutions in the small parts section of the SPATZ+ series.  Details >>>

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