micro welding applications
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Micro Welding Applications for Small Part Joining

In joining for small parts, components made of steel or various non-ferrous metals are joined together using suitable types of welding such as spot welding, coated wire welding, compacting or resistance soldering. These processes are all sub-categories of micro resistance welding.

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 underlying weld timer. Also extensive switch-off and further switching options for individual welding pulses and useful monitoring options are needed.

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 LSK precision weld 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.

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. Therefore high precision and reliable manufacturing equipment is required. Our controls and weld heads provide high quality results with in-system diagnosis capabilities.

Suitable weld timers for medical technology:

Suitable welding pincers for medical technology:

Examples for resistance welding in medical technology

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 contact joining:

Suitable weld heads:

Examples for the welding of contacts

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" 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:

Suitable weld heads:

Examples for the welding of light bulbs

Assemblies / Hybrid Components

Hybrid components combine different materials and geometries. For the control algorithms, this often presents a particular challenge, as the weld spot is often not optimally accessible. In addition to precise micro welding control systems with special monitoring functions, heads and welding guns that know the exact 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 weld 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:

Suitable weld heads:

Examples for the welding of hybrid components

Collectors (Hot Staking / Heat Staking)

This method is used for contact points accessible from one side, where the contact electrode is placed close to the 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:

Suitable weld heads:

  • All ServoSPATZ+ actuators
Examples for the welding of collectors

Lead Batteries

The requirements for joining of connectors within a lead acid battery are very special. On the one hand, it is particularly important to prevent weld 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.

Also for any other battery pack and cell manufacturing, resistance welding is an highly reliable joining technology. Different base metals combinations for various electrical contacts within assembly process can be joined. With increasing demand for traction drive batteries also the demand for high quality manufacturing euipment comes along.

Suitable weld timers:

Suitable extension cards:

Examples for the welding of lead batteries

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 copper hairpin stators of electric motors requires powerful welding equipment 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:

Suitable weld heads:

Examples:
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WELD TIMER

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

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We would be happy to advise you on the selection of suitable solutions for your individual welding tasks and inform you about our training portfolio.  Details >>>