Production weld heads automate stud welding
A stud weld gun often conjures the image of a single, handheld model connected to a power source, moving down a work piece, welding stud after stud. Today’s stud welding technology, however, accommodates a broad range of production weld heads, configured in proprietary designs to achieve the best weld under any condition. If you’re considering acquiring a stud welding system, there are production weld head systems that might work well for your needs.
Stud weld production heads
If you work in an industrial setting, a production stud weld system will save valuable time and money by speeding up your manufacturing process, hastening throughput, and reducing energy consumption. These sophisticated machines can manage multiple guns with automatic feed mechanisms and solid state, programmable control units, all of which guarantee a strong and reliable bond with every stud.
- Fixture Mount / Hand Load
Sometimes the issue is simply accurate positioning and perpendicularity. The demands of many of today’s engineering requirements cannot be met with hand held tools. However, many times the capital cost of fully automated systems can be prohibitive. That’s where the fixture mount/hand load weld head is a perfect fit. These heads are precision machined and located with dowel pins for accuracy. The mechanisms use precision bearing systems to ensure accuracy and repeatability. Typically these heads can work with your existing stud weld equipment so the capital costs are small.
- Automatic stud feed
An automatic feed speeds up the production process significantly because the welding process can only go as fast as the studs are made available. Manually feeding the welding gun takes time, and is affected by the style of the tool and the dexterity of the welder. Manual feeding the gun might result in up to 10 welds per minute.Automatic feeders, however, are designed to produce a stud as fast as the tool completes the last weld. The length of time for a weld to be complete is usually under two seconds; an automatic feeder will have the next stud ready as soon as the prior weld is finished. Speedy feeding of the equipment makes your use of a production stud head more efficient and economical.These systems are more complex in that they have feeding systems (typically a bowl feeder) and control systems to coordinate the operation of the bowl sending a faster and the weld head receiving a fastener.
- Programmable controls & Fixed Automation
Another benefit of a production stud weld configuration is the programmable controls that can be a part of your welding process. By adding fixed automation (air cylinders and actuators) the operator can load the work piece, load the fastener (in the case of hand load) and press palm buttons. The PLC takes over and positions parts, clamps parts, lowers weld heads and initiates weld sequences. This can all be done to improve accuracy and increase production speed.
- Data Reporting
Today’s digital technology has transformed the welding industry by providing accurate, per weld data on every run. Digital controls can be set for any type of fastener and ay type of base material, automating the entire welding process. Additionally, some controls will also report the date and time of the work, the weld tools used, the weld parameters, and results. Quality control documentation features provide reliable reports on each weld.
If you have questions about stud welding contact your sales representative!