DC Motor Armature Commutator Fuser Welding Fusing Soldering Hot Staking Machine

DC Power Supply Spot Welding Machine For Armature Commutator Fusing Hot Staking WIND-DC-CW003
 
 
 
(1) Application:
 
PMDC motor armature with hook commutator, riser commutator
 
Commutator spot welding machine conductor hot staking Fusing for thin or big wire High frequency
 
inverter weld and hot stacking commutator with small big wire thin and big wire, with cooling water device
 
(act as a conditioner)
 
The solder connect commutator segment tang and wire, the fusing machine positioned adjacent the
 
copper wire and tang during hot staking to enhace the electrical and mechanical connection.
 
For hook type commutator, each segment have a tang, the commutator fusing machine hot forging the
 
armature conductor coil wire and commutator segment and filling at least some cavities between the wire
 
and tang with electrode.
 
 
(2) Advantages:

 
 
 
(3) Question and answer of the fusing soldering machine:
   (How to select a suitable welding fusing hot staking machine)
1- Are each segment’s current and time adjustable?
 
--- I think your question is about achieve even and constant fusing quality for each segment,
The DC power supply machine with high requency's output current is even and constant, can make sure even welding quality,
 
On machine parameter set screen, there is 6sections welding current and time setting for armature with many hooks such as 63hooks,
and for a 24 hook commutator, you can divide the welding parameter to 3 stages by setting Bar. no. as 1+22+1 = 24 or divide the setting to set 1+1+1+2+3+16 =24
considering heat up time for electro rod and actual situation,
 
In actual production, some user just set the Bar No. in Section1 as 24,
 
2- How electrode distance is controlled?
--- The distance suggested is about 1.5mm to 2mm, should be more than 1mm in case the commutator OD have some difference
You can check by a 1.5mm thickness commidity as a Plug gauge
 
3- Is there any ruler to measure and feed back this distance?
--- Not yet ruler, just operator observe,
 
4- How the pressure applied by the electrode to the hook is adjusted and controlled?
--- With diffent size of Press Spring the pressure can be adjusted, for rough control with spring, for slight control with screw on top
    and lastest type WIND-TMI-3 with servo motor to control the pressure
 
5- Is there any load cell to control this pressure?
--- Not yet
Wind Automation hydraulic and servo press machine for commutator,
shaft placement have this kind of load cell which can control and show pressure,
We are applying this to the new fusing machine WIND-DC-CW003 with servo device pressure later,
This will be applied for local users who required first
 
6- How the fusing current is controlled, is it kept constant? Current feedback?
--- The fusing constant current is controlled by voltage

 
7- What are the steps of the fusing cycle, how each portion of this cycle is adjusted? (VERY IMPORTANT)
--- Fusing cycle is electrode touch the commutator hook, then press the commutator hook, holding the pressure and release
Please check graphic of the fusing cycle on attached photo
This cycle is related to four factors,
the electrode and commutator hook contacting face area, pressure value, holding the pressure time, fusing voltage
You can get a best cycle by teamwork of this four factors,
The cycle time of WIND-DC-CW003 can achieve is 0.4senconds per slot, fasest in China motor armature fusing machines till now
 
High frequency 15KHz ensure the pure output DC current, while some fusing machine 2KHz, 4KHz not high frequency
The constant current can make sure fusing each segment without hesitate, so DC power supply is faster and save electricity
 
8- Is there any warning sign for bad fusing?
--- Yes, machine have this function
 
 
 
 
(4) Fusing machine Parameter:
 
Wire diameter: 0.01~1.2mm
 
Armature OD: 20~100mm
 
Armature stack height:10~100mm
 
Commutator OD:8~70mm
 
Airsource:5~7KG/cm2
 
Welding power: 10~30KW
 
3phase AC 380V 50~60Hz
 
Weight: about 350KGS
 
Fusing power supply: Wind Automation self developed high frequency 15KHz, 500~5000A
 
Control system: Japan Mitsubishi PLC
 
Indexing control: Japan Mitubishi servo positioning system 7'' Touch screen
 
 
 
(5) Feature: 
 
1)  Commutator spot welding machine conductor hot staking Fusing for thin or big wire High frequency 
 
     inverter weld and hot stacking commutator with small big wire thin and big wire, with separate
 
     cooling water device (act as a conditioner)
 
2)  Welding operation is related to the tungsten rod area, pressure, welding time, voltage current value
 
3)  Armature OD, shaft size is related to the fixture 
 
     Armature OD normal range 20~60mm
 
     Shaft below 16mm Shaft size
(6) International Clinets Feedback:
 
 In the year 2025

 
In the year 2026 
ABC Company use the Fusing machine production in motor making process