Medium Frequency Pneumatic Copper Wire Spot Welding Machine 100KVA Stationary
Product Overview
This Medium Frequency Pneumatic Copper Wire Spot Welding Machine is a stationary resistance spot welding solution engineered specifically for high-efficiency copper wire welding applications. With a rated capacity of 100KVA and a maximum short-circuit current of 30KA, this machine delivers robust welding performance for low-carbon steel, stainless steel, and non-ferrous metals, including copper wire, sheets, and pipes. Designed as a dual-purpose spot and projection welder, it supports plate-to-plate welding, projection nut welding, and bolt welding, making it a versatile asset for modern fabrication lines.
Built by ChengDu Xinweihan, a leading Chinese welding equipment manufacturer with a 20,000 sq.m production facility and an R&D team of over 20 engineers, this machine reflects years of application experience across automotive, hardware, and household appliance industries. The stationary design moves the workpiece while the machine remains fixed, offering a compact, stable, and energy-efficient welding platform that reduces labor intensity and improves production throughput. Backed by overseas technical service teams in Southeast Asia and South America, this equipment is supported globally for installation, commissioning, and maintenance.
Key Technical Advantages
High-Rigidity Integrated Frame Structure
The machine features a unique tree-style body with impact-resistant, earthquake-resistant, and high-rigidity design. Internally welded reinforcing ribs minimize deformation during continuous welding, ensuring stable welding points and safe manual operation. This structural integrity translates into consistent weld quality over long production runs, reducing rework and downtime.
Precision Linear Guide Electrode Movement
The upper electrode moves vertically along a linear guide with high repeat positioning accuracy, guaranteeing precise welding point placement. Combined with a low-damping aluminum alloy cylinder and high-flow electromagnetic directional valve, the electrode delivers fast response and sensitive follow-up performance, enabling exceptionally high spot welding speeds and improved production efficiency.
Capacitive Charging and Discharging for High Efficiency
The capacitive charging and discharging system achieves rapid welding cycles with short weld times, significantly boosting throughput while maintaining consistent weld quality. This feature is particularly beneficial for high-volume copper wire welding operations where speed and reliability are critical to meeting production targets.
Accurate Pneumatic Pressure Control
An electrical proportional valve precisely adjusts welding pressure, allowing operators to fine-tune parameters for different material thicknesses and joint configurations. This ensures optimal weld penetration and reduces the risk of weak or defective welds, leading to higher first-pass yield and lower material waste.
Energy-Saving Fully Water-Cooled Welding Circuit
The main welding circuit employs a fully water-cooled resistance welding transformer and rectifier with strong output power. This design enhances energy efficiency and heat dissipation, allowing continuous operation without overheating. Additionally, air pressure and water pressure switches with alarms prevent water shortage or gas-related welds, protecting equipment and ensuring safe, uninterrupted production.
Insulation Protection with Foot-Switch Operation
The secondary circuit adopts a pressurized cylinder seat and upper arm insulation design, enabling direct installation and welding on the lower seat without short-circuit risk. Foot-switch control meets operator ergonomic habits, increasing production efficiency while reducing labor fatigue. This practical design supports continuous shift operation with minimal operator strain.
Applications
| Industry |
Typical Workpiece |
Welding Mode |
| Automotive Manufacturing |
Body panels, nuts, studs, brackets |
Spot welding, Projection welding |
| Household Appliance Production |
Sheet metal enclosures, wire components |
Spot welding |
| Hardware Fittings |
Fasteners, connectors, brackets |
Spot welding, Projection welding |
| Electrical & Copper Wire Industry |
Copper wire, copper lugs, busbars |
Spot welding (copper wire mode) |
| Transportation Equipment |
Railings, frames, support structures |
Spot welding |
Working Principle
The medium frequency spot welding machine operates by converting standard three-phase AC power into a controlled DC welding current through a fully water-cooled resistance welding transformer and rectifier. The upper electrode, driven by a pneumatic cylinder with proportional pressure control, descends to clamp the workpiece against the lower electrode. A high-current, short-duration pulse is then discharged across the contact point, generating localized resistance heat that fuses the materials together. The capacitive charging and discharging system ensures rapid energy release with precise timing, while the linear guide mechanism maintains accurate electrode positioning. The foot-switch activation allows operators to initiate each weld cycle with minimal effort, while the integrated air and water pressure safety switches continuously monitor system integrity to prevent defective welds and equipment damage. This synchronized sequence of pneumatic pressure, electrical discharge, and thermal consolidation delivers repeatable, high-strength welds across a variety of ferrous and non-ferrous materials.
Technical Specifications
| Parameter |
Unit |
DN(B)-100 |
DN(B)-160 |
DN(B)-200 |
DN(B)-250 |
| Rated Power (at 50% duty cycle) |
KVA |
40 |
63 |
80 |
100 |
| Rated Primary Voltage |
V |
3φAC 380V |
3φAC 380V |
3φAC 380V |
3φAC 380V |
| Max. Short Circuit Current |
KA |
30 |
35 |
45 |
45 |
| Duty Cycle |
% |
50 |
50 |
50 |
50 |
| Max. Electrode Force |
N |
6000 |
6000 |
10000 |
15000 |
| Electrode Length |
mm |
450 |
450 |
450 |
500 |
| Working Stroke |
mm |
80 |
80 |
80 |
80 |
| Cooling Water Consumption |
L/min |
20 |
20 |
20 |
20 |
| Max. Welding Capacity (Steel) |
mm |
3.0+3.0 |
4.0+4.0 |
5.0+5.0 |
6.0+6.0 |
After-Sales and Support
- Warranty — 1-year comprehensive warranty covering manufacturing defects and workmanship issues, with fast replacement of faulty components.
- Field Installation & Commissioning — Professional engineers provide on-site installation, calibration, and operator training to ensure the machine reaches full production capacity quickly.
- Technical Support — Dedicated video technical support and online assistance available for troubleshooting, parameter optimization, and process guidance during and after the warranty period.
- Spare Parts Availability — Free spare parts provided for initial setup, with a reliable supply chain for long-term maintenance needs, ensuring minimal production downtime.
- Global Service Network — Overseas technical service teams in Southeast Asia and South America offer on-site maintenance and repair, reducing response time and logistical complexity for international clients.
Frequently Asked Questions
What is the maximum welding thickness this copper wire spot welding machine can handle?
The DN(B)-100 model can weld steel sheets up to 3.0+3.0 mm, while larger models extend capacity to 6.0+6.0 mm. For copper wire applications, the machine features a dedicated copper wire welding mode that delivers stable, high-quality welds on copper conductors, lugs, and terminals commonly used in electrical and electronics manufacturing.
What is the delivery lead time and does the machine come with installation support?
Standard delivery is typically 15-30 days after order confirmation, with custom configurations requiring additional lead time. All machines include field installation, commissioning, and operator training services. Our engineering team provides on-site support to ensure the equipment is properly integrated into your production line and operating at optimal efficiency from day one.
Can this machine be customized for specific copper wire diameters or welding patterns?
Yes, customization options are available. The copper wire welding mode can be fine-tuned through adjustable welding current, pressure, and timing parameters to match your specific wire gauge and joint requirements. Our application engineers work closely with you to configure electrode geometry, welding schedules, and automation interfaces based on your workpiece drawings and production targets.
What after-sales support and warranty coverage are provided after purchase?
Each machine includes a 1-year warranty covering manufacturing defects. After-sales support includes free spare parts for initial setup, video technical support, online troubleshooting, and access to our overseas service teams in Southeast Asia and South America. We also provide ongoing process consultation to help you optimize welding parameters for new applications or materials.
Request Your Welding Solution
Send us your workpiece drawings and production requirements. Our engineering team will evaluate your application, configure the optimal solution, and provide a detailed proposal with electrode design and automation integration options.
Send Drawing | Request Welding Test | Get Custom Solution
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