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Resistance Welding

The eleven resistance welders pictured above were only part of what was required for this project. Several other more specialized welders were also required. MLS Systems had the capability to design and build them all with plenty of room to spare for other projects.

MLS Systems has built many styles and types of dial table machines including dial table resistance welders like the dual operator design pictured above.

This machine design incorporates a small 48" diameter four station dial table used for assembly and resistance welding of small components. Components were manually loaded and unloaded by the operator.
 

Standard and Special Resistance Welders

  • AC/DC Spot and Projection Welders
  • Cross Wire Rack and Shelf Welders
  • Compressor Projection Welders
  • Robotic Weld Cells
  • Seam Welders
  • Automation for all of the above

MID-Frequency Welding

MFDC welding is a resistance welding process using high frequency to provide a weld. There are many advantages with this welding process. The power supply is physically smaller than equivalent 3 Phase DC power supplies. The primary demand is lower than equivalent AC or DC welding processes. There is up to 10% less total energy used to produce a weld versus conventional AC welding process. This process provides microsecond control over welding process and attains weld current immediately. Weld times can be decreased as much as 33% versus conventional AC welding process. The weld currents and weld forces are lower and the heat zone is reduced. This can increase the life of welding electrodes as well as make welding small or thin parts more effective. It can also improve spot welding of hard to weld materials such as coated steels or aluminum.

Mid-Frequency Concept WelderMid Frequency Welder

Above, you see the concept and final build of a mid-frequency welder used for attaching fittings onto water heater tanks.

Put our knowledge and experience in mid-frequency welding to work for your resistance welding process.

Our team of engineers can custom design a mid-frequency welder to fit your process requirements.

Resistance Welders - Welding Applications Systems

MLS Systems produced many very similar welding machines for this project; however, each machine had a specific welding purpose different from the other. These machines were designed to produce oven door panels. Each machine was designed to an eleven second cycle time.

Base frame spot welding system. This welding system was designed to produce large sheet metal base frames of various sizes. Jib mounted trans-guns were utilized to perform all the spot weld joints needed for the final assembly.
 

This line makes dishwasher baskets. Pre-cut pre-straightened wires are welded into a mat then formed into the final basket shape in the various automated stations.
 

This dual station welder shared light curtains,PLC, transformer and weld controls as a method of minimizing machine cost and providing flexibility to run other models with a selector switch changeover.
 

MLS Systems has built many systems similar to this one which are used to resistance weld wire baskets. Basket sub assemblies are manually loaded and clamped then the wires are welded into position.

Two resistance welders used to produce front consoles.
 

Panel welder machine

Stiffening brackets are first loaded into a tooling nest, indexed under the weld cylinders for welding then, pushed out the back of the machine onto guide rails.
 

Multiple gun drop knee style resistance welder.

Multiple station dial table equipped with C-frame resistance welding heads.
 

Resistance welder with shuttle table used in making appliance cabinets.
 

This resistance welder utilized a servo to rotate the part to produce the required welds. Welds were performed simultaneously to both sides of the part in between actuations of the servo.
 

This custom designed resistance welder performed multiple welds using a combination of swing clamp style welding heads and straight action weld cylinders.
 

This dual shuttle table resistance welder concept allowed operators to be loading parts on both ends of the machine simultaneously. Palm switches would be activated when they had completed their loading tasks. The machine would decide which shuttle would first transfer the parts under the weld heads. Parts would be rapidly welded and be transferred back to the operator(s) for manual unloading at each end.
 

This resistance welder utilized a rotary actuator to move the part into position and then perform the required welds. The machine was tilted for ease of operator load and unload of the drum assemblies.
 

This resistance welder utilized a four station dial table to weld wire baskets. Two operator stations were provided for loading and unloading along with a weld station that performed 16 crosswire welds.
 

This shuttle table resistance welder design is so popular that two divisions of one company have purchased the same machine.

This resistance welder was designed with ergonomics in mind so that parts were easily loaded and unloaded.