Direct Spot Welding Machine

Direct Spot Welding Machine (DISM)

The DISM peels off magnetic wire coating and welds the wire in a single operation.

The DISM is an AC spot welding machine that has no need for pretreatment of the magnetic wire end.
The DISM is not in need of a separate process for peeling off coating,
so increases work efficiency and contributes to improvement of the quality.
The DISM can also be built into an automatic wire-winding line as a welding unit.

Specifications
Model name	Common specifications	KWA061B	KW080B
Power sources	Welder section	AC 200V single phase
Power sources	Controller section	AC 100V
Welder section	Rated capacity	3.2KVA
	Normal air pressure	4~6kgf/c㎡
	Maximum applied force	28kgf
	Coolant flow rate	200ml/minute
	Depth dimension	105~110mm
	Electrode stroke	MAX 20mm
Controller section	Constant current type or power supply compensation type controller using thyristor phase control
Dimensions and weight	W740×H1260×D900mm 110kg
Air pressure detection (for driving welding head)		Air pressure gauge /visual confirmation	Digital air pressure gauge /signal output
Coolant detection		Blade rotation /visual confirmation	Blade rotation /signal output
Counter (for electrode control)		4-digit counter × 1 /signal output	4-digit counter × 2 /signal output

*Product specifications are subject to change. For details, please refer to the specifications.
* The KWA372A is a twin-electrode spot welder that has high welding pressure and current.
It is particularly well-suited for welding work using large-diameter wires.
As an option, a sensor unit for maintaining a constant fusing thickness is available.

Welding flow
Applying pressure	It takes about two seconds from applying pressure to welding completion.
▼
Peeling off coating, and welding
▼
Completion of welding

Example of welding strength data (Unit:kg)
Terminal : Tin-plated phosphor bronze t=0.8 *Welding strength is depending on welding conditions, wire diameter, and wire type; however, standard horizontal tensile strength is 70%-90% of strand strength.
Wire type	Strand strength	Horizontal tensile strength		Ratio of welded wire strength to strand strength
Wire type	Strand strength	Minimum	Maximum	Ratio of welded wire strength to strand strength
PEW φ 0.749	0.749	0.621	0.735	82-98
AIW φ 0.868	0.868	0.649	0.865	74-89
PEW φ 0.3	2.009	1.597	1.957	79-97
AIW φ 0.3	2.075	1.750	2.050	84-98

Examples of combination of wire material, wire type, wire diameter, and object to which wire is welded.
Object to which wire is welded	Tin-plated phosphor bronze
Object to which wire is welded	Tin-plated phosphor brass
Wire to be welded	PWE EW AIW
Wire to be welded	Wire diameter: φ0.03 ~ φ0.8

Examples of DISM application(coil manufacturing)

・Comparison of work processes

Example 1	Coil winding	→	Dipping wire end into "Sol coat" solution	→	Wiping(peeling) off coating from wire end	→	Winding wire and spot welding
Example 2		→	Peeling off coating from wire end mechanically	→	Coating powder removal	→	Winding wire and spot welding
DISM		→					Direct spot welding

・VA effect

	Example 1	Example 2
Reduced peeling rate	0.2min.pcs --> 0min./pcs	0.43min./pcs --> 0min./pcs
Amount of effect	\25/min.×0.2min./pcs=\5/pcs	\25/min.×0.43min./pcs=\10.75/pcs
Annual amount of effect	50,000pcs/month×\5/pcs12months =\3,000,000	50,000pcs/month×\10.75/pcs12months =\6,450,000

・Welding examples

Welding to flat terminal	Welding of wound wire	Fusing
(image)	(image)	(image)

Examples of use : electrical equipment for automobiles, motors, generators, transformers, household electrical appliances.
*We are also pleased to design and manufacture other items to meet customer's demands.