Electroweld Industries

Applications: the Electroweld Pneumatically Operated BiMetal BandSaw Blade Flash Butt Welder is designed for welding Bi-Metal Bandsaw Blades

Electroweld Pneumatically Operated BiMetal BandSaw Blade Flash Butt Welder 30KVA (FBW-2754PN)

Weldability: Bi-Metal Bandsaw Blades - Width 27mm-54mm, Thickness: 0.9mm-1.6mm

Features:

- Fast and simple welding operation saves time.

- High quality weld joints without misalignment.

- No additional solder and flux.

- Fast preparation of strip ends.

Construction

- Robust design - therefore long lasting and reliable.

- Precision control is achieved via movable jaws that run on wear resistant precision ball type guides which reduce friction and ensure utmost welding accuracy.

- The Machine has 2 flat welding Jaws designed with a pneumatic clamping mechanism. This quick and firm clamping arrangement enables automatic alignment of the bandsaw blades for higher weld productivity. The clamping action of the welding jaws is controlled via the Right and Left Clamping foot switches which in turn activate the Pneumatic Clamping cylinders. The machine is also designed with a Horizontal Pneumatic Welding Cylinder for providing horizontal pressure on the welding jaws during the welding process.

Simple Settings:

1. ELECTRODE SPACING: Adjust lever on indexing plate depending on the width of the blade being welded.

2. WELDING CURRENT: Operate knob of the 8 step switch, current making and breaking is automatic via a built-in electromagnetic contactor.

3. UPSETTING PRESSURE: Micrometrically adjustable with pressure control knob for the incoming compressed air line supplying air pressure to the Pneumatic Cylinders.

4. CURRENT ON / OFF: Weld Initiation via Push Button/ Foot Operated Switch and welding duration electronically controlled via timer values.

TIMER AND % HEAT SETTINGS FOR PROGRAMMING THE AUTOMATIC WELDING CYCLE

Following is the sequence of timers which trigger sequentially once the butt welding process is initiated via the pushbutton or foot operated switch:

(A) 'Squeeze 1' Timer (Setting range on 0-100 scale: 0-2 seconds): Timer for initiating clamping of the job via the 2 Vertical Clamping Pneumatic Cylinders. The clamps engage once the timer expires

(B) 'Weld 2' Timer (Setting range on 0-100 scale: 0-120 seconds or 0-360 seconds-depending on machine): Timer for setting the weld cycle time for the duration of the current applied to the weld job. This timer is sequentially triggered once the Vertical Clamping cylinders have clamped the welding job after the 'Squeeze 1' timer expiry. Additionally the initialization of this timer also triggers the activation of the Horizontal Pneumatic Cylinder which provides Upset Pressure for Butt Welding. On expiry of this timer the welding current is stopped.

(C) 'Forge 1' Timer (Setting range on 0-100 scale: 0-2 seconds): Timer for releasing the clamping of the job via the 2 Vertical Clamping Pneumatic Cylinders. This timer is triggered in sequence once the 'Weld 2' timer expires and this timer disengages the 2 Vertical Pneumatic Clamping Cylinders on 'Forge 1' timer expiry.

(D) 'Forge 2' Timer (Setting range on 0-100 scale: 0-2 seconds): Timer for releasing the upset pressure the job via the Horizontal Upset Pressure Pneumatic Cylinder. This timer is triggered in sequence once the 'Forge 1' timer expires and disengages the Horizontal Upset Pressure Pneumatic Cylinder on 'Forge 2' timer expiry.

Following setting controls the % of welding current applied to the job during the welding process when 'Weld 2' timer is engaged:

(E) % Heat Setting (Setting range on 0-100 scale: 0-100%): Weld Power setting adjusted depending on Diameter of Rod being welded.

Electroweld industries is a leading manufacturer of resistance welding equipment, serving the industry for over 45 years. Our welding machines are designed to provide a production solution at an affordable price while ensuring reliability and low cost maintenance.

Applications: The Automatic Upset But Welding machine type UBW-415 is designed as a portable model for heavy duty butt welding operation.

Electroweld Upset Butt Welder 20KVA Model: UBW-415

Weldability (Weldable Option 1)- Mild Steel: 4mm-15mm, High Carbon Steel: 4mm-11mm, Copper: 4mm-8mm, Brass: 4mm-10mm, Aluminium: 5mm-10mm

Weldability (Weldable Option 2) - Carbon Steel Bandsaw Blades width: 30mm-50mm, Bi-Metal Bandsaw Blades width: 20mm-37mm

Construction: Machine is constructed with a sturdy light alloy housing and all high voltage components are housed within the body. The machine is mounted on a four-wheeled trolley type stand for easy portability.

Upset Travel : Moveable platten travel on parallel guides of precision design and construction ensuring accurate and frictionless travel and perfect alignment of the weld.

Upset Pressure : Provided by a precision spring, acting on the moveable platten and micrometrically adjustable by means of a knob, the setting being readable on a scale.

Clamps : Lever operated, adjustable "floating" steel clamps of precision quick acting design, ensure firm preset clamping pressure. Release is quick and easy.

Electrodes : Special wear resisting copper alloy electrodes provided with precision V-grooves for different wire sizes, permit rapid and accurate alignment of the part to be welded.

Welding Current Adjustment : By means of a 8 step rotary switch, the knob of which is located on the Left hand side, enabling current adjustment from 50% to 100%.

Electrode Spacing: Obtained with ease by a lever set against an indexing plate, providing adjustment in 10 steps between minimum and maximum.

Weld Current Initiation : Return of the lever after clamping the job to weld position simply starts the automatic welding cycle.

Current CutOff: Adjustable over a wide range by means of a micrometric thimble the setting of which is read on a graduated scale.

Annealing Facility : Separate annealing electrodes with screw type clamps are provided for easy and quick annealing of the welded job ensuring a flexible zone at both sides of the weld.

Welding Process

Applications: The Automatic Upset But Welding machine type UBW-415 is designed as a portable model for heavy duty butt welding operation.

Electroweld Upset Butt Welder 20KVA Model: UBW-415

Weldability (Weldable Option 1)- Mild Steel: 4mm-15mm, High Carbon Steel: 4mm-11mm, Copper: 4mm-8mm, Brass: 4mm-10mm, Aluminium: 5mm-10mm

Weldability (Weldable Option 2) - Carbon Steel Bandsaw Blades width: 30mm-50mm, Bi-Metal Bandsaw Blades width: 20mm-37mm

Construction: Machine is constructed with a sturdy light alloy housing and all high voltage components are housed within the body. The machine is mounted on a four-wheeled trolley type stand for easy portability.

Upset Travel : Moveable platten travel on parallel guides of precision design and construction ensuring accurate and frictionless travel and perfect alignment of the weld.

Upset Pressure : Provided by a precision spring, acting on the moveable platten and micrometrically adjustable by means of a knob, the setting being readable on a scale.

Clamps : Lever operated, adjustable "floating" steel clamps of precision quick acting design, ensure firm preset clamping pressure. Release is quick and easy.

Electrodes : Special wear resisting copper alloy electrodes provided with precision V-grooves for different wire sizes, permit rapid and accurate alignment of the part to be welded.

Welding Current Adjustment : By means of a 8 step rotary switch, the knob of which is located on the Left hand side, enabling current adjustment from 50% to 100%.

Electrode Spacing: Obtained with ease by a lever set against an indexing plate, providing adjustment in 10 steps between minimum and maximum.

Weld Current Initiation : Return of the lever after clamping the job to weld position simply starts the automatic welding cycle.

Current CutOff: Adjustable over a wide range by means of a micrometric thimble the setting of which is read on a graduated scale.

Annealing Facility : Separate annealing electrodes with screw type clamps are provided for easy and quick annealing of the welded job ensuring a flexible zone at both sides of the weld.

Electroweld industries is a leading manufacturer of resistance welding equipment, serving the industry for over 45 years. Our welding machines are designed to provide a production solution at an affordable price while ensuring reliability and low cost maintenance.

Electroweld Refrigerator Shelves Projection Welder 75 KVA (SPM-75PRR)

-(Weldability Sheet Thickness (2 x mm): S.S/M.S Sheet- 1.0mm-5.0mm, 6-19 SWG, 6-19 AWG)

-(Weldability Cross Wire/Mesh Application-Wire Diameter (2 x mm): 2.0mm-10.0mm, Approx. double the weldability ranges indicated above)

Applications:  The Electroweld Refrigerator Shelves Projection Welding Machine is used to weld shelves for Refrigerator's made with 8mm x 2.5mm wires. The machine comes with a single electrode which can accomodate projection welding of multiple cross-wires in the mesh application at the same time. Capable of Welding Low Carbon Steel,High Carbon Steel,High Strength Steel,Nickel Alloy,High-Temp Alloy,Titanium.

Operation: There one Press Type 75KVA Projection Spot welder provided as per the customer requirement. The operator loads and positions the job for the weld job and then initiates the welding process via foot switch. The weld job is then moved to align with the next set of spots to be made. This sequence is repeated till all the spots are made.

Construction : Heavily fabricated with streamlined appearance, suitably stiffened at points of stress. The transformer is mounted directly on to the body and the bearings for the arm are provided in the same.

Cooling System: Electrodes, Electrode holders secondary water cooled, water required to be free from residue forming impurities and at a temperature of less than 30* C or 85* F. If water temperature is higher, increased water flow is required.

Electrodes: Two pair Morse Taper II straight electrodes supplied as standard with the machine, Other types available on request.

Adjustment of Electrode Force : By means of Air Pressure. The force is adjustable and gives a constant force from 1-5 Kg Cm!by Pneumatic Cylinder, adjusted by Regulating Valve.

Adjustment of Electrode Stroke: By vertical adjustment of electrode holder.

Current Control: By means of 3/6 tap change links between 50% and 100% also fine setting through controller

Weld Initiation: By means of Foot Switch which initiates the weld only after preset pressure is built up.

Electronic Control:

(A) Thyristorised synchronous electronic sequence timer consisting of: Squeeze, weld, forge, off and heat control unit range 1-99 c/s. This is a standard controller offering.

(B) Solid State - three timers provided for squeeze, weld and forge timings - short range 5 - 50 cycles - long range 1 - 10 seconds (50 to 500 cycles). This is a standard controller offering.

(C) Optional Electroweld AY-01 Digital Timer with capability to store upto 25 different weld schedules. This option will replace the standard co

Electroweld industries is a leading manufacturer of resistance welding equipment, serving the industry for over 45 years. Our welding machines are designed to provide a production solution at an affordable price while ensuring reliability and low cost maintenance.

Applications:

• The Automatic Upset But Welding machine type UBW-1020 is designed as a portable model for heavy duty butt welding operation.

• Construction: Machine is constructed with a sturdy light alloy housing and all high voltage components are housed within the body. The machine is mounted on a four-wheeled trolley type stand for easy portability.
• Upset Travel : Moveable platten travel on parallel guides of precision design and construction ensuring accurate and frictionless travel and perfect alignment of the weld.
• Upset Pressure : Provided by a precision spring, acting on the moveable platten and micrometrically adjustable by means of a knob, the setting being readable on a scale.
• Clamps : Lever operated, adjustable "floating" steel clamps of precision quick acting design, ensure firm preset clamping pressure. Release is quick and easy.
• Electrodes : Special wear resisting copper alloy electrodes provided with precision V-grooves for different wire sizes, permit rapid and accurate alignment of the part to be welded.
• Welding Current Adjustment : By means of a 8 step rotary switch, the knob of which is located on the Left hand side, enabling current adjustment from 50% to 100%.
• Electrode Spacing: Obtained with ease by a lever set against an indexing plate, providing adjustment in 10 steps between minimum and maximum.
• Weld Current Initiation : Return of the lever after clamping the job to weld position simply starts the automatic welding cycle.
• Current CutOff: Adjustable over a wide range by means of a micrometric thimble the setting of which is read on a graduated scale.
• Annealing Facility : Separate annealing electrodes with screw type clamps are provided for easy and quick annealing of the welded job ensuring a flexible zone at both sides of the weld.

Welding Process:

• Fix the 4 simple setting, Clamp-job end to end. Return spacing lever to 'Weld' position.
• The welding then takes place automatically. Unclamp job.
• To anneal, put spacing lever to max. position. Clamp job centrally in annealing Clamps. Hold down current switch till annealing temperature is reached.

Electroweld industries is a leading manufacturer of resistance welding equipment, serving the industry for over 45 years. Our welding machines are designed to provide a production solution at an affordable price while ensuring reliability and low cost maintenance.

Applications: 

• Upset butt welding of all profiles of wires and flats of iron, steel, alloy and carbon steel, copper, aluminium, brass and other light metals and their alloys. Carbon Steel and Bimetal Blades Butt Welding

• The machines are constructed with a sturdy light alloy housing and designed as portable models mounted on a moveable chassis fitted with four wheels. They are constructed for quick, easy, and fool-proof operation, the welding process being automatic. Settings are simple, finely adjustable, and reproducible for all variables. Uniform welds of high strength capable of withstanding subsequent drawing ensured. The Machine has 2 welding Jaws with grooves for welding different sized rods. The clamping action of the welding jaws is controlled via the Left and Right Clamping Levers which in turn activate the Pneumatic Clamping cylinders. The machine is also designed with a Horizontal welding cylinder for providing horizontal pressure on the welding jaws during the welding process.

Simple Settings:

• Electrode Spacing: Adjust lever on indexing plate depending on the diameter of the rod being welded.
• Welding Current: Operate knob of the 8 step switch, current making and breaking is automatic via a built-in electromagnetic contactor.
• Upsetting Pressure: Micrometrically adjustable with pressure knob.
• Current On / Off: Micrometrically adjustable with simple thimble.

Welding Process:

• Fix the above 4 simple settings, clamp the job end-to-end in the center of the welding jaws.
• Release gap stopper lever from teeth, press the welding push button and the welding then takes place automatically. Unclamp Job.
• To anneal, put spacing lever to max. position. Clamp Job centrally in the Pneumatically Clamped Welding Jaws or the provided Annealing Jaws. Press the annealing push button till annealing temperature is reached.

Design Features:

• Upset Travel: Movable platen travel on parallel guides.
• Upset Pressure: Provided by a precision spring action on the movable platen and micrometrically adjustable with a knob. Setting is readable on a scale.
• Clamps: Lever operated adjustable 'floating' steel clamps of precision quick acting design ensure firm preset clamping pressure. Release is quick and easy.
• Electrodes: Special wear resistant copper alloy electrodes provided with precision 'V' grooves, permit rapid and accurate alignment of wires/rods/cables/blades..
• Welding Current Adjustment: By means of a 8 step rotary switch from 50% to 100%.
• Electrode Spacing: Obtained with ease by a lever set against an indexing plate, adjusting in 10 steps.

Electroweld industries is a leading manufacturer of resistance welding equipment, serving the industry for over 45 years. Our welding machines are designed to provide a production solution at an affordable price while ensuring reliability and low cost maintenance.

Applications: The Automatic Upset But Welding machine type UBW-516 is designed as a portable model for heavy duty butt welding operation.

Features:

• Construction: Machine is constructed with a sturdy light alloy housing and all high voltage components are housed within the body. The machine is mounted on a four-wheeled trolley type stand for easy portability.
• Upset Travel : Moveable platten travel on parallel guides of precision design and construction ensuring accurate and frictionless travel and perfect alignment of the weld.
• Upset Pressure : Provided by a precision spring, acting on the moveable platten and micrometrically adjustable by means of a knob, the setting being readable on a scale.
• Clamps : Lever operated, adjustable "floating" steel clamps of precision quick acting design, ensure firm preset clamping pressure. Release is quick and easy.
• Electrodes : Special wear resisting copper alloy electrodes provided with precision V-grooves for different wire sizes, permit rapid and accurate alignment of the part to be welded.
• Welding Current Adjustment : By means of a 8 step rotary switch, the knob of which is located on the Left hand side, enabling current adjustment from 50% to 100%.
• Electrode Spacing: Obtained with ease by a lever set against an indexing plate, providing adjustment in 10 steps between minimum and maximum.
• Weld Current Initiation : Return of the lever after clamping the job to weld position simply starts the automatic welding cycle.
• Current CutOff: Adjustable over a wide range by means of a micrometric thimble the setting of which is read on a graduated scale.
• Annealing Facility : Separate annealing electrodes with screw type clamps are provided for easy and quick annealing of the welded job ensuring a flexible zone at both sides of the weld.

• The welding then takes place automatically. Unclamp job.
• To anneal, put spacing lever to max. position. Clamp job centrally in annealing Clamps. Hold down current switch till annealing temperature is reached.

Electroweld industries is a leading manufacturer of resistance welding equipment, serving the industry for over 45 years. Our welding machines are designed to provide a production solution at an affordable price while ensuring reliability and low cost maintenance.

Applications: The Automatic Upset But Welding machine type UBW-1020 is designed as a portable model for heavy duty butt welding operation.

Electroweld Upset Butt Welder 50KVA Model: UBW-1020

Weldability (Weldable Option 1)- Mild Steel: 10mm-20mm, High Carbon Steel: 8mm-15mm, Copper: 8mm-12mm, Brass: 8mm-14mm, Aluminium: 8mm-14mm

Weldability (Weldable Option 2) - Bi-Metal Bandsaw Blades width: 35mm-60mm

Construction: Machine is constructed with a sturdy light alloy housing and all high voltage components are housed within the body. The machine is mounted on a four-wheeled trolley type stand for easy portability.

Upset Travel : Moveable platten travel on parallel guides of precision design and construction ensuring accurate and frictionless travel and perfect alignment of the weld.

Upset Pressure : Provided by a precision spring, acting on the moveable platten and micrometrically adjustable by means of a knob, the setting being readable on a scale.

Clamps : Lever operated, adjustable "floating" steel clamps of precision quick acting design, ensure firm preset clamping pressure. Release is quick and easy.

Electrodes : Special wear resisting copper alloy electrodes provided with precision V-grooves for different wire sizes, permit rapid and accurate alignment of the part to be welded.

Welding Current Adjustment : By means of a 8 step rotary switch, the knob of which is located on the Left hand side, enabling current adjustment from 50% to 100%.

Electrode Spacing: Obtained with ease by a lever set against an indexing plate, providing adjustment in 10 steps between minimum and maximum.

Weld Current Initiation : Return of the lever after clamping the job to weld position simply starts the automatic welding cycle.

Current CutOff: Adjustable over a wide range by means of a micrometric thimble the setting of which is read on a graduated scale.

Annealing Facility : Separate annealing electrodes with screw type clamps are provided for easy and quick annealing of the welded job ensuring a flexible zone at both sides of the weld.

Electroweld industries is a leading manufacturer of resistance welding equipment, serving the industry for over 45 years. Our welding machines are designed to provide a production solution at an affordable price while ensuring reliability and low cost maintenance.

Applications: Electroweld Wire Butt Welders are specially designed for the wire and cable processing industry. This welder is used for butt welding of ferrous and non-ferrous wires.

Electroweld Micro Wire Butt Welder 1KVA (MBW-825)

• Weldability - Diameter - 0.8mm-2.5mm.
• Weldability - Cross-Sectional Area - 0.5mm²-4.91mm².
• Weldability - Welding Range - 20-10 AWG.
• Weldability - Welding Range - 21-13 SWG.
• Weldable Materials: Iron, Steel, Nickel

Features: These machines are designed as table models and constructed with a particular regard to quick and easy operation. The welding process being automatic requires minimal training for operators and ensures uniform welds of high tensile strength, capable of withstanding subsequent drawing.

Construction The Electroweld Micro Wire Butt Welders are designed as portable models on moveable trolley stand, with spring loaded clamping devices, and foot pedal release Main body, housing the welding transformer, fixed and moveable platens, constructed from light alloy. Each machine is mounted on a wheeled trolley type stand provided with brakes. All machines are equipped with annealing facility.

Upset Travel: Moveable platen travel on two parallel guides of precision design and construction ensuring accurate, frictionless travel and perfect alignment of the Weld.

Upset Pressure: Provided by a precision spring action on the moveable platen, pre-calibrated at the factory

Electrodes: Special wear resistant copper alloy electrodes provided with precision'V'grooves, permit rapid and accurate alignment of wires.

Clamps: Copper alloy clamps of precision quick acting design ensure fixed clamping of wires.

Variation of Initial Upset Gap: Obtained by setting of a calibrated cam mounted on the fixed platen and acting on a stop fitted on the moveable platen

Weld Current Adjustment: Adjustment of welding current by 8 position rotary switch.

Weld Current Initiation: Automatic, current make and break via incorporated magnetic contactor. Current initiation effected by a manual push button fitted on one side of the fixed platen and current cut off effected automatically in relation to the preset upsetting distance Separate annealing electrodes for annealing of the welded wire is provided.

Weld Current Cutoff: Effected automatically in relation to the preset upsetting distance.

Magnifying Glass and Lamp Assembly: Available as standard optional extra, to ensure visibility of thin wires for correct spacinq of the wire ends and prooer overhang from the electrodes.The entire assembiy, mounted on a vertical post at the rear of the machine, can be moved up and down and swivelled.

Annealing Facility: Separate annealing electrodes for annealing of the welded wire provided as a standard feature.

Shearing Attachment: Shearing attachment to prepare the wire ends in the range specified, available as standard optional extra

Trolley Stand: Wheeled trolley available as optional extra

Welding Process

• The ends of the wires to be joined are 'prepared' on the special shearing attachment.
• Welding current and initial up-set gap set according to the size of wire, the up-setting pressure being preset at the factory.
• The wire ends are rigidly clamped by special quick acting clamps and viewed through an illuminated magnifying glass to ensure correct alignment of the wire ends.

Electroweld industries is a leading manufacturer of resistance welding equipment, serving the industry for over 45 years. Our welding machines are designed to provide a production solution at an affordable price while ensuring reliability and low cost maintenance.

Applications: 

• The 3-Head Projection/spot welder is used for welding three welds simultaneously. This ensures quality, repeatabiity and higher production rate. A 3-Head Projection/Spot Welder is the long term cost effective solution for multiple weld applications and avoids the quicker wearing off one pair of electrodes, repeatedly used for multiple welds. Spot / Projection Welding, Electro-Brazing, Cross Wire Welding, Sheet Metal- 2-ply or Multi-ply, Mark-less Welding, Resistance Heating and Soldering. Capable of Welding Low Carbon Steel,High Carbon Steel,High Strength Steel,Nickel Alloy,High-Temp Alloy,Titanium. Confirmation of weldability of other materials can be provided on request.
• Users Include:   General engineering work-shops, makers of furniture, electrical instruments, containers, barrels and drums, telephone, radio communication devices, clocks, kitchenware, textile machinery and spares, automobiles, bicycles, motor-cycles, scooters, auto-ancillaries, toys, air-conditioners, refrigerators, transformers, motor, switch gear, etc.
• Construction : Heavily fabricated with streamlined appearance, suitably stiffened at points of stress. The transformer is mounted directly on to the body and the bearings for the arm are provided in the same.
• Cooling System: Electrodes, Electrode holders secondary water cooled, water required to be free from residue forming impurities and at a temperature of less than 30* C or 85* F. If water temperature is higher, increased water flow is required.
• Electrodes: Three pair Morse Taper II straight electrodes supplied as standard with the machine, Other types available on request.
• Adjustment of Electrode Force : By means of Air Pressure. The force is adjustable and gives a constant force from 1-5 Kg Cm!by Pneumatic Cylinder, adjusted by Regulating Valve.
• Adjustment of Electrode Stroke: By vertical adjustment of electrode holder.
• Current Control: By means of 3/6 tap change links between 50% and 100% also fine setting through controller
• Weld Initiation: By means of Foot Switch which initiates the weld only after preset pressure is built up.
• Electronic Control: (A) Thyristorised synchronous electronic sequence timer consisting of: Squeeze, weld, forge, off and heat control unit range 1-99 c/s (B) Solid State - three timers provided for squeeze, weld and forge timings - short range 5 - 50 cycles - long range 1 - 10 seconds (50 to 500 cycles)

Electroweld industries is a leading manufacturer of resistance welding equipment, serving the industry for over 45 years. Our welding machines are designed to provide a production solution at an affordable price while ensuring reliability and low cost maintenance.

Applications: 

• The Electroweld Portable Seam Welder is designed for small jobs and repair jobs that can't be accommodated in a conventional type seam welding machine
• Construction : This is a portable welding machine and has a gun type electrode. The machine uses a 15KVA transformer mounted on a portable chasis.
• Electrodes: The circular electrode is specially designed with a copper alloy and is mounted on a roller attached to the Portable Seam Welder Gun.
• Welding Process: The Seam welding process involves heating of the specific spot under the contact of the electrodes when they are rolled over the job. The energy produced at the site of the spot depends upon the resistance between electrode and magnitude of the current supplied. The seam welding electrodes have a feature of producing more heat at a point or spot which is tightly held by the electrodes thus producing spot welding.
• Current Control:  Current Control by means of 6 tap change links between 50% and 100%
• Electronic Control: Synchronous built-in electronic timer with SCR from 2 to 65 cycles.Compensation circuit starts the timer only when there is proper passage of current, which enables to perform on oxidized sheets, on surfaces with paint residue or on black sheets.

Electroweld industries is a leading manufacturer of resistance welding equipment, serving the industry for over 45 years. Our welding machines are designed to provide a production solution at an affordable price while ensuring reliability and low cost maintenance.

Applications: Electroweld Wire Butt Welders are specially designed for the wire and cable processing industry. This welder is used for butt welding of ferrous and non-ferrous wires.

Electroweld Micro Wire Butt Welder 1KVA (MBW-31)

- Weldability - Diameter - 0.3mm-1.2mm.

- Weldability - Cross-Sectional Area - 0.07mm²-1.13mm².

- Weldability - Welding Range - 31-18 AWG.

- Weldability - Welding Range - 31-18 SWG.

- Weldable Materials: Iron, Steel, Nickel

Features: These machines are designed as table models and constructed with a particular regard to quick and easy operation. The welding process being automatic requires minimal training for operators and ensures uniform welds of high tensile strength, capable of withstanding subsequent drawing.

Construction The Electroweld Micro Wire Butt Welders are designed as portable models on moveable trolley stand, with spring loaded clamping devices, and foot pedal release Main body, housing the welding transformer, fixed and moveable platens, constructed from light alloy. Each machine is mounted on a wheeled trolley type stand provided with brakes. All machines are equipped with annealing facility.

Upset Travel: Moveable platen travel on two parallel guides of precision design and construction ensuring accurate, frictionless travel and perfect alignment of the Weld.

Upset Pressure: Provided by a precision spring action on the moveable platen, pre-calibrated at the factory

Electrodes: Special wear resistant copper alloy electrodes provided with precision''V''grooves, permit rapid and accurate alignment of wires.

Clamps: Copper alloy clamps of precision quick acting design ensure fixed clamping of wires.

Variation of Initial Upset Gap: Obtained by setting of a calibrated cam mounted on the fixed platen and acting on a stop fitted on the moveable platen

Weld Current Adjustment: Adjustment of welding current by 8 position rotary switch.

Weld Current Initiation: Automatic, current make and break via incorporated magnetic contactor. Current initiation effected by a manual push button fitted on one side of the fixed platen and current cut off effected automatically in relation to the preset upsetting distance Separate annealing electrodes for annealing of the welded wire is provided.

Weld Current Cutoff: Effected automatically in relation to the preset upsetting distance.

Magnifying Glass and Lamp Assembly: Available as standard optional extra, to ensure visibility of thin wires for correct spacinq of the wire ends and prooer overhang from the electrodes.The entire assembiy, mounted on a vertical post at the rear of the machine, can be moved up and down and swivelled.

Annealing Facility: Separate annealing electrodes for annealing of the welded wire provided as a standard feature.

Shearing Attachment: Shearing attachment to prepare the wire ends in the range specified, available as standard optional extra.

Trolley Stand: Wheeled trolley available as optional extra.

Electroweld Wire Butt Welder 5KVA (WBW-28)

• Weldability - Diameter - Steel: 2mm-8mm, Copper: 2mm-3mm, Aluminium: 3mm-5mm
• Weldability - Cross-Sectional Area - Steel: 3.14mm²- 50.27mm², Copper: 3.14mm²- 7.07mm², Aluminium: 7.07mm²- 19.63mm².
• Weldability - Welding Range - Steel: 12 - 1/0 AWG, Copper: 12 - 9 AWG, Aluminium: 9 - 4 AWG.
• Weldability - Welding Range - Steel: 14 - 1/0 SWG, Copper: 14 - 11 SWG, Aluminium: 11 - 6 SWG.
• Weldable Materials: Iron, Steel, Copper, Aluminium Light Metal

Features: The machines are designed for quick and easy operation. The settings for electrode spacing and upsetting pressure are calibrated directly for the different wire size to be welded. The welding process being automatic requires minimal training for operators and ensures uniform welds of high tensile strength, capable of withstanding subsequent drawing.

Construction The Electroweld Wire Butt Welders are designed as portable models, with spring loaded clamping devices, and foot pedal release. Main body, housing the welding transformer, fixed and moveable platens is constructed from light alloy. Each machine is mounted on a wheeled trolley type stand provided with brakes. All machines are equipped with annealing facility.

Upset travel: Movable platen travel on two parallel guides.

Upset Pressure: Provided by a precision spring action on the movable platen.

Electrodes: Special wear resistant copper alloy electrodes provided with precision'V'grooves, permit rapid and accurate alignment of wires.

Current Initiation: Automatic, current make and break via incorporated magnetic contactor. Current initiation effected by a manual push button fitted on one side of the fixed platen and current cut off effected automatically in relation to the preset upsetting distance Separate annealing electrodes for annealing of the welded wire provided

Weld Current Adjustment: Adjustment of welding current in 6 steps from 50% to 100% by rotary switch.

Welding Process

• Electrode spacing is adjusted by a lever set against a plate calibrated for wire diameter.
• Upsetting pressure is adjusted by means of a dial calibrated for wire diameter.
• Welding current is selected by a rotary switch.
• Wires to be joined should be cut straight, exactly at right angles and free from burrs.
• Wire ends are clamped by spring loaded clamping device which can be opened singly or together by food pedals.
• Releasing the foot pedals leaves the wire clamped under adequate pressure.
• By the push of the button, welding cycle is initiated and completed automatically by buit-in controls.
• Weld completed, the job is then de-clamped and annealed if necessary in the separate annealing electrodes.

* Power Requirement is 220V AC 50/60Hz or 415V AC 50/60Hz(Price includes customization as per requirement before shipping)

**Butt Welders upto 30KVA can operate on either 2 Lines/Phases 220V (+10%/-10%) or 400V (+10%/-10%) 50/60Hz

***Butt Welders greater than 30KVA can only operate on 2 Lines/Phases 400V (+10%/-10%) 50/60Hz

****Additional set of spares and consumables can be quoted to be added to the shipment as required

1. Model WBW-28 - For butt welding of Iron and Mild steel wires.

2. Model WBW-28C and Model WBW-28CC - For butt welding of Alloy Steel and Carbon steel wires.

3. Model WBW-14 - For butt welding of copper and brass wires.

4. Model WBW-256 - For butt welding of aluminium and light alloy wires.

this timer the welding current is stopped.

(C) ''Forge 1'' Timer (Setting range on 0-100 scale: 0-2 seconds): Timer for releasing the clamping of the job via the 2 Vertical Clamping Pneumatic Cylinders. This timer is triggered in sequence once the ''Weld 2'' timer expires and this timer disengages the 2 Vertical Pneumatic Clamping Cylinders on ''Forge 1'' timer expiry.

(D) ''Forge 2'' Timer (Setting range on 0-100 scale: 0-2 seconds): Timer for releasing the upset pressure the job via the Horizontal Upset Pressure Pneumatic Cylinder. This timer is triggered in sequence once the ''Forge 1'' timer expires and disengages the Horizontal Upset Pressure Pneumatic Cylinder on ''Forge 2'' timer expiry.

Following setting controls the % of welding current applied to the job during the welding process when ''Weld 2'' timer is engaged:

(E) % Heat Setting (Setting range on 0-100 scale: 0-100%): Weld Power setting adjusted depending on Diameter of Rod being welded.

Welding Process:

The Machine is provided with a toggle switch to alternate between Welding and Annealing functionality. The actual Welding or Annealing is is initiated with a common push button switch.

1. Fix the above simple settings, clamp the job end-to-end in the center of the welding jaws.

2. Press the welding push button and the welding then takes place automatically. Unclamp Job.

3. To anneal, put spacing lever to max. position. Clamp Job centrally in the Pneumatically Clamped Welding Jaws or the provided Annealing Jaws. Press the annealing push button till annealing temperature is reached.

Design Features:

UPSET TRAVEL: Movable platen travel on parallel guides.

UPSET PRESSURE: Provided by the Horizontal Pneumatic Cylinder and adjustable with a knob controlling the incoming air pressure.

CLAMPS: Lever operated adjustable ''floating'' steel clamps of precision quick acting design ensure firm preset clamping pressure. Release is quick and easy. Foot operated switch operation also supported for clamping operation if required.

ELECTRODES: Special wear resistant copper alloy electrodes provided with precision ''V'' grooves, permit rapid and accurate alignment of wires/rods/cables/blades..

WELDING CURRENT ADJUSTMENT: By means of a rotary switch from 50% to 100%.

ELECTRODE SPACING: Obtained with ease by a lever set against an indexing plate.

WELD CURRENT INITIATION: By pressing welding / annealing push button after clamping the job to weld position simply starts the automatic welding cycle. Foot operated switch operation also supported for weld initiation operation if required.

ELECTRONIC CONTROLS:

(A) Thyristorised synchronous electronic sequence timer consisting of: Squeeze, weld, forge, Weld/No-Weld and heat control unit range 1-99 c/s. This is a standard controller offering.

(B) Solid State - three timers provided for squeeze, weld and forge timings - short range 5 - 50 cycles - long range 1 - 10 seconds (50 to 500 cycles). This is a standard controller offering.

(C) Optional Electroweld AY-01 Digital Timer with capability to store upto 25 different weld schedules. This option will replace the standard controller at an additional cost.

CURRENT CUT OFF: Adjustable over a wide range by means of micrometric thimble the setting of which is read on a graduated scale.

ANNEALING FACILITY: Annealing on same welding jaw setup for Low Carbon Steel Rods. For High Carbon Steel, Copper, Brass and Aluminum annealing can be done using the annealing electrodes with screw type clamps provided for ease and quick annealing of the welded job ensuring a flexible zone at both ends of the weld.

PORTABILITY: The machine is mounted on a four wheeled chassis for easy portability.

Electroweld Pneumatically Operated Rod Butt Welder 15KVA (RBW-15PN)

Weldability - Mild Steel: 3mm-12mm, High Carbon Steel: 3mm-9mm, Copper: 3mm-7mm, Brass: 4mm-9mm, Aluminium: 5mm-9mm, Carbon Steel Bandsaw Blades (width): 20m-40mm, Bi-Metal BandSaw Blades (width): 5mm-27mm.

Applications: Upset butt welding of all profiles of wires and flats of iron, steel, alloy and carbon steel, copper, aluminium, brass and other light metals and their alloys. Carbon Steel and Bimetal Blades Butt Welding

Users: Include wire strip and rod drawing mills, transformer motor and switch gear manufacturers, bandsaw and hacksaw blade users, small tool makers for welding mild steel shanks to alloy steel portion of taps, drills, bits, screw drivers, chisels, etc., hoop and ring manufacturers, wire forming industries, cable industries, automobile industries, air-conditioner and refrigerator makers, office equipment makers, etc.

Construction: The machines are constructed with a sturdy light alloy housing and designed as portable models mounted on a moveable chassis fitted with four wheels. They are constructed for quick, easy, and fool-proof operation, the welding process being automatic. Settings are simple, finely adjustable, and reproducible for all variables. Uniform welds of high strength capable of withstanding subsequent drawing ensured. The Machine has 2 welding Jaws with grooves for welding different sized rods. The clamping action of the welding jaws is controlled via the Left and Right Clamping Levers which in turn activate the Pneumatic Clamping cylinders. The machine is also designed with a Horizontal welding cylinder for providing horizontal pressure on the welding jaws during the welding process.

Simple Settings:

1. ELECTRODE SPACING: Adjust lever on indexing plate depending on the diameter of the rod being welded.

2. WELDING CURRENT: Operate knob of the 8 step switch, current making and breaking is automatic via a built-in electromagnetic contactor.

3. UPSETTING PRESSURE: Micrometrically adjustable with pressure control knob for the incoming compressed air line supplying air pressure to the Pneumatic Cylinders.

4. CURRENT ON / OFF: Weld Initiation via Push Button/ Foot Operated Switch and welding duration electronically controlled via timer values.

Electroweld industries is a leading manufacturer of resistance welding equipment, serving the industry for over 45 years. Our welding machines are designed to provide a production solution at an affordable price while ensuring reliability and low cost maintenance.

Applications: 

• Electroweld Wire Butt Welders are specially designed for the wire and cable processing industry. This welder is used for butt welding of ferrous and non-ferrous wires in the range of 0.3mm - 3.8 mm diameter.

• These machines are designed as table models and constructed with a particular regard to quick and easy operation. The welding process being automatic requires minimal training for operators and ensures uniform welds of high tensile strength, capable of withstanding subsequent drawing.
• Construction The Electroweld Micro Wire Butt Welders are designed as portable models on moveable trolley stand, with spring loaded clamping devices, and foot pedal release Main body, housing the welding transformer, fixed and moveable platens, constructed from light alloy. Each machine is mounted on a wheeled trolley type stand provided with brakes. All machines are equipped with annealing facility.
• Upset Travel: Movable platen travel on two parallel guides.
• Upset Pressure: Provided by a precision spring action on the movable platen.
• Electrodes: Special wear resistant copper alloy electrodes provided with precision'V'grooves, permit rapid and accurate alignment of wires.
• Current Initiation: Automatic, current make and break via incorporated magnetic contactor. Current initiation effected by a manual push button fitted on one side of the fixed platen and current cut off effected automatically in relation to the preset upsetting distance Separate annealing electrodes for annealing of the welded wire is provided.
• Weld Current Adjustment : Adjustment of welding current by 8 position rotary switch.

Welding Process:

• The ends of the wires to be joined are 'prepared' on the special shearing attachment (optional).
• Welding current and initial up-set gap set according to the size of wire, the up-setting pressure being preset at the factory.
• The wire ends are rigidly clamped by special quick acting clamps and viewed through an illuminated magnifying glass (optional), to ensure correct alignment of the wire ends.
• By pushing the button, butt welding cycle is initiated and completed automatically by built-in controls.
• Weld completed, the job is then de-clamped and annealed in the annealing device (optional), if necessary.

• Weldable Materials-iron,steel,nickel.
• Power Requirement is 220V AC 50/60Hz or 415V AC 50/60Hz (Price includes customization as per requirement before shipping)
• Separate annealing electrodes for annealing of the welded wire provided.
• Shearing attachment to prepare the wire ends in the range specified is available as as an optional extra.
• Wheeled trolley available as optional extra.
• Additional set of spares and consumables can be quoted to be added to the shipment as required.

Electroweld industries is a leading manufacturer of resistance welding equipment, serving the industry for over 45 years. Our welding machines are designed to provide a production solution at an affordable price while ensuring reliability and low cost maintenance.

Applications:

• The Electroweld Pneumatically Operated BiMetal BandSaw Blade Flash Butt Welder is designed for welding Bi-Metal Bandsaw Blades

• Fast and simple welding operation saves time.
• High quality weld joints without misalignment.
• No additional solder and flux.
• Fast preparation of strip ends.

Construction

• Robust design - therefore long lasting and reliable.
• Precision control is achieved via movable jaws that run on wear resistant precision ball type guides which reduce friction and ensure utmost welding accuracy.
• The Machine has 2 flat welding Jaws designed with a pneumatic clamping mechanism. This quick and firm clamping arrangement enables automatic alignment of the bandsaw blades for higher weld productivity. The clamping action of the welding jaws is controlled via the Right and Left Clamping foot switches which in turn activate the Pneumatic Clamping cylinders. The machine is also designed with a Horizontal Pneumatic Welding Cylinder for providing horizontal pressure on the welding jaws during the welding process.

Simple Settings:

• Settings are simple, finely adjustable and reproducible for all variables.
• Electrode Spacing: Adjust lever on indexing plate depending on the diameter of the rod being welded.
• Welding Current: Operate knob of the 8 step switch, current making and breaking is automatic via a built-in electromagnetic contactor
• Upsetting Pressure: Micrometrically adjustable with pressure knob.
• Current On / Off: Micrometrically adjustable with simple thimble.

Welding Process:

• The Saw Blades to be joined should be cut straight, exactly at right angles and free from burrs on special shearing attachment (optional equipment).
• Welding Current, Upsetting Pressure and Upsetting Way are set according to the blade width.
• The blade ends are rigidly clamped in special quick acting clamps provided on the machine.
• By depressing the welding lever, the welding process begins.
• The two ends are heated to forging temperatures in a few seconds and are then automatically forged (upset).
• The welding current switches off automatically.
• The job is de-clamped and the weld completed.

Process for Annealing:

• The upsetting way switch lever is now turned to annealing and the job is clamped again with the extended jaw distance which comes in automatically on flipping the lever to annealing position.
• By pressing the annealing switch on which two heat positions are provided, the job is annealed in order to normalize the brittleness of the welded area.
• Depending on the type of material, the annealing process should be repeated several times if need be.

Design Features:

• Upset Travel: Movable platen travel on parallel guides.
• Upset Pressure: Provided by a precision spring action on the movable platen and micrometrically adjustable with a knob. Setting is readable on a scale.
• Clamps: Lever operated adjustable 'floating' steel clamps of precision quick acting design ensure firm preset clamping pressure. Release is quick and easy.
• Electrodes: Special wear resistant copper alloy electrodes are provided with the machine. Attached precision guides allow for quick and easy alignment of blades.