DALEX INDUSTRIAL MACHINES CLASS PMS

PMS
DALEX INDUSTRIAL MACHINES
CLASS PMS
made
in
Germany
w w w. d a l e x . d e
DALEX Schweißmaschinen GmbH & Co. KG
DALEX INDUSTRIAL WELDING MACHINES
The industrial manufacturing requires highest when it
SPECIFICATION
concerns capability, quality and reliability of welding
The modularity of the PMS line find its application as spot-,
machines in use.
projection- and roll seam welding machines in industrial
The DALEX PMS line enables a range of machines to the
series production.
industry which consistently proves its capability in a wide
• Rated power
from 16 up to 630 kVA (alternating current),
range of industrial applications.
from 60 up to 1200 kVA (3-phase-direct current)
from 80 up to 1000 kVA (medium frequency);
• Electrode force from 20 up to 15000 daN (0,2 – 150 kN);
• Maximum welding current up to 300 kA;
• Modifications for individual applications;
• Optimum cost-performance ratio;
• Wide range of accessories;
• Optimum quality and durability;
• Exclusive high-grade components of well-known brands
manufacturers;
• High-performance transformer self manufactured
without thermal problems for shift operation;
• High performance, robust and modern engineering.
MODELS OF PMS
A =
Spot welding machine with spot welding fitting
and foot switch for sport welding
B =
Combined Spot-Projection welding machine with changeable
fittings and key-operated switch for preselection of operation
mode. Operation optional by foot switch or 2-hands safety start
desk for spot- and projection welding
C =
Projection welding machine with projection fitting
and 2-hands safety start desk for projection welding
NL =
Longitudinal Seam welding machine with longitudinal
welding heads and foot switch
NQ =
Transversal Seam welding machine with transversal welding
heads and foot switch
NQ 1 = Transversal seam welding machine with top drive gear
NQ 2 = Transversal seam welding machine with bottom drive gear
NQ 3 = Transversal Seam welding machine with top and bottom drive gear
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CLASS PMS
MODELS OF CYLINDERS
SINGLE-STROKE CYLINDER EH
Standard equipment for every machine
is the single-stroke cylinder. The range of
electrode force as well as the stroke are
corresponding with the type of machine
and the electrical capability.
DOUBLE-STROKE CYLINDER
DH
The piston for the work clearance stroke
is floating positioned. The operation mode
long-stroke can be used on demand.
DOUBLE-STROKE CYLINDER WITH
ADJUSTMENT-STROKE DHZ
The piston for the work clearance stroke is
floating positioned. The required work clearance stroke can be adjusted by spindle. The
operation mode long-stroke can be activated
optionally by a switch selector.
DOUBLE-STROKE CYLINDER
WITH ADJUSTMENT-STROKE
AND SEQUENCE SWITCH
DHZF
The piston for the work clearance stroke
is floating positioned. The required work
clearance stroke can be adjusted continuously by spindle. On this cylinder the
reach of the desired position of the work
clearance stroke is electrically detected
and is used to switch automatically into
the work stroke. Likewise a absolutely
hit-free and bounce-free placing of the
electrode can be achieved.
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SERVO-MOTOR
DRIVEN MODEL
SII 1000
1000 daN
SII 2000
2000 daN
SII 4000
4000 daN
RANGE OF STANDARD MACHINE
PMS 10-6 T
TECHNICAL DATA
PMS 11-6
PMS 10-6
PMS 14-6
TECHNICAL DATA
TECHNICAL DATA
TECHNICAL DATA
80 or 100
Nominal Power at
50% duty cycle
(kVA)
100, 160
or 200
Nominal Power at
50% duty cycle
(kVA)
16 or 32
Nominal Power at
50% duty cycle
(kVA)
80
Nominal Power at
50% duty cycle
(kVA)
Throat Length
(mm)
200, 350
or 550
Throat Length
(mm)
250, 350, 550
or 750
Throat Length
(mm)
250, 350, 550,
750 or 1050
Throat Length
(mm)
250, 350, 550,
750 or 1050
Electrode force
(daN)
65 - 390 or
20 - 390
Electrode force
(daN)
65 - 390, 20-390
or 115-690
Electrode force
(daN)
100-600, 20-600
or 190-1140
Electrode force
(daN)
200-1200, 80-1200
or 300-1800
Stroke
(mm)
max. 65
Stroke
(mm)
max. 65
Stroke
(mm)
max. 90
Stroke
(mm)
max. 100
PMS 16-6
PMS 32-6
PMS 12-6
PMS 36-6
TECHNICAL DATA
TECHNICAL DATA
TECHNICAL DATA
TECHNICAL DATA
Nominal Power at
50% duty cycle
(kVA)
200 or 250
Nominal Power at
50% duty cycle
(kVA)
100, 160
or 200
Nominal Power at
50% duty cycle
(kVA)
100, 160
or 200
Nominal Power
at 50% duty
cycle(kVA)
160, 200
or 250
Throat Length
(mm)
350, 550, 750
or1050
Throat Length
(mm)
350, 550, 750
or 1050
Throat Length
(mm)
250, 350
or 550
Throat Length
(mm)
175 or 250
Electrode force
(daN)
340 -2040,140-2040,
or 500-3000
Electrode force
(daN)
120 - 720, 165 - 990,
215-1290, 300-1800
Electrode force
(daN)
120 - 720, 165 - 990,
215-1290, 300-1800
Electrode force
(daN)
360-2160,160-2160,
500-3000, 230-3000
Stroke
(mm)
max. 120
Stroke
(mm)
max. 100
Stroke
(mm)
max. 100
Stroke
(mm)
max. 120
Illustrated machines are in standard frequency.
All machines are available in three-phase or medium frequency direct current
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OPTIONAL FEATURES
4-RANGE SELECTOR SWITCH
for coarse adjustment of the
welding performance installed
in attached cabinet
MAIN SWITCH
according to VDE installed in
attached cabinet.
FLOW CONTROL
INSTRUMENT
(water control switch) installed
in water feed
ARM SUPPORT
TURBE ARM
for bottom spot fitting
TUBE ARM FITTING
with special wide working
length of the spot fitting
FITLER-SOUND ABSORBER
for oil-free outgoing air
installed at air exit
PENDULUM ELECTRODE
HOLDER
as top fitting
BAR ELECTRODE HOLDER
as bottom fitting
ADJUSTMENT DEVICE
with ratchet for height
adjustment of bottom fitting
HYDRAULIC WELDING UNIT
(Compensating element)
Side flexible conductors to improve
the current partition as well as
rubber spring for optimized followup and to compensate tolerances of
work piece
PROJECTED ELECTRODE
HOLDER
PRESSURELESS LOWER
of the top fitting by manual
valve installed at cylinder
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VISE ELECTRODE
for conductive clamping and
manual operation, air-operated
available
ELECTRODE FORCE SWITCH
electronic operated
BAR ELECTRODE
with current partition for
mounting on top and bottom
platen
RETURN STROKE
MONITORING
electrical operated
PRESSURE COMPENSATOR
for projection welding tools to
be mounted of the top platen
PROGRAM SELECTOR
SWITCH
for preselection of the welding
program
FLANGED ELECTRODE
HOLDER
to be used on a projection
welding machine for spot
welding
POSITION ENCODER
electrical operated
COMPARISON OF DIFFERENT KINDS OF CURRENT
For an objective comparison one needs identical welding appli-
The different impedances in the secondary circuit of welding
cations which demands certain welding current.
machines and connection related factors defines the size of
A good quality spot welding of an aluminium sheet with a thick-
the required mains transformer.
ness of 4 + 4mm requires a welding current of approx. 57 kA.
SINGLE-PHASE ALTERNATING CURRENT
THREE-PHASE DIRECT CURRENT
DOUBLE CONNECTION (G3)
MEDIUM FREQUENCY DIRECT CURRENT
The following example is based of 350 mm throat length:
kind of current
welding current
primary current
no-load voltage
mains cross section
fuse protection
connected mains power
single-phase alternating current
57 kA
850 A
12,5 V AC
150 mm
315 A
550 kVA
three-phase direct current
57 kA
500 A
6,7 V DC
25 mm
100 A
260 kVA
medium frequency DC
57 kA
500 A
7,0 V DC
25 mm 2
100 A
260 kVA
ADVANTAGES OF DIRECT CURRENT MACHINES
UNIFORM CURRENT PARTITION IN ELECTRODES AND
WORK PIECE
The current partition in electrodes and work pieces is related
only to the ohmic resistance of the material which results in a
relatively uniform current partition.
This effect is especially interesting with several spot welding
joints on projection and cross-wire application.
LOW TREND-TO-ALLOY OF THE ELECTRODES
Continuous flow of current because of no zero crossing
of the current curve results in low specific load of the
electrodes.In general the effect is reduced alloying of
the electrodes and the service life will be increased.
BIG POWER FACTOR – SMALL LOSSES
Compared to alternating current machines with a low
power factor, a power factor of 0,9 (cos phi) is achieved.
The inductive losses in the secondary circuit are practically
zero.
LOW ENERGY CONSUMPTION
Because of the eliminated inductivity in the secondary
SHORT WELDING DURATION WITH REDUCED HEAT AFFECTED ZONE circuit an optimized transmission ratio of primary to
secondary is achieved. A lower need of energy from
The feed of heat into the weld by welding with direct current
supply network is the result.
is higher than welding with alternating current of the same
duration, because the current curve is not sinus-formed and
HIGH WELDING CURRENT WITH LOWER SECONDARY VOLTAGE
shows no zero crossings. Work piece and electrodes are
thermally lower loaded and the heat affected zones keep small. Low secondary voltage enables a high welding current with
GOOD CONDITIONS FOR MAINS CONNECTION
The load for the mains supply is symmetrical for all three
phases of the supply network. Low cost of installation and
mains transformer, mains connection and main switch.
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adequate dimensions of the secondary circuit on machines
with long throat because of the eliminated inductive resistance.
This kind of machines weld more softly and spatter formation
is avoided.
TECHNICS OF MEDIUM FREQUENCY
The DALEX MF-technics offers essential elements towards
ADVANTAGE
efficient series production. This welding technology is the
• direct current in high quality
answer to increasing demands of quality, productivity and
• minimal inductive loss
capacity of resistance welding.
• energy saving
• regulation and time adjusting in ms
METHOD
• fast upslope
In an special inverter the three-phase power supply is rectified
• long life of electrodes
and converted to alternating two phase current of 1000 Hz.
• compact and lightweight transformer
A compact, close coupled transformer is primary fed with this
• high quality of welding spot
current, which is rectified again on secondary side. The result is
• wide range welding application
a welding current which can be regulated fast and precise
• symmetrical load of supply network
because of the 1000 Hz.
• low trend of spatter formation
MEDIUM FREQUENCY TRANSFORMATOR
TECHNICAL DATA
TECHNICAL DATA
TECHNICAL DATA
TECHNICAL DATA
TECHNICAL DATA
nominal capacity
at 20 % duty
cycle (kVA)
80 up to 90
nominal capacity
at 20 % duty
cycle (kVA)
130 up to 180
nominal capacity
at 20 % duty
cycle (kVA)
250 up to 300
nominal capacity
at 20 % duty
cycle (kVA)
500
nominal capacity
at 20 % duty
cycle (kVA)
700 up to 1000
no-load direct
voltage (V)
6.3 up to 8.3
no-load direct
voltage (V)
7.0 up to 10.2
no-load direct
voltage (V)
10.2 up to 16.0
no-load direct
voltage (V)
11.8
no-load direct
voltage (V)
8.4 up to 15.9
weight (kg)
17
weight (kg)
26,5
weight (kg)
33
weight (kg)
54,5
weight (kg)
167
2
number of diodes
(pieces)
4 or 6
number of diodes
(pieces)
4 or 6
number of diodes
(pieces)
6
number of diodes
(pieces)
10
number of diodes
(pieces)
PLANNED USE
• short-time welding (f. e. annular projections), partially as
replacement of capacitor discharge welding machines
DALEX MEDIUM FREQUENCY TRANSFORMERS
ARE REMARKABLE FOR
• low self-impedance
• low need of cooling water
• welding of galvanized sheets
• series connection of all cooling circuits
• joining of different materials as well as nonferrous metals
• secondary voltage suppressor wiring beginning with size MF 180
• welding of coated materials
• diodes are tightened max. as a pair
• high capability with small size
LIFE OF ELECTRODES MF DIRECT CURRENT / ALTERNATING CURRENT
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COMPARISON OF WELDING CURRENT CURVES
DALEX-SERVOTRONIC®
SERVOTRONIC® - PRODUCT RANGE
THE WORKS
Our developers have provided the DALEX „S-class“
with a new design featuring 3 power stages.
In this process, great importance was attached to optimal
SII 1000 1000 daN
SII 2000 2000 daN
SII 4000 4000 daN
compatibility with the system construction kits for PMS
series spot, projection and seam welding machines.
GENTLE POWER WITH BRAINS
„Less is more“ goes the old saying.
What this means for spot, projection or seam welding is
illustrated by the second generation of DALEX servomotor
welding machines.
Instead of simply „flattening“ the projections before
Pneumatic
the actual welding process, as would be the case
with conventional pneumatic systems, the geometry
of the projections is kept completely intact with a
Servo technology
DIAGRAM: PRE-WELDING PROJECTION GEOMETRY
DALEX SERVOTRONIC®.
SCHEMATIC: DYNAMIC CHARACTERISTICS OF A SERVO-MOTOR DALEX PROJECTION WELDING MACHINE
WITH SERVOTRONIC®
Process safety and welding quality are drastically
increased.
The success factors:
• Die-to-die blow-free welding electrode touch-down
on the component
• Constantly adjusted preliminary force for defined
press-on of components to be welded (projection
geometry remains intact)
• Welding current build-up synchronized with
welding force build-up with an also constantly
adjusted end force
• Optimal process operation reproducibility with
typical welding cycles of 20 ms to 150 ms
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DALEX SERVOTRONIC®
EXAMPLE: SLIDING SELECTOR SHAFT
The component geometry of the sliding selector shaft
within the welding area,the shape of the annular projection
DALEX robotwelding station with
2 projection machines
with servomotor drive
at the welding stud, and the material properties of both
weld elements placethe highest demands on the welding
technology.
The SERVOTRONIC® developed by DALEX now provides an
optimal solution for this challenge.
APPLICATIONS: WELD NUTS/LOCK PLATES
Especially with safety-relevant elements, the quality of
the weld (welding projection) is a decisive factor for a
component’s lifetime. In the final analysis this is the point
where, particularly in car manufacturing, questions of
stability, solidity and hence also of the vehicle’s and
human safety are settled.
DALEX SERVOTRONIC® dynamically readjusts the welding parameters by virtue of an intelligent control technology and ensures optimal lens formation in resistance
welding to a high degree.
With the SERVOTRONIC®, DALEX welds an enormous variety of material pairings. Avoidance of spatters inside the
thread when nut welding is solvable. Welding to measure
is controllable with the SERVOTRONIC®.
DALEX-CNC-coordinate
welding system in medium
frequency technology with
servomotor drive
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MODIFIED PMS CLASS
CUSTOM-MADE SOLUTIONS FOR
INDUSTRIAL DEMANDS
The DALEX concept of modifications of high-capable standard
machines in response to individual demands is a well proved and
secured base for industrial welding with high productivity and
economic efficiency.
The machines are used in the various branches such as automotive
manufacturing, utility and agricultural manufacturing, aircraft
construction, wire grating manufacturing, luminous advertising,
household appliances, electrical engineering, furniture manufacturers
as well as window and door manufacturers.
For complex welding applications the series of DALEX
machines type PMS can be fast and cost efficient
modified thanks to their modular design.
For reproducible welding results they can be completed
by special tools designed for the intended application.
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MODIFIED PMS CLASS - EXAMPLES OF USE
MACHINE DESCRIPTION
DALEX Medium Frequency Projection
Welding Machine PMS 14-6 MF
with special tools
WELDING TASK
projection welding of wire console
MACHINE DESCRIPTION
DALEX Spot Welding Machine PMS 11-6
with special fittings
WELDING TASK
stepp-spot welding of sink basin
MACHINE DESCRIPTION
DALEX Three-Phases Direct Current Machine
PMS 11-6 G3 with special fittings
WELDING TASK
spot welding of luminous aluminium letters
MACHINE DESCRIPTION
DALEX 3-Cylinder Projection welding
machine PMS 36-4 MF
in medium frequency technics
WELDING TASK
projection welding of parts for
automotive manufacturing
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MODIFIED PMS CLASS - EXAMPLES OF USE
MACHINE DESCRIPTION
DALEX Transversal Roller Seam Welding
Machine PMS 14-6 with special fittings
WELDING TASK
roller seam welding of chimney pipe
MACHINE DESCRIPTION
DALEX Medium Frequency Projection Welding
Machine PMS 32-6 MF with special tool
WELDING TASK
projection welding of fuel distributor
MACHINE DESCRIPTION
DALEX Double Head Projection Welding
Machine PMS 32-6 with special tool
WELDING TASK
projection welding of reinforcement of hinges
MACHINE DESCRIPTION
DALEX Bench Spot Welding Machine
PMS 10-6 T
WELDING TASK
spot welding of copper stranded wire
on mains terminal
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MODIFIED PMS CLASS - EXAMPLES OF USE
MACHINE DESCRIPTION
DALEX Projection Welding Machine
PMS 36-6 with special tools
SCHWEISSAUFGABE
projection welding of lock case on
door frame
MACHINE DESCRIPTION
DALEX Medium Frequency Projection Welding
Machine PMS 36-6 MF with special tool
WELDING TASK
projection welding of cylindrical tubes
MACHINE DESCRIPTION
DALEX Three-Phase Direct Current Projection
Welding Machine PMS 38-6 G3
WELDING TASK
projection welding of diffuser on
compressor housing
MACHINE DESCRIPTION
DALEX Projection Welding Machine
PMS 32-6 with automatic nut feeding device
WELDING TASK
projection welding of nuts on
sheet metal parts
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MODIFIED PMS CLASS - EXAMPLES OF USE
MACHINE DESCRIPTION
DALEX Transversal Seam Welding Machine
PMS 16-6
WELDING TASK
seam welding of lye drums
MACHINE DESCRIPTION
DALEX Double-Head Projection Welding
Machine PMS 32-6
WELDING TASK
projection welding of barrel clamping ring
MACHINE DESCRIPTION
DALEX Roller Seam Welding Machine
PMS 11-6 with special tools
WELDING TASK
seam welding of filtering bag fabrics
MACHINE DESCRIPTION
DALEX Double-Head Projection Welding
Machine PMS 36-6 with special projection tool
WELDING TASK
projection welding of case of a lock on
lock plate
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MODIFIED PMS CLASS - EXAMPLES OF USE
MACHINE DESCRIPTION
DALEX Transversal Roller Seam Welding machine
PMS 11-6 with special fittings
WELDING TASK
seam welding of filter screen
MACHINE DESCRIPTION
DALEX Projection Welding Machine
PMS 36-6 with special tools
WELDING TASK
projection welding of
fire-extinguisher case
MACHINE DESCRIPTION
DALEX Medium Frequency Projection
Welding Machine PMS 36-6 MF with
special fitting
WELDING TASK
projection welding of adapter on flue gas part
MACHINE DESCRIPTION
DALEX-Projection Welding Machine
PMS 32-6 with special fitting
WELDING TASK
projection welding of fine screen parts
You will find further examples of application at
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www.dalex.de
Stand 11/2012
DALEX
Schweißmaschinen GmbH & Co. KG
Koblenzer Strasse 43
D - 57537 Wissen
Tel.
Fax
made
in
Germany
+49 (0) 2742-77-0
+49 (0) 2742-77-101
Internet: www.dalex.de
E-Mail: [email protected]
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