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Fully Automatic copper braid solidificationA machine

Fully Automatic copper braid solidificationA machine Specification

Welding Area
Up to 80 mm80 mm

Pulse Frequency
Adjustable 1-20 Hz

Motor Type
Servo Motor

Voltage
380 V / 415 V

Output Current
Adjustable up to 1000 A

Weight
980 kg

Rod Diameter
Customization available, up to 16 mm

Cooling Method
Water Cooling

Power
5 kW

Function
Braid End Solidification and Welding

Efficiency
>90%

Frequency
50/60 Hz

Dimension (L*W*H)
1500 mm x 950 mm x 1800 mm

Condition
New

Usage
Copper Braid Solidification and Welding

Insulation Grade
F Grade

Type
Fully Automatic Copper Braid Solidification Machine

Arc Current
1000 A max

Input Current
14 A

Material
Industrial Grade Steel and Copper Contact Points

Fully Automatic copper braid solidificationA machine Trade Information

Minimum Order Quantity
1 Unit

Payment Terms
Cash Advance (CA), Cash in Advance (CID)

Supply Ability
5 Units Per Week

Delivery Time
4 Days

Sample Policy
Contact us for information regarding our sample policy

Main Export Market(s)
Asia

Main Domestic Market
All India

About Fully Automatic copper braid solidificationA machine

A Fully Automatic Copper Braid Solidification Machine uses resistance welding to flatten and compact copper foils, strands, or ropes into a stable, solidified form, typically for manufacturing flexible connectors, shunts, and busbars. These machines feature automated operation with a gripper-puller, a microprocessor-based control system for precise settings, and safety interlocks. Key benefits include maintaining electrical conductivity, achieving dimensional stability, eliminating carbon deposition, and enabling operation by unskilled labor.

Key Components and Functionality

Feeding and Gripping:

A pneumatic gripper-puller unit grips the braid and pulls it through the welding area.
Solidification/Welding:

Resistance welding is employed, pressing the copper material between electrodes to flatten and fuse it into a stable, solid shape.
Automatic Control:

A microprocessor-based control unit synchronizes the operation, allowing for easy setting of weld parameters and providing fault diagnostics.
Cutting:

After solidification, the braid is cut to the required length by a gripper-puller unit.
Safety Features:

The system includes safety interlocks, thermal protection for the welding transformer, and a water flow switch to ensure proper operation and prevent overheating.

Applications

Flexible Connectors: Used to produce flexible terminal connectors.
Busbars: Creates flexible busbars for electrical applications.
Shunts: Manufacturing shunts, which are used for electrical current measurement.
Flexible Links: Produces flexible links for low-voltage switchgear.

Benefits

Efficiency: Fully automated operation reduces manual intervention and increases speed.
Quality: Maintains the high electrical conductivity of the copper and ensures dimensional stability.
Cleanliness: The process results in no carbon deposition.
Ease of Use: The microprocessor control and automated sequence allow even unskilled operators to use the machine effectively.

A fully automatic copper braid solidification machine automatically flattens and solidifies copper wire braids, foils, and ropes into a desired shape, often a flexible bar or connector, for applications like shunts and terminal connections. It uses resistance welding technology with precision control to ensure dimensional stability, maintain high electrical conductivity, and prevent carbon deposition. The process involves a gripper-puller unit that feeds, centers, and cuts the braid, while a microprocessor-based control unit synchronizes the welding and cutting operations, ensuring safety and operational efficiency.

How it Works

1. Feeding and Gripping:

A pneumatically operated gripper-puller unit grips the end of a continuous copper braid.
2. Solidification:

The machine then uses a welding process, likely resistance welding, to flatten and compact the copper material. This is achieved by pressing the material against electrodes, creating a stable, solid form.
3. Control and Precision:

A microprocessor-based control unit manages the entire operation, ensuring precise current control for energy efficiency and consistent results.
4. Cutting and Ejecting:

After solidification, the braid is cut to a required length and dropped into a chute.
5. Automatic Cycle:

The process is fully automatic, with the gripper-puller pulling the required length, centering it for cutting, and then gripping the next section to repeat the cycle.

Advanced Control & Flexibility

Equipped with a user-friendly PLC touch screen interface, the machine offers seamless operation in both fully automatic and semi-automatic modes. Users can swiftly adjust settings, monitor parameters, and switch between modes to align with varying production requirements and levels of automation.

Precision & High Output

The servo-controlled feeder ensures exact positioning and feeding, while adjustable pulse frequency (1-20 Hz) and arc current deliver consistent solidification and welding quality. With output efficiency above 90% and a capacity to process up to 30 units per hour, productivity and quality are both maximized.

Comprehensive Safety & Support

Multiple safety features-including an emergency stop, over-current protection, and door interlock-ensure operator security. In addition, on-site installation and training are provided, making it easy for new users or teams to set up and start production swiftly and confidently.

FAQ's of Fully Automatic copper braid solidificationA machine:

Q: How does the fully automatic copper braid solidification machine operate?

A: The machine utilizes a PLC touch screen interface which allows operators to select between fully automatic and semi-automatic modes. Once set, the precision servo-controlled feeder positions the copper braid, and solidification is performed through an adjustable arc current, ensuring consistent quality and output.

Q: What wire sizes and welding areas are compatible with this equipment?

A: This solidification machine is compatible with wire sizes from 0.5 mm8 mm up to 16 mm8 mm and can handle welding areas up to 80 mm by 80 mm, making it suitable for a wide array of copper braid applications.

Q: When is on-site installation and training available for this machine?

A: On-site installation and operator training are provided as part of the standard support package upon delivery of the machine across India, ensuring users can start production promptly and safely.

Q: Where can this machine be installed?

A: Designed for industrial use, this machine can be installed in manufacturing plants, workshops, or any facility requiring efficient copper braid solidification, provided there is access to 380 V or 415 V power supply and water for cooling.

Q: What is the copper braid solidification process on this machine?

A: Copper braid solidification involves feeding the prepared braid into the welding area, using a servo-controlled mechanism for positioning. The machine then applies an adjustable arc current and frequency to solidify and weld the braid end, ensuring a secure and consistent bond.

Q: What are the primary benefits of using this machine for copper braid solidification?

A: The main benefits include high production efficiency (>90%), uniform weld quality, flexible compatibility with various wire sizes, robust safety features, low noise operation (<70 dB), and full compliance with international CE and ISO 9001 standards.

Q: How is safety ensured during machine operation?

A: Safety is prioritized through features such as an emergency stop button, over-current protection, door interlock mechanisms, and a water cooling system to prevent overheating. These safeguards offer reliable protection for operators and equipment during all phases of operation.

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