Projection welding represents a specialized resistance welding technique that concentrates heat at predefined projections on workpieces, creating strong, repeatable joints with minimal distortion. Heron Welder's projection welders, featuring capacitor discharge technology, excel in applications requiring precision and efficiency across diverse materials and thicknesses.
How Projection Welding Works
Projection welders focus electrical current through embossed or machined projections on one metal surface, generating localized heat for fusion while limiting impact on surrounding areas. This method suits thin sheets, studs, nuts, and complex geometries where uniform heat distribution prevents warping. Capacitor discharge variants store energy for ultra-short weld cycles, ideal for heat-sensitive components.
Heron's systems integrate advanced controls for consistent projection collapse and nugget formation, ensuring joints withstand mechanical stresses in automotive chassis, battery assemblies, and electrical enclosures.
Key Advantages of Heron Projection Welders
Minimal Heat-Affected Zones: Short discharge times protect base materials and coatings from damage.
High-Speed Production: Rapid cycles boost throughput in high-volume manufacturing.
Versatile Material Compatibility: Handles steel, aluminum, dissimilar metals, and thin gauges effectively.
Superior Joint Strength: Projections ensure reliable fusion points with excellent shear and peel resistance.
Compact and Integrable: Suited for robotic arms, presses, or benchtop setups in automated lines.
Capacitor Discharge Technology Benefits
Heron's capacitor discharge projection welders use stored energy banks (e.g., 20,000 μF volumes) for precise power delivery up to 60 kVA, minimizing electrode wear and power supply demands. This technology shines in electronics and aerospace, where weld aesthetics and minimal flash are critical, outperforming traditional AC or MFDC methods for small projections.
Power ratings align with needs from bench welders (e.g., 500-1500J) to heavier-duty units, supporting 380V/3-phase inputs common in global factories.
Applications Across Industries
Automotive suppliers use these welders for nut and stud projection welding on chassis and body panels, meeting OEM strength standards. Electronics benefit from clean welds on busbars and terminals, while HVAC and appliances leverage them for robust component assembly. Heron’s solutions also extend to projection welding lines for air conditioning compressors.
Integration and Customization
Heron projection welders feature programmable interfaces, quality monitoring, and optional servo actuators for seamless automation. Custom throat depths (up to 540mm) and arm gaps accommodate varied part sizes, with cooling systems ensuring continuous duty cycles.
Compared to AC welders (25-500KVA range with 12-40KA short-circuit currents), capacitor discharge models offer sharper control for precision tasks.
For manufacturers seeking reliable projection welding that enhances quality and reduces costs, Heron Welder provides proven, scalable solutions backed by decades of expertise. Explore specifications and configurations at Projection welders.
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