Contour II
The flexible 3D electrode wire rolled seam resistance welding machine
Bio-fuel, Hybrid vehicle and organic coated materials create new development for 3D steel fuel tanks. As a world leader in high-end segments for steel fuel tank welding machines, steel tanks benefit where plastic tanks cannot keep up.
The servo driven multi axle welding machine enables new ways in designing complex geometries, easy programming and change over from one product to another with in seconds. The steel tank therefore put now many aspects over the plastic tank that allows the designer for more design freedom.
The patented and continually improved Soutec copper wire, intermediate electrode system with its profile specially adapted to the material to be welded enables a faultless welding even with the latest complex coating system that is required for all types (including flex fuels). Exterior cooling is not necessary as the roller heads are maintenance free.
The weld current is controlled (specially designed for Soutec mash-seam welders) together with the monitor supported PLC and CNC machine controls. This guarantees safe production even under the toughest manufacturing conditions common in industrial mass production.
The Pulsar, a static frequency converter enables a multitude of current patterns, frequencies and currents for an easy weld set up. The perks also lay in the design to allow for a 3 phase hook up and equal load (high efficient) is distributed on the power network with negligent interference to the network.
Soutec is a member of SASFT (Strategic Alliance for Steel Fuel Tanks):
www.sasft.org
Benefit at glance
- High complex 3D tank design can be welded without any problem
- weld speed up to 9 m/min for steel fuel tanks
- Integration in a fully automated production line easy possible
- Production of various tank designs in alternative mode (fixture and program change within seconds)
- Organic, aluminized and galvanized coating can be processed due to patented wire profile
- Stainless steal can be processed
- Low energy consumption (30kVA) due to wire electrode an PULSAR frequency converter
- No electrode redressing necessary (constant welding condition)
- A Fuel tank fixture with its CNC program allows easy adjustment of the weld path (geometry), without a need for mechanical adjustment.
- Tank templates with direct mechanical correlations to the shape of the tank is no longer needed, it therefore eliminates costly rework of the original template if the design should change (with some limitations)
Technical data
Parameter | Value |
|---|---|
Welding length | 2000 x 2000 rectangular + 2 x 100mm radius |
Material thickness | 0.5 – 1.3 mm |
Overlap | > 11 mm |
Copper wire | 2.5 mm profiled |
Weld speed | Up to 9 m/min. |