Resistance Welding Machines
a.i.i. designs and manufactures a large range of Resistance Welding Machinery that will be sure to fit your manufacturing needs. We offer standard resistance welders and special resistance welders. Our standard welders consist of press welders, bench welders, rocker arm welders and pedestal welders. Special resistance welders range from multi-guns, dial feeds, AC, DC and mid frequency, in-line transfers, palletized transfers, seam welders, etc. Our dedicated sales team can direct you to a welder that best fits your specification/application needs. Single phase, mid-frequency and three phase.
Standard Resistance Welding Machines
Rocker Arm and Press Style Welding Machines
Our Rocker Arm and Press Welding machines are heavy duty general purpose machines for a broad variety of welding applications from commercial to military--specified applications.
Rocker Arm Welder
Press Welder Spot / Projection
Bench Type Welding Machines
The Bench Type Welders are sturdy, compact machines and are designed for applications that require high performance and flexibility at a modest capital investment. These machines are ideal for situations where both spot and projection welding are required.
Pedestal Style Welding Machines
Pedestal Style Welders are ideal for applications involving nut and stud welding. They can be furnished with bowl type feeders, part-locating tooling and either single or dual gun style. Excellent for Robotic Applications.
Special Resistance Welding Machines
Multi-Gun Welders
These dedicated machines are custom-designed and engineered for specific customer and/or product applications in order to provide maximum output. Basic components include an open fabricated frame, weld guns, weld transformers, tooling, control, etc.
Multi-Gun Welders are available as spot and projection type welders and can be arranged as a two-or four-post fixed bridge frame, toggle lift or shuttle designs or "C" frame type welders with fixed, inclined or tilting lower knee or flat top design.
Dial Feed Welding Machines
For higher production rates, multi-station dial indexing tables are offered and arranged to overlap machine functions, welding or assembly operations as well as loading and unloading in. Automatic unloading is quite common to reduce the operator duties. Many applications include component parts which can be automatically loaded which generate very fast and economical manufacturing solutions.
Dial Feed Welder
Specialized Dial Feed Welder
Dual Tooled Dial Welder
4 Station Dial Feed
Large Projection Welder
AC & DC Welding Machines
Many applications require large amounts of welding current which impose heavy demands on primary plant power supplies. These can be accommodated by single phase DC (direct current) power supplies, low frequency, frequency converter transformers or including the mid-frequency power conversion supplies.
a.i.i. designs and manufactures both AC & DC Transformers for these applications.
Seam Welding Machines-
Circular, Longitudinal or Universal Design
Another process within the resistance welding family is Seam Welding. These welders are arranged in either a longitudinal style or circular style.
Automation International, Inc. designs and manufactures our exclusive seam weld head designed for heavy duty cycle applications.
Many applications require special tooling packages to assist in nesting or holding the parts to be welded throughout the weld cycle.
Seam welders can be designed for special applications.
Seam Welder Example
Circular
Seam Welding
Longitudinal
Seam Welding
Flash and Butt Welding Machines
Automation International is a world wide leader in supplying flash and butt welders for many applications from the smallest to the largest!
Applications include; wheels, aerospace, structural members, rings, rods, stationary rail application, anodes, bands and many more.
Our smallest Flash or Butt Welders are capable of small applications including band-saw blades, wire applications and flat stock materials.
Our largest models range from 100 Ton upset to 200 Ton upset with 500 Ton clamp force. These welders weigh up to 45 Ton.
- Available as Flash or Butt (flashless) or combination.
- Designed to withstand the most stringent industrial demands and environment
- Provides complete, precise control of the entire weld cycle
- Covers full range of flash and butt weld applications in weldable ferrous and non-ferrous materials up to maximum capacity of each unit
- Single phase AC or three phase DC
Experienced
Sales Engineers will
evaluate your application and process to determine the size of welder and tooling
arrangement to fit your needs.
The flash and butt weld process provides an excellent weld quality using no filler materials, requires no flux or gas coverage and is extremely fast.
a.i.i. Flash and Butt welders are available in standard or custom clamping mechanisms for vertical, horizontal and angular applications. Horizontal slide style clamps for straight butt welds, or on an angle for miter welding. For special applications, combinations of vertical and horizontal clamps can be supplied.
From smaller mechanical driven units up to hydraulic/servo powered model.
- B Series (Bandsaw Blade)
- F1 - F4 Series
20 KVA - 250 KVA - AC or DC - F5 - F9 Series
250 KVA - 1000 KVA - AC or 2000 KVA DC
Flash Welder
Typical Wheel Rim Flash Welder w/ ASSURANCE® Control
ASSURANCE®
Patents # 5,367,138 & 6,180,910
Flash and Butt Welding Control
The ASSURANCE® control system is a highly advanced control system comprised of a Computerized Weld Controller, Machine Interface and Human Interface.
The Weld Controller uses a high speed digital signal processor (DSP) on a custom designed board to provide high speed control, data acquisition and storage. a.i.i. can provide a control platform capable of extremely complex high speed control unattainable with standard control schemes. In addition to the control of the welder, the speed of the system allows the Weld Controller to perform statistics gathering and data acquisition during the weld.
The Machine Interface is a PLC and provides the "glue" to connect the ASSURANCE® to a wide variety of welding platforms. The PLC controls all the items which are customized from machine to machine. These items include the lubrication system, water cooling system, air system, hydraulic system, operator stations, etc. Programmed in standard ladder logic, adding or customizing features can easily be done by plant personnel or Automation International technicians. An optional diagnostic system allows access to status information from this computer.
The Human Interface is a PC based unit with monitor, and storage options and network connectivity. This machine maintains the operator display and is responsible for maintaining the various databases on the system. These include part setup information, statistical tolerance information, stored statistics, weld graphic information and more. The software is designed to separate the more complex operation from those used during normal operation. This allows the operators to become comfortable and productive with the machine very quickly and progress to other advanced features of the software.
Some of the control capabilities of the Flash ASSURANCE® system are
- Pre-Weld Cycles
- Burnoff
- Preheat
- Flash
- Upset
- Post Weld Cycles
- Butt (flashless)
Optional Packages
At Automation International, we are committed to providing you with the most advanced welding technologies in combination with the tools you need to maintain the machine, diagnose problems, and measure the quality of the welds being produced. We offer several optional packages which greatly aid in this effort.
The ASSURANCE® also provides storage of the graphics data. The system is usually configured to store the last 200 welds and provides easy to use, zooming graphs. It also supports printed output of the data in a variety of printer languages. Stored weld data can archive weld information to various data storage. Data from individual channels may be exported for inclusion in spreadsheets and analysis packages. An off-line viewer is also provided which allows one to examine archived data from a normal desktop PC. In addition, the weld data also contains a copy of the weld statistics information for the weld.
The Diagnostics package provides access to the PLC status information. The PLC connects the ASSURANCE® weld computer to a specific welding machine. As such it is connected to the myriad of sensors, limit switches and valves on the machine. This puts it in the position of "knowing" what is wrong with the machine.
In many cases, the ability to see what the welder is doing or responding to can provide the answers to difficult problems such as an intermittent wire connection. With the ASSURANCE® graphics package, you gain all of these capabilities and more.
The Weld Statistics package of the ASSURANCE® control system allows you to chose individual weld statistics that you wish to have present in your weld report. The system allows you to use any of the 40 input signals in the system. These signals include "real" analog input values from sensors on the machine to derived first and second order functions like velocity and crossover.
Automation's newest product Net ASSURANCE® has been designed from the ground up to be a strong component in your total quality effort. By supporting remote access to the weld data, statistics and reports, product can be tracked through the welder and statistical data can be combined with data from other machines on your line to give you a handle on your part quality. All the features of the standard ASSURANCE® are here: graphics, diagnostics, statistics, and advanced weld control. But added to this potent combination is the ability to easily get to this data, to be able to instantly see what the machine is doing from the office or even from across the country.