Capacitor Discharge Stud Welding Equipment Explained

Capacitor Discharge Stud Welding Equipment Explained

The capacitive discharge stud welding equipment mainly consists of a power supply, a controller, and a welding torch. The power supply and controller are often integrated into one unit, available in both handheld and fixed styles. Figure 7-16 shows a schematic diagram of a handheld capacitive discharge stud welding device.

Figure 7-16 Schematic diagram of a handheld capacitive discharge stud welding device

Welding Torch

Capacitive discharge stud welding torches come in handheld and fixed styles. Because the procedures for the three types of capacitive discharge stud welding vary, the internal structure of the welding torch differs accordingly.

In capacitive discharge stud welding torches, the structure of the pre-contact welding torch is simple, consisting of a stud holding mechanism and a spring-press mechanism that presses the stud into the molten pool.

A gap-reserving welding torch needs to be equipped with a mechanism to lift the stud, typically using an electromagnetic coil. Before welding, the coil is energized to suspend the stud above the workpiece. During welding, the coil is deactivated, and the spring moves the stud towards the workpiece.

The structure of the arc-drawing welding torch is similar to that of an arc stud welding torch.Figure 7-18 shows a photograph of the external appearance of the Taylor arc-drawing stud welding torch.

Figure 7-17 Schematic diagram of the structure of a capacitive discharge stud welding torch

Power Supply

The power supply of a capacitive discharge stud welding machine mainly consists of a group of energy-storing capacitors and a device that charges the capacitors. It is usually designed based on the maximum stored energy. The charging device stores energy from the network in the energy storage capacitor group at low power.

Figure 7-18 Appearance photo of Taylor arc stud welding gun

The capacitance of the capacitors is in the range of 20,000 to 200,000 μF, and the charging voltage of the capacitor group does not exceed 200V. To speed up the charging process, the input power supply voltage is either single-phase 220V or three-phase 380V.

Table 7-9 lists the main technical parameters of some domestic capacitive discharge stud welding machines.

Table 7-9 Main technical parameters of some capacitive discharge stud welding machines

ModelNewRSR-400RSR-800RSR-1250RSR-1600RSR-2500RSR-1000RSR-4000
Old——————————DLR4-1000JLR-4000
CategoryContactContactContactContactContactGapContact
Power Supply
/V
220/110220/110220/110220/380220/380220V, 50HzSingle-phase, 380V, 50Hz
Power Capacity
/kVA
<1<1.5<2<2.5<360000μF
(Input 0.8kVA)
0.225F
Rated Energy Storage
/J
40080012501600200010004500
Capacitor Voltage Adjustment Range
/V
40~16040~16040~16040~16040~160Charging Voltage 35~190Maximum Charging Voltage 200
Stud Diameter/mmCarbon Steel, Stainless Steel2~53~63~84~104~122~6
(M3~M6)
2~12
(M4~M12)
Copper, Aluminum and their Alloys2~32~43~63~83~8————
Stud Length
/mm
Gap Welding Torch≤100≤100≤100≤100≤100————
Contact Welding Torch100~300100~300100~300100~300100~300————
Welding Production Rate
(units/min)
2015121010105
Weight
/kg
~20~35~60~80~10028——
Dimensions (Length x Width x Height)
/ (mm x mm x mm)
——————————480×280×3501000×500×1200

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