Cable welding
high-quality non-ferrous metal compounds with maximum service life and durabilityWelding of copper cables or other alloys with or without a coating
Through the connection of cables, the so-called splicing (cable welding), through connectors and end connectors can be realized. Resistance welding technology makes it possible to reliably connect copper cables or other alloys with or without a coating. With the right equipment for every range, cable connections from 0.1 to 400 mm² can currently be implemented.
In the case of large quantities, a system variant with an application-specific tool adapted to the individual workpiece is recommended, while our automatic welding heads with different transverse positions are the better solution for constantly changing configurations (sequences) with different cross-sections. The latter make it possible to map any cable configuration as a node within a range. This concept can be implemented thanks to our sequence-capable control system, which is able to operate customer-specific cable sets (KSK).
All of our systems impress with their extreme rigidity and high speed. STRUNK’s own drives guarantee optimal repositioning behavior, which achieves reliable and repeatable welding results with the shortest possible welding currents and at the same time high forces. The heat input is also low due to the short welding times.
Reliability and flexibility are important criteria for cable connections in motor vehicles. The perfect electrical conductivity must be guaranteed as well as the long-term durability of the connections.
Machinery
( Individual customer solution as an example)
S-MMD1 for welding strands and end connectors
The S-MMD1 machine is designed for welding strands to form splices in customer-specific dimensions …
S-MMD2 for welding strands and compacting
The S-MMD2 machine is designed for welding strands to splices and compacting tinned strands as a manual workstation with an interchangeable tool set on …
WWS1 sequence welding machine for splices and compaction in the range from 0.5 to 20 mm2
The WWS1 welding machine is designed for the sequential production of end and through connections of copper and tinned cable strands …
Y-LB welding machine for splices and compaction in the range from 0.35 to 2.5 mm2
The Y-LB welding system is suitable for end connections or through connections of copper strands as well as strands with coating in the micro range …
S-MMD1 for welding strands and end connectors
The S-MMD1 machine is designed for welding strands to form splices in customer-specific dimensions. The system is equipped with a quick tool change system and can process twin lines / twisted pairs. The system has a highly dynamic STRUNK drive with high speed for repositioning. Special guides put the power centrally in the welding area in order to deliver high quality and reproducible results at all times. The welding tool with locks is used for the most precise dimensions after welding.
The STRUNK machine module is suitable for welding end connectors. The strands are fed in from the front.
The STRUNK machine module is also supplied as a pure module. The connection to the control is realized via 19 “housing and plug connections.
S-MMD2 for welding strands and compacting
The S-MMD2 machine is designed for the welding of strands to splices and compacting of tinned strands as a manual workstation with an interchangeable tool set on quick-release plates. Thanks to the quick-release plates, the system can be set up for another application (including terminal welding) that is within the machine’s performance range.
The welding tool with interlocks is used for the most accurate dimensions after welding.
WWS1 sequence welding machine for splices and compaction
The WWS1 welding machine is designed for the sequential production of end and through connections of copper and tinned cable strands. The special tool offers the possibility of continuously adjusting the electrodes to a desired width by means of a motor. This means that the entire cross-sectional area can be covered without changing electrodes. This makes the WWS welding machine ideal for the production of short series or for varying cable cross-sections.
The machine is prepared as a table-top device, where the components such as switch cabinet, control, power section, cooler and all pneumatic and electronic units are easily accessible and easy to maintain.
Technical specifications
Working range: 0.50 mm – 20 mm2 (depending on the strand type and the desired strand combination)
Assembly : manually, from the left & right of the welding tool
Welding control: MCD-PC / 2
Y-LB for splicing, compacting and welding cables
Y-LB micro welding module is suitable for splices (connection welding of cables), compacting and welding of cables in the micro range.
The welding tool is tailored to the respective customer application. The assembly is done manually from the left and right of the welding tool. The work area is secured with a plexiglass hood.
The machine can be designed as a module both as a tabletop device and integrated in a work table. In the work table (optional) all additional components such as switch cabinet, control, power unit, cooler (optional) as well as all pneumatic and electronic units are easily accessible and easy to maintain.
Sample
Resistance-welded stranded connections can not only be used in the low-voltage electrical system. The high-voltage areas with their high cross-sections are also predestined for our systems. High holding forces and definable dimensions facilitate subsequent installation and laying. Cross-sections of well over 300mm² can be implemented and so, in addition to the accumulators (battery) or traction distributors, fuel cell applications can also be safely welded.
Muster Kabelverbindungen (Splice) von CU-CU oder CU zu verzinnten Materialien
Muster Kabelverbindungen (Splice) von CU-CU oder CU zu verzinnten Materialien
Muster Kabelverbindungen (Splice) von CU-CU oder CU zu verzinnten Materialien
Muster Kabelverbindungen (Splice) von CU-CU oder CU zu verzinnten Materialien
Muster Kabelverbindungen (Splice) von CU-CU oder CU zu verzinnten Materialien
(Hochvolt) HV-Splice 120mm²
Nicht nur im Niedervoltbordnetz können widerstandsgeschweißte Litzenverbindungen eingesetzt werden. Auch die Hochvoltbereiche sind mit hohen Querschnitten prädestiniert für unsere Anlagen. Hohe Haltekräfte und definierbare Abmessungen erleichtern den späteren Einbau und das Verlegen. Querschnitte von weit über 300mm2 sind umsetzbar und so können neben den Speichern (Batterie) oder Traktionsverteilern auch Anwendungen bei Brennstoffzelle sicher geschweißt werden.
(Hochvolt) HV-Splice 120mm²
Nicht nur im Niedervoltbordnetz können widerstandsgeschweißte Litzenverbindungen eingesetzt werden. Auch die Hochvoltbereiche sind mit hohen Querschnitten prädestiniert für unsere Anlagen. Hohe Haltekräfte und definierbare Abmessungen erleichtern den späteren Einbau und das Verlegen. Querschnitte von weit über 300mm2 sind umsetzbar und so können neben den Speichern (Batterie) oder Traktionsverteilern auch Anwendungen bei Brennstoffzelle sicher geschweißt werden.
