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The Importance of Welding

Welding, as a crucial joining technology, plays an indispensable role in modern industry. It is widely applied in various fields such as construction, automotive manufacturing, aerospace, shipbuilding, and energy, providing essential guarantees for the strength, durability, and safety of structures. For instance, in the automotive industry, precise welding is essential for connecting car body panels, ensuring both safety and performance.

As a professional provider of welding process solutions, we are committed to offering customers efficient and reliable welding equipment and technology. Through continuous research and development as well as innovation, we have introduced an important innovative product — the energy-storage resistance welding controller.

Energy-storage Resistance Welding Controller

This advanced welding product combines inverter technology with energy storage mechanisms, enabling precise control of current and voltage, thereby achieving efficient energy utilization and stable output. It utilizes electronic boost and constant-current charging circuit technology to effectively store electrical energy in capacitors.

During welding, the stored energy is swiftly discharged onto the workpiece via a pressure mechanism, generating extremely high welding currents, ranging from tens of thousands to potentially hundreds of thousands of amperes, within a brief timeframe, thereby melting the metal at the contact point. Therefore, it’s especially suitable for projection welding processes, such as welding of nuts, bolts, tank ports, and other workpieces.

 

High Current Accuracy

Flexible Control

Reduced Welding Spatter

Energy Saving

Low Grid Demand

Balanced Grid Load

High Thermal Efficiency

Stable Current Output

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Inverter-based Energy Storage Welding VS Traditional Energy Storage Welding

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The Advantages of Sunke Inverter-based Energy Storage Welding

1 Energy Efficiency

At Sunke, we use an inverter-based constant-current charging circuit without a current-limiting resistor, ensuring stable current and reducing capacitor damage. Power loss is just 1% of traditional methods, saving 48-195% energy compared to traditional energy storage welding machines.

2 Customizable Discharge Method

The discharge method can be customized (SCR/IGBT). When using IGBT for discharge, the welding time and welding current can be set.

3 Consistent Welding Quality

Each welding process utilizes balanced welding of the same polarity to ensure consistent penetration depth and welding quality every time.

4 Compact and Cost-Effective

The inductive boost charging circuit used for charging is characterized by its small equipment size, low cost, energy efficiency, and environmental friendliness.

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The Pain Points of Traditional Energy Storage Welding

1 High Energy Consumption

Traditional energy storage welding generally limits the charging current to no more than 100 amperes when charging capacitors, utilizing step-up transformers, water-cooled resistors, and air-cooled resistors. Taking a 30,000-joule compressor terminal welder as an example, during each welding charging cycle, the energy lost in the current-limiting resistors (with resistances ranging from 2.5 to 10 ohms) accounts for 49% to 196.6% of the energy stored in the capacitors.

2 Large Size

The large size, high cost, and complex structure of step-up transformers make installation inconvenient. For example, those ranging from 15 to 50 KVA are bulky, weighing between 100 and 300 kilograms.

3 Fluctuations in Welding Quality

To prevent magnetic saturation of the welding transformer, the electrodes of the welding machine must discharge alternately with positive and negative polarity. This polarity effect results in inconsistent weld nugget penetration depths when the polarity of the workpiece changes.

4 Uncontrolled Welding Time

Once a welding transformer is selected, the maximum discharge time cannot be extended. When a Silicon-Controlled Rectifier (SCR) is turned on, it cannot be turned off, which does not meet the requirements of workpieces that need longer welding times.

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Why Choose Us?

In our 40 years of development, we have never ceased to innovate. Our advanced energy storage welding technology efficiently connects vehicle fuel tank openings, the fuel tank itself, and other fuel system components. The resulting welds are smooth, uniform, and leak-free, ensuring the high quality and reliability of the products. This has enabled us to maintain close cooperation with top domestic and international automotive manufacturers.

We invite you to explore our cutting-edge electric resistance weld solutions, experiencing how they enhance your welding efficiency and elevate your product quality.

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