Overview of the Central Components of a Projection Welding System
Robust Basic Structure for Stability and Reproducibility
The foundation of every welding system is a mechanically stable basic structure—often in a C-frame or portal design. This provides the necessary rigidity to ensure uniform force application during the welding process. It is important that no deformation occurs, even with multiple welds or changing component geometries.
Typical features:
- Vibration-damping frame construction
- High repeat accuracy even in series production
- Variable mounting for different component sizes
Efficient Power Source and Precise Control
The heart of the system is the power source—it supplies the necessary welding current in precisely measured quantities. Modern systems rely on inverter-based systems with high clock frequencies and fast control.
Important for practical use:
- Constant energy supply even during power fluctuations
- Finely adjustable parameters such as current, time, and force
- Integration into higher-level control systems (e.g., via OPC UA or Profinet)
Electrodes – Individually Adaptable for each Component
The shape and position of the electrodes determine where and how the current flows into the component – and thus the quality of the weld seam. Modern systems enable quick electrode changes and offer high flexibility in terms of geometry.
Technical highlights:
- Coolable electrodes for longer service life
- Interchangeable systems for automated adjustment
- Adaptation to special geometries (e.g., for planned projection welding)
Power Systems – Pneumatic, Electric, or Servo-controlled
The contact force is crucial for the interaction between heat generation and material flow. Depending on requirements, modern projection welding systems use pneumatic, hydraulic, or servo-controlled drives.
Differences at a glance:
- Pneumatic: robust, cost-effective, proven
- Servo-electric: high-precision, dynamic, ideal for quality assurance
- Hydraulic: for high forces, less common in fine welding applications
Process Monitoring and Quality Assurance
You can't control what you can't measure – that's why modern systems are equipped with comprehensive sensor technology and monitoring systems. This allows deviations to be detected and corrected immediately.
Typical functions:
- Power-displacement monitoring
- Current-time logging
- Connection to CAQ and MES systems
Conclusion: Technology that fits the component
A modern projection welding system is more than just a power source with two electrodes. It is a precisely coordinated system that adapts flexibly to workpieces, materials, and production conditions.
At Gatzsch Schweißtechnik, we place particular emphasis on tailoring our systems precisely to your requirements—from design and power supply to intelligent process monitoring.
Are you planning a new project or looking to modernize your production? Talk to us—we will develop the right solution for your application.
