Careful and constant ...
... wire feeding using the Master-feeder-system for laser- and MIG/MAG-welding.
Materials such as aluminium and bronze are very demanding when it comes to welding. Especially when the joining is to be integrated into large-scale production. Because the wire elctrodes are very soft and thus sensitive during feeding. The Master Feeder System, developed by ABICOR BINZEL in co-operation with leading car manufacturers, now makes this integration possible and guarantees a technological advantage for the future in large-scale production.
The challenge of light-weight design
Not only in the automotive industry and its supplier industries, in the whole area of industrial production aluminium light-weight design is becoming more important all the time. Joining is by means of extremely thin and soft wire electrodes which are very susceptible to bending and abrasion. The twin-roll drives used up to now in push-pull operation often deformed the welding wire which then leads to increased abrasion and consequently to wire problems in the contact tip.
Smooth and reliable processing can only be guaranteed if wire feeding is careful and constant.
The Master Feeder System masters these demands with a high degree of precision and dynamics and creates the basis to reduce the constructive, manufacturing and economic expenditure when jointing aluminium and its alloys.
The technology ...
... tested in series production.
Whether the wire is hot or cold, whether from a barrel coil, or a large or small coil, the digitally controlled feeding system APD-MF feeds critical weld metals optimally in automated use.
Two four-roll drives which are exactly adapted to one another with large enough drive rolls make precise wire feeding and an extremely constant welding process possible.
Highest quality standard of the weld seam, processing safety and a minimum of interruptions in series production are only some of the positive aspects of the system which allows universal adaption to the usual commercial current sources and robots.
Digitally controlled wire feeding
At the heart of the system are the two high-grade four-roll drives in connection with the digital motor control unit. Digital stands for accuracy, reproducibility and flexibility. The no-touch digital shaft encoders supply the motor control unit with information about speed. The current and the required speed are calculated exactly by the control processor and the speed of the motor is then set accordingly. Individual system components can be exchanged by replacement parts without any further adjustment. This means time-consuming calibration of tachometers is a thing of the past.
Both drives have been adapted to one another in such a way that there is no pull on the wire anywhere in the system. All drives work in push mode.There is always enough wire supply in the cable assembly to make sure there is no pull on the wire during operation.
In the reeling off mode APD, too, the wire roll is driven separately. A compensating arm makes sure there is enough buffer. Only two drives guarantee the careful wire feeding. There are no trouble-causing wire joints as in conventional push-pull-systems. The Master Feeder System is wire feeding in one cast.
High-grade four-roll drive
The qualitative high-grade four-roll drives transfer the driving moment over a large area and with very little pressure onto the wire.This means there is hardly any abrasion. Modern power sources and laser applications require extremely dynamic wire feeding, especially for the beginning and the end of the seams. Within milliseconds the wire is pulled back from the forward movement without any slipping. Only a drive with four rolls offers this dynamic solution. A pre-set and reproducible application force of the wire feeding rolls avoids time-intensive faulty operation.
Service-friendly and always available
The Master Feeding System covers all wire coils from 7 kg (aluminium) up to 40 kg (aluminium) and is therefore universally usable and expandable, depending on the application. To avoid humidity being introduced in the welding bath by the wire, the recirculating air heating makes sure of the correct temperature in the interior. The dew point is not reached. A wire end monitoring function makes it possible to replace the wire coils in time. Easy coil replacement, a movable housing and quick replacement of all the system components are only some of the convincing advantages.
Modular and flexible ...
... for versatile use.
Whether MIG/MAG welding or laser applications. The Master Feeder System is universally usable for the different process points.
ABICOR BINZEL offers just the right welding torch even for the welding and soldering of critical applications using aluminium or CuSi wires. A srew-on, quick change MIG/MAG welding torch on the master drive is the answer to different application requirements.
Laser wire feeding
A four-roll drive which has been reduced in size is adaptable to any commercially available laser head using a universal adapter plate.The stable wire feed has a slim geometry.
Three-dimensional fine adjustment ensures highly precise wire feeding. All components are prepared for hot wire feeding and water cooling. The simple control via digital inputs and a set point value of 0...10V allow the easy integration of the ABICOR BINZEL Master-Feeder-System.