Mechelonic Welders Private Limited

Most popular types of resistance welders are designed to operate from 2 lines of the 3-phase power supply. Such machines are economical to buy but their highly inductive nature and unbalanced loading of the power supply are very problematic especially in smaller sized Indian factories.

Standby generators of about 250-1000 kVA capacity are commonly thought of us captive power source in many factories where shock absorbers, compressor parts, fuel tanks, etc. are welded. Few of the 75-100 kVA single phase welders become difficult to be used in such plants additionally because of the short ckt type of loading caused by Projection Welders.

Three welding transformers of smaller kVA ratings combined with hexa-phase rectifier system and microprocessor controllers are meeting this type of need since 1985. We have many types and sizes serving widespread spectrum of satisfied Indian clients. Happy to share our experiences.

These products are appropriate for joining of small parts commonly applied in electro- mechanical industries. Relay contacts, bimetal strips, brass to silver brazing, metallic sub- assemblies of C.R.Ts spectacles etc. are processed by these machines.

Component holding fixtures (manual types/ mechanised types) and well-designed contact toolings are most important items needed to ensure quality and productivity. Precision offered by microprocessor controllers and process monitoring instrumentations are available from Mechelonic. 230 V Single-Phase types up to 5 kVA power level and 415 V types recommended for 10-30 kVA sizes. For every case a weldability trial and tooling issues will be considered before deciding the price/delivery targets.

We have been able to design, to develop and to support three major generations of weld controllers. The microprocessor based products originating to 1986 was a big leap for us. We gained experience by commissioning hundreds of units in very difficult environments, and almost every user got convinced that imported alternatives are unnecessary.

Encouraged by MUL, we made rapid improvements and a large number of units are networked to PCs. Today, many transnational companies prefer our products for installation at their plants. By simply comparing features or field reports, we may conclude that we are superior to our competition. We have 1-phase, 3-phase DC, 3-phase frequency converter, multi-transformer, and multi-programs as per needs. Further, since we design, build and commission full tooled up welder machines, using our controllers, we can prove the consistent performance of our controllers from weldwise as well as current meteringwise.

Recently, we developed and added Personal Computer aided Quality Monitoring is an additional value feature.

Auto bodies and large sub- assemblies of cars, such as doors, need many spot welded joints.

Weld Guns operating from hanging transformers of 75-150 kVA rating used to be the conventional way for this type of jobs. Power loss due to the inefficiency of 2 to 3 m of welding cables is reducible by these later day products wherein compact transformers of about 35 kVA rating are built into the basic guns. However, such I.T. Guns find to be less popular especially when the sizes are larger and operator convenience is important.

Robot mounted integral transformer guns are the latest trends in advanced countries. Smaller sub-suppliers are often benefited by the evolution of these products, but careful study about safety, operator efficiency, fixture interference, and maintenance must be considered to decide the overall suitability.

These products are most popular with automobile ancillaries who prepare sub- assemblies like door panels, chassis parts, fuel tanks, exhaust pipes etc. Projection Welding of weld nuts, studs, reinforcements is done by machines of rating 25-50 kVA. Larger machines 75-150 kVA single phase and larger sizes in 3-phase versions are being standardised.

Shock absorber studs, brake shoes, air conditioner compressor parts and similar items are projection welded by specially tooled-up machines and even by special machines optimised for these tasks. Mechelonic Welders has extensive experience through hundreds of proven solutions, and a professional team engaged in continuous innovation.

Very economic products for general purpose fabrication needs of shops that handle M.S. boxes and sub-assemblies of size less than 1 m cube using sheets thinner than 2 mm. Air operated type 15-30 kVA are most beneficial.

Leaklight assemblies for petrol tanks, shock absorbers, oil barrels, shells of paint cans etc. are welded with high-speed weld wheel pairs carrying 10-25 kA and 300-1500 kg force. Modern Seam Welders are controlled by high speed Mup Controllers and P.L.C. aided mechanisation systems, MWPL experience includes steel mill coil joining, petroleum barrels, defense jobs, aero engine parts, and more.

Resistance Welding Transformers, Thyristor Contactors, Timing Control P.L.Cs pneumatic and hydraulic items are integrated to produce equipment that efficiently welds parts like brake shoes, shock absorbers, sub chassis and others. Multi-Spot Welders with many transformers, fixture guns and matching fixture tables are also beneficial for respective items. Projection Welders are capable of welding many spots at one stroke also as specials.

When spot welds are required on a large object such as the body of a car, Weld Guns have to be small and handy to be reached around the locations. This need is met by hanging the step down transformer (typically 75-150 kVA) from an overhead construction while the weld gun is powered through water- cooled cables designed to carry 10-15 kA. Pneumatic and/or hydraulic means are employed to generate the weld force at the gun tips. A modern car line consists of over 150 of suspended Welder Guns.

Integral Transformer type spot welders are also being introduced as more energy efficient alternatives. Today, robot mounted weld guns compete/ compliment with the conventional models of weld guns.

ultra-small Controller having state-of-the-art features for Resistance welders.

• PLC type wiring interface & DIN-RAIL mounting provision.
  
• Diagnostic LEDs for each I/O.
  
• 100(H) x 75(W) x 110(D) mm size & weighs less than 1 Kg.
  
• Now Programmable by a PDA!
  
• Also compatible with HHT-1000 / 2000 / 3000, Reset-Box RB-1000 & Weld-net systems.
  
• Constant-current and all other features similar to our proven 45-40 series of controllers.
  
• Variety of versions available to suit every application & Budget.

Model WCA – 1000
Hand-Held instrument for the measurement, logging & analysis of Current in Resistance Welders.

• Highly accurate measurement of the Amplitude (RMS or Peak) and duration of Welding-currents, even when the 440V AC welding power frequency varies between 45 to 65 Hz.
• User friendly 'Menu’ oriented setup and configuration.
  
• Storage of 500 welds with date-time and RS-232 PC interface for download of data.
  
• Ergonomic design with Keystroke beeps and yellow Back-lit 2-line alphanumeric LCD.
  
• Suitable for AC, DC and Multi-impulse welding currents.

Auto body assembly shops consider weld guns as a most essential tool in their hands. Size, weight, material quality of cu. alloys combined by mechanical accuracy of replaceable tips and semi-consumable gun parts are equally relevant to the successful performance of the plant.