Car Muffler Welding Machine | MFDC Spot Welder DB-220-20027
Car Muffler Welding Machine | MFDC Spot Welder DB-220-20027 - Image 2

Car Muffler Welding Machine | MFDC Spot Welder DB-220-20027

8-Point Car Muffler Spot Welding Machine is designed for multi-point welding of muffler partitions to the main body. It integrates MFDC spot welding, part transfer, positioning, clamping, and machine control for automated loading, welding and unloading, with process management and weld data traceability for high-volume production.

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Specifications

Model # DB-220-20027
Rated Capacity KVA 220
Power Supply V/Φ/HZ 380/3/50
Max. Primary Current A 130
Max. Short Cut Current KA 24
Max. Working Pressure KN 2
Dimension(LxWxH) mm 1900x3215x2960
 

01

Integrated Design

The machine combines the MFDC spot welding unit, transfer mechanism, positioning and clamping fixtures, and Heron’s dedicated control system. Factory assembly and testing help reduce on-site installation and commissioning work, shortening the time to production. 

02

Synchronized Multi-Point Welding

16 weld points are completed in 8 cycles, with two points welded simultaneously in each cycle. Independent A/B gun return-pressure settings help balance heat distribution, minimize weld distortion, and meet different welding requirements.

03

Servo-Driven Transfer & Positioning

A Mitsubishi servo-driven transfer mechanism moves and positions the part across multiple stations. Adjustable origin offset and deceleration distance settings help maintain positioning accuracy during station changes.

04

Automated Loading & Unloading

Conveyors, indexing wheels, lifting fixtures, and ejector mechanisms automate part loading, transfer, and unloading. Roller positioning and lifting fixtures secure the part during welding, reducing manual handling and re-clamping while supporting a consistent production cycle.

05

Precision Pneumatic Control

Filtered compressed air and proportional valve control provide precise electrode pressure adjustment. An FRL unit with an oil mist lubricator provides automatic lubrication for cylinders and guide components, helping maintain reliable pneumatic performance.

06

Centralized Parameter Management

A Mitsubishi PLC and touchscreen provide centralized control of key welding parameters, including welding pressure, pressure thresholds, squeeze time, and A/B gun return pressure. Multiple welding schedules can be stored and recalled for quick changeovers between different products.

07

Process Monitoring & Protection

Cooling water flow, air pressure, and key welding parameters are monitored during operation. If welding current or pressure falls outside the set range, an alarm is triggered for timely adjustment.

08

Production Line Integration

Automated feeding, positioning, clamping, welding, and unloading form a continuous production workflow. Welding and process completion signals support communication with upstream and downstream equipment, reducing equipment idle time.

09

Multi-Stage Welding Control

Supports pre-weld, Weld 1, Weld 2, Weld 3, and post-weld stages, with repeatable welding pulses as needed. Squeeze, forge, cool, upslope, downslope, and hold times can be configured for different welding requirements.

10

Intelligent Weld Compensation

Eight-level weld-step compensation adjusts welding parameters as the electrodes wear, helping maintain consistent weld quality. Automatic re-welding is also available for abnormal welds, providing an added layer of process control.

11

Consistent Production Cycle

The measured cycle time is approximately 40.7 seconds per part, including around 3 seconds for manual loading and unloading. The automated welding cycle takes approximately 37.7 seconds, with provisions for future automation upgrades.

12

Weld Data Traceability

Primary-side and secondary-side constant-current control supports current monitoring for Weld 1 and Weld 2, with upper and lower current limits for process control. Quality records, parameter changes, and alarm history can be stored, while real-time welding current curves and USB data export support process review and quality analysis.

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