English
DeutschCapacitor discharge welding – CD-welding – CDW
KAPKON GmbH: the only supplier of the innovative low-voltage charging technology (1,300 V peak voltage, KAPKON USP). KAPKON GmbH also produces the patented CP combination pulse technology, which enables a direct combination of capacitor discharges. The use of CP combination pulse technology enables a far-reaching increase in process capability (KAPKON USP)
KAPKON-CD technology
Concentrated welding energy, precision welding, projection welding
CD-Welding
For CD-welding in a capacitor bank stored energy is used.
This is discharged suddenly.
The resulting pulse current is ignited into the parts being joined.
Due to the very short welding time, the surrounding material is minimally affected by heat, as almost no heat conduction takes place during the welding process.
KAPKON
Conventionally, a single capacitor bank is used for CD-welding. KAPKON offers this as a single-pulse technology (SP).
KAPKON is the only manufacturer on the market to have further developed the capacitor technology that up to four independent capacitor banks can be used for welding.
This technology is called combined pulse technology (CP) and is used for extensive process optimization. In addition to a reduction in cycle time, a significant reduction in rejects is possible.
Process characteristics
Extremely fast current rise
- max. 1 – 4 ms to the peak
Extremely short welding time
- max. 3 – 10 ms
- CP: variable adaption of the welding time
Extremely high pulse currents
- 30 kA to 1,200 kA
Advantages of KAPKON-CD machines and modules
Low voltage, no danger of medium voltage (competitors) – max. 1300 V charging voltage (KAPKON USP)
No need for specially trained electrical personnel
Safety regulations according to the Low Voltage Directive (Germany)
No saturation phenomenon of the pulse transformers
SP technology (single-pulse technology)
Use when CD-welding is recommended.
Possible current forms: discharge of (ONE) capacitor bank.
KAPKON recommendation: use of patented combi-pulse technology (CP) without recharging.
CP technology (combipulse technology)
Use when CD-welding is recommended.
Possible current forms: variable combination of the FOUR capacitor banks.
Extensive possibilities to vary the current flow and time:
Advantages of the combipulse technology (CP):
01
Reduction of weld spatter
02
Significantly increased process capability through combination of discharges
03
Usability: One machine for a wide variety of different joining tasks.
Example of a KAPKON combipulse sequence:
1st pulse: cleaning of the surface, same starting condition for the following pulses
Preheating, conditioning
2nd pulse: weld connection
Material connection sufficient strength, height adjustment
Additional pulses can be used to:
to further influence the sinking path,
to enable post weld heat treatment (to reduce temperature gradients)
Low mains fuse of 16 – 125 A (adjustable as required, KAPKON USP)
Only supplier of voltage-accurate charging through boost converter technology (KAPKON USP)
Easy Plug & Play
One hardware for global use, easy relocation possible, high flexibility in terms of power supply 350 to 480 V – 50/60 Hz)
Low sensitivity to voltage fluctuations
Symmetrical mains grid load
Excellent reproducibility through precise voltage charging
Short cycle times
High economic efficiency
- Low electrical demand/lowest energy costs
- No need for external cooling
- Low maintenance, easy to maintain (low-voltage charging technology)
- Low electrode wear due to concentrated and extremely short-term heat load
Holistic process control: PrimusKE welding control system
Monitoring of welding parameters within specified tolerances
Step-by-step process control, for consistent constrains
Recording and storage of numerous process and machine data
Documentation in .csv data according to ISO 9000ff
Direct assignment possible (order ID etc., printer integration)
Possibility of integration into higher-level line systems (Profinet, Ethernet, OPC server)