How To Improve Motor Manufacturer User Experience For Armature Commutator Fusing

DC Power Supply Spot Welding Machine For Armature Commutator Fusing Hot Staking WIND-DC-CW003

(1) Application:

PMDC motor armature with hook commutator, riser commutator

(2) Advantages:

Opeator friendly device installed since the year 2026

Motor Manufacture JC Feedback

The only difference I see with the new fuser is a safety facture I do like.

The new fuser wont run if the water chiller is not on vs the fuse we purchased last year will run without it on.

The old fuser will run until high temperature alarm if an employee forgets to turn of the water chiller.

We’ve had if go in to high temperature a few times because an employee forgets to turn on the chiller.

Other than that, everything is run smoothly. Thank you

Wind Automation Solution

Thank you very much for your feedback with the detail information!

After discussion,

(3) History of becoming star product:

The first two pcs welding machine WIND-DC-CW003’s user was a car motor manufacturer who produce

motors and supply to BMW , they used Italy and English imported welding machine and

WIND-DC-CW003 worked as backup machine. After several months test user found welding result and quality

is same as imported welding machine and ordered 1pc more three years later.

High frequency inverter DC power supply is a trend in commutator welding, some supplier said they use

high frequency actually they use 2KHz, while Wind Automation can achieve 15KHz, with real and pure DC

power supply which achieve constant welding quality!

(4) Fusing machine Parameter:

Wire diameter: 0.01~1.2mm

Armature OD: 20~100mm

Armature stack height:10~100mm

Commutator OD:8~70mm

Airsource:5~7KG/cm2

Welding power: 10~30KW

3phase AC 380V 50~60Hz

Weight: about 350KGS

Fusing power supply: Wind Automation self developed high frequency 15KHz, 500~5000A

Control system: Japan Mitsubishi PLC

Indexing control: Japan Mitubishi servo positioning system 7'' Touch screen

(5) Feature:

Commutator spot welding machine conductor hot staking Fusing for thin or big wire High frequency

inverter weld and hot stacking commutator with small big wire thin and big wire, with separate cooling

water device (act as a conditioner)

How to acheive good fusing quality, below four factors you can check

1. Adjust the fusing current to suitable current

2. Right pressure to the fusing soldering area

3. Fusing time

4. Conductor resistance, it is related to the electrode contacting area

Please click below picture to view video

This armature commutator DC spot welding machine is a specialized device for welding motor rotors, utilizing direct current (DC) for resistance welding. Compared to traditional AC spot welding machines, it employs DC or medium-frequency inverter technology, offering advantages such as fast response speed, high energy utilization, and stable and precise welding. It effectively reduces workpiece deformation and ensures consistent weld quality.

Core Components and Working Principle armature DC spot welding machine typically consists of the following core components: Power Supply System: This is the heart of the equipment. It generally comprises a rectifier, filter, inverter, and control module. Its function is to convert the input AC power into a stable and controllable DC welding current. * Control System: Responsible for setting and monitoring welding parameters (such as current, time, and pressure) and precisely controlling the welding process according to a preset program. Modern equipment typically features multiple control modes, including constant current, constant voltage, and constant power, as well as self-diagnostic functions. * Welding Actuator: Includes clamps, electrodes, etc., used to hold the workpiece and apply welding pressure. The automated equipment also integrates a multi-axis linkage system and a rotary clamping structure to adapt to the welding needs of rotors of different specifications. The equipment's workflow typically involves placing the rotor workpiece to be welded in the designated position, and the equipment automatically completing the entire process of clamping, positioning, rotation, welding, and unloading.