Copper-aluminum Tube Insert Resistance Welding Machine

The free-adjustable electrode base system, protected under Chinese patent ZL 2007 1 0011656.3, allows rapid and precise electrode alignment when switching between tube sizes. This eliminates the trial-and-error repositioning common on conventional resistance welders, reducing setup scrap and ensuring every weld meets pressure-test standards.

Unlike traditional machines that rely solely on welding time, this unit monitors and controls the actual welding stroke — the physical displacement of the electrode during fusion. This approach compensates for real-world variables such as tube surface condition, ambient temperature, and material batch differences, producing uniform joint quality regardless of shop-floor conditions.

Copper and aluminum have significantly different electrical resistivities, making current control critical for sound joints. The 8-grade adjustable output voltage with thyristor regulation lets operators dial in the exact energy profile for each tube diameter and wall thickness combination, preventing burn-through on thin aluminum while ensuring full fusion at the copper interface.

At 5–7 seconds per weld with foot-pedal-activated pneumatic clamping, operators maintain a hands-free workflow that supports sustained daily output. The Mitsubishi PLC and Kinco touch screen provide straightforward parameter storage and recall, so changeovers between product models take minutes rather than hours.

The 600kg steel frame absorbs vibration and maintains electrode alignment over years of continuous use. Core electrical and pneumatic components — Mitsubishi PLC, Kinco HMI, Delixi contactors, cylinders, and valves — are CE-certified and widely available for field service, minimizing spare parts lead times in any market.