Principle of Heat Pressure Welder(Upset butt Welder)
The ends of the wire rods to be joined are butted together over a length (TD) of 2 to 2.5 times the wire diameter (φD) and then the wires are clamped. Initially, small pressure (P1) is applied to the butt section. After the squeezing period (t1)，a large current (I) is applied to the section until a specified length (L1) of material becomes molten due to joule heat. Simultaneously，a high pressure (P2) is applied，which causes the excess molten material to be pushed out of the joint. After holding time (t2)，the clamp is released to complete the operation.
Features
Applicable to a wide variety of materials
The heat pressure welders(Upset Butt Welder) have been designed primarily for use with high carbon steel wire rods that are normally difficult to join, and copper wires that are required to have high connection performance to cope with high-speed wire drawing machines. However, they can be applied to many other materials.
Ferrous
- P.C. steel wire rod, spring steel wire rod, and other high carbon steel wire rods.
- Various types of stainless steel wire rods.
- Various types of welding rods.
- Low alloy steel wire rods.
- Steel wire strand.
Non-ferrous
- Copper wire rods for electrical conduction.
- Oxygen-free copper wire rods for electrical conduction.
- Aluminum wire rods for electrical conduction.
- Flat wire rods for electrical conduction.
- Brass wire rods.
- Welding of stranded wires.
- Welding of different types of metallic wires and rods.
High Performance of the Welded Section
With the heat pressure welding process, which is a two-step upsetting type, undesirable defects within the metal structure are eliminated when the excess molten material is forced out from between the joining surfaces. This feature assures unprecedented weld performance. In the case of high carbon steel is a rod, the decarburization and hardness loss typical of traditional processes will be reduced. In the case of copper wire rods for electric application, the welded section is less subject to the formation of overheat zone, oxygen absorption, or decrement in strength, unlike in the conventional process. These features are particularly useful in the welding of oxygen-free copper stock which must be protected against oxygen absorption of flat pieces that are subject to severe working conditions.
Finishing the welded section is very easy
A tip of special material attached to the end of the clamp section is used to remove the burr. This deburring is so efficient that the subsequent finishing operation takes a far shorter time than in the conventional method.
Skilled workers are not required
Automatic operation. Once the wire rods are clamped，no subsequent attention is required up to the deburring step. This assures uniform results regardless of the skill of individual operators.
Specifications
Annealing Unit
| System | Model No. | Annealing Temperature range |
|---|---|---|
| Programable type(For thin lines) | AH-1 | 400℃～1100℃ |
| Programable type | PY-6 | 400℃～1100℃ |
Upset butt welder for steel wire and rod.
| Model No. | Welding Capacity
(mm) |
Electrical Capacity | Dimension | Weight
(kg) |
|||
|---|---|---|---|---|---|---|---|
| Rated Capacity (kVA) |
Max.Capacity (kVA) |
Width
(mm) |
Depth
(mm) |
Hight
(mm) |
|||
| BSH-1 | φ0.6～φ2.6 | 0.42 | 1.34 | 400 | 250 | 510 | 45 |
| BSH-5 | φ1.0～φ6.0 | 0.9 | 3.0 | 500 | 500 | 850 | 200 |
| BSH-10 | φ3.0～φ10.0 | 4.4 | 7.0 | 1,150 | 650 | 1,400 | 850 |
| BSH-15 | φ5.0～φ18.0 | 25.3 | 40.0 | 1,700 | 980 | 1,580 | 2,000 |
| BSH-30 | φ15.0～φ30.0 | 48.0 | 77.0 | 1,900 | 1,600 | 1,800 | 3,200 |
Upset butt welder for Copper Wire and Rod
| Model No. | Welding Capacity
(mm) |
Electrical Capacity | Dimension | Weight
(kg) |
|||
|---|---|---|---|---|---|---|---|
| Rated Capacity (kVA) |
Max.Capacity (kVA) |
Width
(mm) |
Depth
(mm) |
Hight
(mm) |
|||
| BFH-1 | φ0.6～φ2.6 | 0.95 | 3.0 | 500 | 350 | 600 | 70 |
| BFH-5 | φ1.0～φ7.0 | 6.3 | 20.0 | 550 | 610 | 850 | 250 |
| BFH-10 | φ3.0～φ10.0 | 12.8 | 41.0 | 1,150 | 650 | 1,460 | 800 |
| BFH-19 | φ8.0～φ19.0 | 110 | 447 | 1,700 | 1,200 | 1,580 | 2,300 |
| BFH-25 | φ15.0～φ25.0 | 257 | 470 | 1,750 | 1,900 | 1,800 | 3,500 |
Upset butt welder for Brass Wire and Rod
| Model No. | Welding Capacity
(mm) |
Electrical Capacity | Dimension | Weight
(kg) |
|||
|---|---|---|---|---|---|---|---|
| Rated Capacity (kVA) |
Max.Capacity (kVA) |
Width
(mm) |
Depth
(mm) |
Hight
(mm) |
|||
| BFS-5 | φ1.0～φ7.0 | 6.3 | 20.0 | 550 | 610 | 850 | 250 |
| BFS-10 | φ3.0～φ12.0 | 18.7 | 30.0 | 1,300 | 750 | 1,460 | 800 |
| BFS-16 | φ8.0～φ16.0 | 83.0 | 153 | 1,700 | 980 | 1,580 | 2,000 |
| BFH-25 | φ16.0～φ25.0 | 257 | 470 | 1,750 | 1,900 | 1,800 | 3,500 |
Upset butt welder for Copper Stranded Wire
| Model No. | Welding Capacity
(mm) |
Electrical Capacity | Dimension | Weight
(kg) |
|||
|---|---|---|---|---|---|---|---|
| Rated Capacity (kVA) |
Max.Capacity (kVA) |
Width
(mm) |
Depth
(mm) |
Hight
(mm) |
|||
| BFY-5 | 2～22 | 6.3 | 20.0 | 550 | 610 | 850 | 250 |
| BFY-8 | 14～150 | 48.0 | 154 | 1,300 | 750 | 1,510 | 1,100 |
| BFY-19 | 80～400 | 110 | 447 | 1,700 | 1,200 | 1,580 | 2,300 |
| BFY-30 | 150～640 | 257 | 470 | 1,750 | 1,900 | 1,800 | 3,500 |
Upset butt welder for Aluminum
| Model No. | Welding Capacity
(mm) |
Electrical Capacity | Dimension | Weight
(kg) |
|||
|---|---|---|---|---|---|---|---|
| Rated Capacity (kVA) |
Max.Capacity (kVA) |
Width
(mm) |
Depth
(mm) |
Hight
(mm) |
|||
| BL-5 | φ1.0～φ7.0 | 6.3 | 20.0 | 550 | 610 | 850 | 250 |
| BL-10 | φ5.5～φ12.0 | 10.4 | 33.0 | 1,150 | 650 | 1,460 | 800 |
| BL-16 | φ10.0～φ16.0 | 22.0 | 70.0 | 1,300 | 750 | 1,510 | 1,000 |
| BL-19 | φ14.0～φ20.0 | 41.0 | 130 | 1,700 | 980 | 1,580 | 2,000 |
| BL-30 | φ16.0～φ30.0 | 257 | 470 | 1,750 | 1,900 | 1,800 | 3,500 |
- DESIGN/PARTS may be changed without notice.
- Various options can be added depending on the application.
Vendor
T.Fukase & Co., Ltd
TEL：+81-3-3553-9531
FAX：+81-3-3555-2730
Contact Us(T.Fukase & Co., Ltd)