Resistance welding technology

WELTAC®

Assembly systems for resistance element welding

Flexible and reliable

Flexible technology

WELTAC® is a process used in resistance welding technology. It creates mechanically strong joints for modern multi-material construction.

Plus factors

Advantages of WELTAC®

Proven technology

The first stage of the WELTAC® Automation process is based on the proven processing systems RIVSET® Automation E and EH.
Long service life

Low maintenance requirements
Existing equipment

Existing resistance spot welding systems for modern body construction can be used for the second stage of the WELTAC® process.

Method and principle

How does resistance element welding work?

Resistance element welding is a further development of resistance spot welding. In contrast to the conventional procedure, a rivet-like resistance element made of a material which is compatible with the base sheet is used as the auxiliary joining part. In the first stage of the process, the WELTAC® welding element is punched in to the upper material layer. This component is then welded to the lower steel material layer(s) in the second stage of the process. (Böllhoff only supplies WELTAC® elements and WELTAC® Automation for the first stage of the process.)

WELTAC® resistance element welding for modern multi-material construction

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WELTAC® Automation

WELTAC® uses our proven RIVSET® Automation E and EH assembly systems.

WELTAC® Automation E
The highlights of WELTAC® Automation E at a glance:

Smart: modular and comprehensive machine designs

Quick: machine configuration via plug & play

Flexible: remote access to the control software

Powerful: fast high-performance CPU

Plug & play: mobile manual control unit for more than one control during commissioning

Process times ≤ 1.5 seconds/element (depending on the setting tool – also EH)
Tool – EH setting tool
Due to the modular design, the tool is designed for applications in large-scale production with maximum flexibility during production planning.
A long service life and minimal maintenance are important factors here, forming the basis for successful production.

Setting tools with electrical drive for setting forces ranging from 10–35 kN

Pre-clamping force adjusted with pressure springs

Various mounting points on the setting tool for perfect positioning on the robot and elsewhere
C-Frame
The modular system – the new C-frame allows you to create a large number of setting tools with a small number of C-frames.

Advantages

Effective
The process of designing rivet setting tools, whether creating new models or altering existing ones, is drastically shortened.

Lightweight
The new C-frame is on average 20 % lighter and thus contributes to a compact design.
Setting head
Blow feeding and processing of WELTAC® elements via pneumatic-controlled transport into the duct bend.

Also ensures the feeding of small WELTAC® elements (shaft Ø 4 mm, total length 2.6 mm), with or without clamping ring.
Feed
Minimal maintenance workload

Feeds approx. 45 elements/minute

Stores approx. 4,000 elements (can be increased if required)

Find the right solution for your application

Manual processing

Hand tools for stage one of WELTAC® processing.

Portable C WELTAC®
The new generation of the Portable C electrohydraulic setting tool enables flexible combination options using the same basic tool. The self-pierce riveting heads can be replaced directly on site.

Advantages

Defined setting cycle

Precise pressure setting via display

Digital pressure control

Battery power

The Portable C can be used for process stage 1.

The base unit is also suitable for RIVSET® processing.

To our WELTAC® Portable C operating manual