Productivity boost and more profit with individual machine configurations
The demand for special machines in electrical engineering is constantly increasing. This is because the manufacturer-specific production tasks are too varied, for example in cable assembly, the production of current strips, copper strands and more, for which there is often no off-the-shelf processing machine. Support is promised by innovative special plant manufacturers such as DALEX GmbH & Co KG from Wissen. With highly complex production cells, automated systems and interlinked complete solutions that are individually tailored to the requirements of the user, the company provides an excellent calling card in a wide variety of key industries worldwide . For example, with customised special plant solutions for companies in the electrical engineering sector that are consistently designed for quality and production optimisation.
As a leading medium-sized company with a long tradition, DALEX has specialised in the manufacture of high-quality technical products for more than 100 years. Experience that the company has gained over the years in the industrial production of welding machines and components for a wide range of individual applications is incorporated as profound know-how based on high process competence and innovative strength in the development of special systems with a high degree of automation.
As a broad-based system solution provider for a wide range of market segments, DALEX specialists work closely with customers to develop the right solution for almost any automation task. Christoph Desch, authorised signatory and sales manager at DALEX GmbH & Co.KG: "In order to guarantee the high quality standards of the products during their manufacture, DALEX has already developed and supplied many systems for well-known manufacturers of current tapes, springs, copper strands and cable assembly. These include fully automated systems that cut the cables to length, feed in the strands, weld the connections and sign and discharge the finished parts. One example is the construction of a fully automated turntable system for cable assembly for a customer."
In order to optimise the production of the stranded cables and to combine several work steps, the manufacturer was looking for a system solution that would take over all tasks fully automatically - from cable feeding to measuring, cutting and stripping processes, feeding the wire end contacts to welding the contacts on both sides and discharging the finished products, even with a high number of variants.
DALEX technology ensures leaps in productivity
DALEX configured a 16-station rotary assembly machine that produces welded tube connectors with cross-sections of 16, 25, 35, 50, 70 and 95 mm2 as well as lengths of 75 to 300 mm with a grid spacing of 1 mm in the shortest possible time and in high quantities in a safe, repeatable and productive manner.
At the heart of this fully automatic production of contacted stranded cables are the two welding stations, each of which welds one end of the cable to the end contacts. This way, there are always two cables in the system and the quantities can be fulfilled much faster. Christoph Desch: "Our customer is completely satisfied: By linking separate work steps in the system combined with the possibility of producing many variants on a single machine, as well as the significant reduction in production times due to the powerful handling concept and parallel welding in two welding stations, he can now produce even more efficiently, economically and, above all, profitably."
With DALEX technology to the perfect welding result
Further examples of high-performance system solutions for electrical engineering are customised machines from the DALEX 3-phase DC series for the production of current strips and Cu strands. Longer, stable welding times are also easily possible with the configured, low-maintenance 3-phase projection welding machines. They convince with low alloying tendency of the electrodes, favourable connection conditions, uniform current distribution in electrodes and workpieces, low energy consumption as well as a large power factor.
In addition to systems from the DALEX AC series, the special solutions with medium-frequency technology are also energy-efficient and economical. DALEX medium-frequency transformers from our own production are particularly compact, weight-saving and free of thermal problems. They are used successfully in manual welding tongs, industrial robots and high-performance stand welding machines, for example, for short-time welding, welding galvanised materials, joining different materials and non-ferrous metals and welding coated materials. Customised DALEX welding machines in medium-frequency technology are predestined for welding cable lugs and copper flat-stranded wires or for welding the assembled cables to the component. They have a long electrode life, low inductive losses and ensure a high weld spot quality with low spatter tendency.
Christoph Desch: "The diversity in electrical engineering special machine construction is a world full of exciting challenges that we gladly accept. Our strength is based, among other things, on flexibility and extensive product and process know-how in different market segments. That's why we don't have any off-the-peg standards. For example, the applications in electrical engineering are very diverse. We find - from the modified machine to the special system - the solution tailored to the application for precise and economical production. Our customers receive solutions from a single source - from the individual machine to an interlinked concept - completely adapted to the respective workflow and the specified interfaces."
To support welding technology consulting, the DALEX specialists invite anyone interested to the DALEX Technology Centre. There, it is possible to carry out test welds with ready-to-use spot, projection and roller seam welding machines in alternating current, three-phase direct current, medium frequency and KE technology and to demonstrate the best welding process for the respective application.
Photo 1: The fully automated turntable system for cable assembly from DALEX takes care of all tasks from cable feeding to measuring, cutting and stripping processes, feeding the wire end contacts to welding the contacts on both sides and ejecting the finished products.
Photo 2: The DALEX three-phase DC projection welding machine with double cylinder for press projection welding of Cu lamella strips works very stably even over longer welding times.
Photo 3: The machines are individually equipped with special fittings for each application, such as the DALEX medium-frequency projection welding machine with a special welding tool for soldering or welding silver contacts on switch fingers.
Photo 4: The applications are versatile - DALEX has already developed and supplied many systems for well-known manufacturers of power tapes, copper strands and cable assemblies.