Prospot UK Product Brochure by ProspotUK

COMPANY HISTORY

Prospot Ltd. has developed an enviable reputation in Resistance Welding machines, refurbishments, fixtures and consumable supplies, alongside automation design, contract weld and development services, training and service packages.

Prospot, which also incorporates leading Resistance Welding machine brands British Federal, Meritus and micro bench welding companies Hirst Holden & Hunt and Gatwick (FPE), was established back in 1997.

Key partnerships include Serra, Luvata, Becker, Jurado Clinching and CEA. We have the ability to design, manufacture and supply a comprehensive range of products from a single special electrode to a fully automated multi robot assembly cell. Prospot services clients such as BMW, Gestamp, GKN, JLR, Nissan and Sertec.

Known for Resistance Welding, Prospot also offers a multitude of additional joining solutions including clinching, SPR, Nelson and Gluing, alongside adaptive solution welding via the Fleximan and Multiman ranges.

Prospot continues to grow across Europe with dedicated manufacturing facilities in Slovakia serving the Nitra automotive manufacturing hub and beyond including Czech, Hungary, Poland and Germany.

Over recent years Prospot has evolved its business model to further support the needs of the Aerospace, Automotive, Oil, Rail, Renewable Energy and Construction Industries and has seen a pattern of significant growth particularly for fully automated solutions in the Automotive sector.

WATER CONNECTOR. WASHER.

CAP ADAPTOR.

FLAT CAP ELECTRODE.

NUT LOCATION PIN. NUT ELECTRODE.

PROJECTION WELD BODY "WATER COOLED".

WATER CONNECTOR. WASHER.

TOOLPOST.

FLAT CAP ELECTRODE.

PROJECTION WELD BODY " NON WATER COOLED."

CERAMIC COATED STEEL LOCATION PINS LONG SERIES

PROJECTION

M18 × 1.5

3/4” 5 Deg Taper

M22 × 1.5

3/4” 5 Deg Taper

B13-M18 M18 × 1.5

1/2” BSP-25 Dia

B4 ASSY

B5 ASSY B34-M18 B5 B4

CuCrZr & ELKANITE FACED

WPN TMS WS17 TP TMS3

CERAMIC COATED STEEL LOCATION PINS LONG SERIES

CASTELLATED TYPE

DOLPHIN TYPE

CONE DESIGN - LONG SERIES

CHARACTERISTICS

Cerazur SN750

Blue Grey

1300MPa 750MPa

12MPa m 6.7MPa m Vickers Hardness 1.150HV 0,5 1.650HV 0,5

CASTELLATED - SHORT SERIES

DOLPHIN NOSED - SHORT SERIES

SUPER SOLID CERAMIC PINS

CERAMIC COATED STEEL LOCATION PINS

SERIES

CASTELLATED - SHORT SERIES

DOLPHIN NOSED - SHORT SERIES

NUT ELECTRODES - SHORT SERIES

CERAMIC COATED SLEEVES FOR STUD WELDING

SE25-CS2ASSY SE25ELK-CS2

SE25-CS3ASSY SE25ELK-CS3

SE25-CS4ASSY SE25ELK-CS4

SOLID CERAMIC SLEEVES FOR STUD WELDING CERAMIC SLEEVES

STUD ELECTRODES

M10 SEBM10 SEBM10ELK

M12 SEBM12 SEBM12ELK

SPRINGS

M6 C-5505740

M8 C-5507520

PROJECTION WELDING BODIES

CuCrZr & ELKANITE FACED

SILICON NITRIDE

TE13-75ELK 1/2” 5 DEG INC

TE25-75ELK 25mm DIA 3/4” DEG INC

TE16-75ELK 5/8” 5 DEG INC

TE30-75ELK 30mm DIA 3/4” 5 DEG INC

TE19-75ELK 3/4” 5 DEG INC

NEBELK 30mm DIA M20 × 1.5mm

DBO750ELK 3/4” 5 DEG INC

FEATURES

• Prevents welding the wrong nut.

• Prevents welding upside down nuts.

• Detects missing nuts.

• Detects missing workpiece.

• Detects double workpiece under nut.

To set the machine, simply put the required panel and the correct nut onto the location pin, initiate the machine and press the teach button on the panel.

Improve your welding quality and reduce your customer complaints by fitting our Nut Checking System.

OPTIONS: TRAVEL HEAD SENSORS CAN ALSO BE FITTED TO STOP DOUBLE NUTS FROM BEING WELDED.

NUT FEEDER

• High performance and accuracy in resistance welding.

• Up to 30 nuts per minute.

• Single or dual feeding.

• Top cover for low noise and high protection.

Hopper capacity

Feeding head stroke

Nut impaler / selector

Nut transport (to feeding rod / centering device)

(205 under request)

Feeding head length / interconnection

Feeding head placement angle ° 15 to 80

Standard programmable relay Allan Bradley REQUEST INLETS

Power Supply

* Specify on order

NUT TYPES:

• 7/16

• M5 to M12

• Other types on request

NUT SHAPES:

• Square

• Round

• Hexagonal

• With or without washer

OPTIONS:

• “T” shape

• Rectangular

• Diamond shaped

• Hexagonal with washer

• Double square

• Rounded with washer

PNEUMATIC UNIT WITH SHUT OFF, FILTER REGULATOR.

• Feeding Capacity: up to 30 bolts per minute

• Single or Dual feeding

• Top cover for low noise and high protection

• Control cabinet allows future upgrades

• CE marked

Head Interconnection

WELDING CONDITIONS FOR SQUARE WELD NUTS

WELDING CONDITIONS FOR WELD BOLTS

RESISTANCE SPOT WELDING GUIDELINES

Taken from British Standards BS 1140 : 1993 Resistance spot welding of uncoated & coated low carbon steel.

IMPORTANT: These are recommendations only, settings must take account of actual conditions and be verified using a destruct test.

NOTES: When welding sheets of dissimilar thickness, welding conditions may be based on the thinner sheet or the second thinnest sheet on three thicknesses.

MODULE 1 (5-6 HOURS, UP TO 6 PEOPLE)

• A course specifically designed for production operators, machine setters and line inspection personnel. This module includes

• Resistance welding fundamentals and methods (basic)

• Welding electrodes and materials

• Operator health and safety , good workshop practices

• Electrode dressing

• Weldable materials (basic), changing and cooling of electrodes

• Weld quality requirements (basic)

• Inspection and testing of resistance welds.

(5-6 hours) up to 6 people. Course includes theory and practical elements and can be completed at Prospot or Customer Site.

MODULE 2 (5-6 HOURS, UP TO 6 PEOPLE)

• A course specifically designed for engineers and technicians with an in-depth detail of technical content. This module includes

• Resistance welding principles and methods

• Welding electrodes and materials

• Operator health and safety, good workshop practices

• Electrode dressing

• Weldable materials, changing and cooling of electrodes

• Weld quality requirements

• Inspection and testing of resistance welds.

(5-6 hours) up to 4 people. Course includes theory and practical elements and can be completed at Prospot or Customer Site.

WELDING ENGINEERING CONSULTANCY

• We are able to supply engineers with a wealth of expertise in resistance welding processes within the automotive and sheet metal industries, who can give support for the following areas: Manufacturing and Production Engineering, quality and conformance engineering, and maintenance engineering.

CERTIFICATE FOR COMPLETION OF COURSE

CAP ADAPTORS

Adaptors with different tapers ie, 1:10 & 1:20 are also available. Please ask for details.

STRAIGHT ADAPTORS

ADAPTORS

CAP ADAPTORS

REDUCING ADAPTORS

DOUBLE BEND CAP ADAPTORS

Adaptors with different tapers ie, 1:10 & 1:20 are also available. Please ask for details.

THREADED ADAPTORS

Threaded adaptors are available in numerous configurations with any thread and taper combinations.

All cap electrodes are cold formed and may be available in up to three materials and different geometries. Please contact us to find out in which materials they are available.

Z-TRODE CuZr ie FB13Z00

For light to medium gauge coated steels and aluminium.

NITRODE Dispersion

Strengthened Copper ie FB13N00

For coated steels and heavy duty applications, giving superior performance and reduced sticking on coated steels.

A-TRODE CuCrZr ie FB13C00

For general uncoated applications.

All cap electrodes are cold formed and may be available in up to three materials and different geometries. Please contact us to find out in which materials they are available.

Z-TRODE CuZr ie FB16Z00

For light to medium gauge coated steels and aluminium.

NITRODE Dispersion

Strengthened Copper ie FB16N00

For coated steels and heavy duty applications, giving superior performance and reduced sticking on coated steels.

A-TRODE CuCrZr ie FB16C00

For general uncoated applications.

PROSPOT MANUFACTURE THE HIRST HOLDEN & HUNT RANGE OF ELECTRODES. PROSPOT MANUFACTURE A VAST RANGE OF MALE ELECTRODES.

1/2” BSP SCREWED FOR THREADED ELECTRODES

FLAT ELECTRODES BS 807 5 DEGREE INC TAPERS

CENTRE ELECTRODES BS 807 5 DEGREE INC TAPERS

VERTICAL OFFSET ELECTRODES BS 807 5 DEGREE INC TAPERS

MALE ELECTRODES BS 807 RANGE

STANDARD MERITUS ELECTRODE FITTINGS - NO2 MORSE TAPER

STANDARD MERITUS ELECTRODE FITTINGS - 3/4” BS 807 5 DEG TAPER STANDARD MERITUS ELECTRODE FITTINGS - FOR

ELECTRODES UP TO 20 k VA TECNA MACHINE

PRO-E1436

PRO-E0097

TP22-16-180-MT2 SIP TOOLPOST

16mm CAP AND ADAPTORS TO SUIT SIP SPOT WELDER

AMT16 - X X mm: 36, 41, 47, 55, 60, 69, 73, 83, 93, 97, 107

FB16_14 12mm 1:10

DBA16-16MT

DOUBLE BEND OFFSET ADAPTOR 90mm O/L

FB16_23 12mm 1:10

FD16_00 12mm 1:10

AMT16 - A13 CONVERTS SIP MACHINE TO USE 13mm ADAPTORS & 13mm CAPS

FB16_08 12mm 1:10

BRITISH FEDERAL SPARES

ANGLED OFFSET ELECTRODES

DOUBLE BEND OFFSET ELECTRODES

CRANK OFFSET ELECTRODES

BALL TYPE ELECTRODES

VERTICAL CENTRE TYPE ELECTRODES

VERTICAL OFFSET TYPE ELECTRODES

STANDARD ELEKTRODE HOLDERS

CEA ELECTRODES

different configurations to suit CEA Machines

Prospot has the ability to design and manufacture gun arms and manual welding guns, made from CuCrZr or high strength aluminium. We have the capability to bend over 65mm CuCrZr arms using our 60T hydraulic press.

ALUMINIUM ROBOT GUN ARMS - COPPER COATED

CuCrZr MANUAL WELDING GUN ARMS WITH CAST HOLDERS

CuCrZr DOUBLE BENT GUN ARMS FLAT TYPE

CuCrZr BENT AND FABRICATED MANUAL GUN ARM

MODULAR ROBOT GUN ARMS WITH LINEAR SLIDES MADE FROM BOTH HIGH STRENGTH ALUMINIUM AND CuCrZr.

RESISTANCE WELDING MATERIALS

Prospot are able to supply a wide range of welding materials suitable for all types of resistance welding applications.

This information is for guidance only. Please speak to our technical staff for more assistance in selecting the correct materials.

MACHINE TOOLING

All brass toolposts are 300mm long with brass water connectors.

TOOLPOST – ANGLED

WATER CONNECTORS

WATER TUBES

HORIZONTAL ADAPTORS

MACHINE TOOLING

HORIZONTAL TOOLPOST HOLDER

BOLSTER

HORSE SHOE ADAPTOR

MACHINE ARMS

Machine arms manufactured to suit any machine and size.

SEAM WELDING WHEELS

Manufactured to your requirements.

PLATTERNS

Replacement platterns or convert your spot welder to a projection welder.

LAMINATED SHUNTS

Flexible laminated shunts supplied to your requirements.

WA2

• The Weld Analyser offers the engineering professional the facilities to analyse, fault-find and improve process quality on today’s sophisticated welding control systems.

• Full traceability gives you the confidence in your processes that your customers demand.

• Includes a 150mm flexible toroid, batteries and carry case.

• Measures 2.00 to 60.00 kA, 9999 cycles AC, 199.9 seconds DC, number of pulses, average conduction angle and weld time.

WELD FORCE GAUGES

TIP DRESSERS PEDESTAL AND

HAND HELD

- 22mm

Jaw Type 16mm - 20mm

Jaw Type 10mm - 16mm

TAPERED REAMERS

TORQUE TESTING SOCKETS FOR SQUARE NUTS

The INSULATION BAND is used where permanent insulation of the part is required.

Fibreglass band coated in epoxy resin guarantees a permanent insulation up to 11,000 volts and is heat resistant up to 300 Deg C.

50mm wide × 1500mm long

MANUAL MTD-1

Jointing and Sealing Compounds

HERMATITE RED Semi hardening gasket compound

COPPER GREASE Conductive grease

Manual tip dresser MTD-1 can quickly remove the mushroomed portions of the electrodes and renews the operating contour. The dresser machines both upper and lower electrodes on the job. The dresser is 240mm long and cuts 5mm dia x 120 angle.

WELD COUNTER WC-1

PROSPOT WELD COUNTER – WCT-1:

• THE WCT-1 IS A SIMPLE AND ECONOMICAL SOLUTION TO COUNT RESISTANCE WELDS FOR BATCH PRODUCTION AND ELECTRODE MANAGEMENT.

FEATURES:

• INTERNAL LONG-LIFE BATTERY ALLOWS EASY FITTING TO NEW AND EXISTING MACHINES – NO WIRING REQUIRED

• 8 DIGIT LCD DISPLAY

• RESET BUTTON

• THE WCT-1 CAN BE EASILY POSITIONED ANYWHERE ON THE MACHINE

• LOW COST, FLEXIBLE SOLUTION

• TYPES OF WELDERS: SOFT TOUCH can be used with all types of metals on press welders, rocker-arm welders, portable gun welders, and hanging gun welders doing spot, projection and seam welding

• FULLY PASSIVE: There are no operator adjustments. Even if electrode height or travel is changed, the SOFT TOUCH system continues to function without any operator changes. There is nothing for an operator to adjust once installed.

• FAIL SAFE OPERATION: If any of the system sensor wires become disconnected, the SOFT TOUCH system will lock out and not let the electrodes close or the welding sequence to proceed. If the SOFT TOUCH sensor board detects electrode continuity before the foot switch or hand switches are closed, the system will lock out and not allow any electrode movement.

WATER COOLERS & CHILLERS

The ETD18F manual pneumatic tip dresser is a cost effective way of re-cutting your welding electrodes. It can dress both 13mm & 16mm electrodes depending on the cutter collet fitted.

RPM 1,300 1.6kg Weight

CUTTERS

SHAPE

The SK11D is designed to use off line as a pedestal drill tip dresser, for both 13mm and 16mm electrodes depending on which cutter collet is fitted.

ELECTRODE SHAPE

COLLET

PART NO

OUTER DIAMETER OF DRESSED ELECTRODE KM1-13 Ø13 KM1-16 Ø16

• Comes with one-touch bayonet mount holder which does not require any tool for replacement.

• Simultaneous dressing of the upper and lower electrodes enables a reduction in dressing time and the alignment of the face after dress.

• Balancer unit is a standard requirement, enables the reduction of the load on the welding gun and the dresser.

• Dresser with built-in rotation confirmation function by proximity sensor. (Option)

• Splash proof construction for terminal box.

• High torque, high-speed rotation. (1 sec, dressing)

• Cutter dress upper and lower electrode simultaneously ensuring tip face alignment and its life span is long.

BEFORE PLACEMENT AFTER PLACEMENT HOLDER /CUTTER

The tip dresser comes as a complete set with vacuum device for chip extraction. This tip dresser set is very easy and quick to integrate and ensures great economic efficiency in your maintenance department. It has a compact design which is designed for intuitive operation, highest quality longevity, uncomplicated maintenance and reliable tip dressing even under the most challenging conditions.

PLUG & PLAY SET

JUMPER CABLES

STANDARD DIMENSIONS

Available with or without perforation. Other dimensions available upon request. Jumper cables are available in the following designs:

• F = flexible – thread dia 0.15 mm (standard design)

• HF = highly flexible – thread dia 0.07 mm. HF available only upon request, unavailable on stock.

The permissable secondary current I , at a given duty factor may be calculated from / I - I

JUMPER CABLES

CONNECTOR 1

CABLE

CONNECTOR TYPES

STANDARD DIMENSIONS

Minimum bending radius is approximately 5 times cable diameter. Cable length upon your request. Other connector types manufactured custom based on your drawing.

CONNECTOR 2

The permissable secondary current I ; at a given duty factor , may be calculated from I = I x x x 2P

Laminated shunts transfer welding current to the moving parts of machine, such as upper arm. Shunts are custom manufactured upon request.

LAMINATED SHUNTS

• shunts flexible on one axis used for connection of machine parts moving linearily

• custom manufactured laminated shunts

• fill out the form below for a quote

• to connect highly flexible machine parts (robot arms) use jumper cables

1. CHOOSE SHUNT SHAPE

2. CHOOSE TERMINAL OR DRAW YOUR OWN

3. FILL OUT DATA

WELDING TRANSFORMERS

• standard 50 Hz low frequency transformers for various applications

• standard DIN transformers

• compact medium frequency transformers LOW FREQUENCY

LOW FREQUENCY

TRANSFORMERS FOR SEAM WELDERS

WELDING TRANSFORMERS LOW AND MEDIUM FREQUENCY

MEDIUM FREQUENCY TRANSFORMERS

LOW FREQUENCY TRANSFORMERS FOR WELDING GUNS

MEDIUM FREQUENCY TRANSFORMERS FOR WELDING GUNS

ALSO SUPPORTING NEW AND REPURPOSED TRANSFORMERS FROM CEA, ROMAN, BRITISH FEDERAL AND MERITUS.

WELDING TRANSFORMERS

AND MEDIUM FREQUENCY

LOW FREQUENCY TRANSFORMERS FOR ROBOT CELLS

MEDIUM FREQUENCY TRANSFORMERS FOR ROBOT CELLS

TSMF-250JE (Primary 500V)

TSMF-120KI (Primary 500V)

SERRATRON 100B WELD CONTROLLER FOR RESISTANCE WELDING

• 217 Welding programmes

• Constant current mode

• Integrated programming unit

• Proportional valve control

• Sequence with 3 weld times

BASIC FUNCTIONS

• Max. Number of Power Units: 1

• Electrode wear compensation

• Electrode tip dressing control

• Ethernet connectivity

• Wide weld sequences: Chained mode, Successive...

• Communication Network: Ethernet + TCP/IP

• Control Modes: constant current, current monitoring, firing angle

• Electrode wear compensation through editable curves

• Sequence of 3 weld times

• Log of the latest welds / Log of the latest error messages 512

PHYSICAL CHARACTERISTICS

• Dimensions (H × W × D)

• Weight

ELECTRICAL CHARACTERISTICS

• Synchronisation

•

• Working Modes 2

• Hanging Stations (no. of weld programs) MAN (127)

• Pedestal Welders (no. of weld programs) STA (127)

• Digital Inputs (18...28V/10 mA) 18

• Current Measuring Input (20 ÷ 2300 mV/kA) 1

• Firing Outputs (24 VDC/1A, 5kHz Pulses) 1

ELECTRICAL CHARACTERISTICS OPTIONALS OPTIONALS

• CPC - Connect: Central programming software via Ethernet

• Applications

– Spot, projection and seam welding.

– Up to 4 inverters & up to 4 weld guns.

• Operating Modes

– MUX: One thyristor group (AC single phase welding)

– PLC: All I/O free programmable.

• 127 Welding Programmes

– 3 Welding time sequences & pulsations & up/down slope.

– Operation in phase shifting, current monitoring or constant current mode.

– Voltage changes compensation function.

– 1/2 wave welding function.

• Electrode Wear Compensation

– Predefined curves (can be edited)

– Easy tuning, few parameters to be adjusted.

• Tip Dressing Function

• Coldfire embedded microprocessor

• Central Programming

– Ethernet 10/100 base-T (Standard)

– Ethernet 10/100 base-FL (Optical Fiber - under request)

– TCP / IP Protocol

• CPC-Connect Programming Software

– Via ethernet for lap-top

• PLC

– 20 Inputs 16 Outputs 0,7 A short circuit protected.

– Up to 260 l + 256 O using external expansion modules.

– User interface TP-10: messages and commands managed by PLC program.

– Ladder mode programming (up to 990 equations)

– Marks, latches, timers, counters, welding functions

• Analogue Output for Proportional Valve

– 0 - 10 V/4 - 20 mA/0 - 20 mA

• Field Buses – Optional modules for robot installations:

– 100ib InterBus

– 100dp Profibus-DP

– 100net DeviceNet

• Weld spot quality assurance system (WISE System®)

• Crucial reduction of transformer weight and volume.

• Shorter cycle time.

• Balanced consumption between the 3 line phases.

• Splash free welding.

• Wise Adapt and Wise Synergic functions for automatic parameters regulation 255 Weld programmes.

WISE ADAPTIVE CONTROL

Adaptive control system of welding spots. Smart control for ensuring the quality of welding from a pre-set pattern. Use of measurements of current and voltage during welding to mathematically generate the dynamic resistance curve.

Two WISE Control modes:

• WISE-Adapt: adaptive welding control through dynamically varying the welding current only.

• WISE-Synergic: adaptive welding control through dynamically varying the parameters of welding current and time. MFC - 3000 WELD CONTROL

3007W

35 kA – Water cooling

1 × 100kVA parallel transformer

3015W

60 kA – Water cooling

2 × 100kVA parallel transformers

COMPATIBLE WITH SERRA HMI

FEATURES

• New CDF (Capacitor Discharge Functionality that minimizes rise time of the welding).

• Current with slopes of up to 10 kA/ ms, it allows the regulation of the energy applied to the welding with a current rise time like those that can be obtained with capacitor discharge machines.

• For optimal use of the CDF mode, it should be combined with optimized secondary circuit SERRA machines equipped with low impedance TSCDF SERRA transformers.

Total reliability is provided by British Federal BF450 type electronic welding control using ‘state of the art’ technology providing all electronic fully synchronous welding control and solid-state thyristor switching.

HEAVY DUTY SPOT WELDERS FEATURING:

• A choice of transformer and arm reach.

• A ‘T’ slotted face plate giving both vertical and horizontal adjustment of the lower arm.

• Optional reversible upper and lower electrode arms, one drilled to accept vertical electrodes with the other end a 22½°

• Inclined electrode.

• Optional water-cooled lower arms and adapters for cross wire and ‘T’ wire welding.

• Adjustable weld time.

• Current range infinitely adjustable from 0% to 99% phase shift control.

• Weld / No Weld switch.

BF450 WELD CONTROL FEATURES:

• 16 Selectable Weld Programs

• Two Weld Intervals in each Weld Program

• Pulsation of 2nd Weld Interval

• ½ Cycle function

• Internal / External Program Selection

• Second Stage Input

Diameter Top and Bottom

Electrode Holders

Electrode (Mallory 328)

(32)

Built to British Federal’s high-quality standards, these bench welders are designed for welding small parts with high accuracy. The bench top welder range is available as a projection welder or spot welder format, with both AC and MF Controls and transformer sizes to suit a range of applications.

• Range of transformer powers available at 32, 54 and 76kVA

• 40kVA Medium Frequency options available with the Serra MFC3007 welding inverter controls fitted.

• Can be mounted to a workbench for a more compact workstation.

• For basic AC machines the renowned British Federal BF450 timer is fitted.

• Reliability – fitted with 50% duty cycle encapsulated transformers fitted.

• Weld initiation by means of 2 hand start

OPTIONAL EXTRA:

• Monitoring functions can be provided through the Serratron 1B timer option. (Standard with the Medium Frequency version) 40kVA Medium Frequency options available with the Serra MFC3007 welding inverter controls fitted.

• Proportional valve for correct setting of pressure for basic AC machines the renowned British Federal BF450 timer is fitted. Foot pedal initiation weld initiation by means of 2 hand start.

• Water Cooler.

BMFDC OFFERS THE FOLLOWING BENEFITS:

• Improved weld quality.

• Reduced Power consumption costs.

• Lower peak currents providing increased electrode life.

• 3-phase even load distribution.

• Ideal for welding coated materials and Aluminium.

• Weld times reduced through increased rate of heat input to work piece.

• Reduced weld splash owing to lower peak currents.

• Can be retrofitted to existing machines.

BENCH PROJECTION WELDER

British Federal Heavy Duty Compact spot welding machines incorporate a weld head design, easily adapted to spot and nut / bolt welding. They are supplied with ISO standard watercooled transformers and a choice of programmable weld controls giving constant current and full monitoring capabilities.

• Adaptability - 450mm or 600mm reach.

• High Quality Welding – Choice of state of the art weld controls.

• High Productivity - Up to 250 spot welds per minute.

• Reliability - 50% duty cycle encapsulated transformers.

• Versatility - Adjustable lower arm.

OPTIONAL EXTRA

Reduced Power consumption costs.

• Lower peak currents providing increased electrode life.

• 3-phase even load distribution.

• Ideal for welding coated materials and Aluminium.

• High lift and or 160mm air cylinder. 150KVA , 250KVA, 300KVA single phase AC or 250KVA 3-phase DC Medium Frequency Transformer.

• Custom Built tooling.

• Closed circuit water cooled system.

• Integration of automatic nut and bolt feed machines.

• Light guard and peripheral guarding systems.

• Weld times reduced through increased rate of heat input to work piece.

• Reduced weld splash owing to lower peak currents.

• Can be retrofitted to existing machines.

HEAVY DUTY COMPACT SPOT WELDER TYPE 40/63

British Federal Heavy Duty Compact Projection welding machines are designed for medium duty applications. Built to British Federal’s high-quality standards, they are available as dedicated projection welders, complete with custom built tooling or as conversions from the HD Compact spot welder.

• EASY TOOLING ALIGNMENT - Spherical seating for the lower platen.

• TOOLING VERSATILITY - Fully adjustable platen gap.

• RELIABILITY - 50% duty cycle encapsulated transformer.

• HIGH QUALITY WELDING - Choice of state of the art microprocessor weld control.

OPTIONAL EXTRA:

• High lift and or 160mm air cylinder.

• 100KVA, 150KVA single phase AC or 100KVA 3 phase DC Medium Frequency Transformer.

• Soft Touch Safety System.

• Closed-circuit water-cooled system.

• Integration of automatic nut and bolt feed machines.

• Light guard and peripheral guarding systems.

MFDC OFFERS THE FOLLOWING BENEFITS:

• Improved weld quality.

• Reduced Power consumption costs.

• Lower peak currents providing increased electrode life.

• 3-phase even load distribution.

• Ideal for welding coated materials and Aluminium.

• Weld times reduced through increased rate of heat input to work piece.

• Reduced weld splash owing to lower peak currents.

• Can be retrofitted to existing machines.

HEAVY DUTY COMPACT PROJECTION WELDER

• ADAPTABILITY - Infinitely adjustable reach from 500 -800mm.

• HIGH QUALITY WELDING - Choice of state-of-the-art microprocessor weld control.

• PRODUCTIVITY - Welding speeds up to 250 spots per minute.

• RELIABILITY - 50% duty cycle encapsulated transformer.

• VERSATILITY - Simple adaption to projection welding

OPTIONAL EXTRAS

• High lift system.

• Soft Touch Safety system.

• Water-cooled lower arm.

• Reversible arms for angled electrodes.

• Closed circuit water-cooled system.

• Analogue PV valve.

• MFDC Transformer / Weld Control.

• Serra controls with optional Colour Touchscreen HMI.

MFDC OFFERS THE FOLLOWING BENEFITS

• Improved weld quality.

• Reduced Power consumption costs.

• Lower peak currents providing increased electrode life.

• 3-phase even load distribution.

• Ideal for welding coated materials and Aluminium.

• Weld times reduced through increased rate of heat input to work piece.

• Reduced weld splash owing to lower peak currents.

• Can be retrofitted to existing machines.

STRONGHOLD SPOT WELDER

• ADAPTABILITY - Infinitely adjustable reach from 500 -800mm.

• HIGH QUALITY WELDING - Choice of state-ofthe-art microprocessor weld control.

• PRODUCTIVITY - Welding speeds up to 250 spots per minute.

• RELIABILITY - 50% duty cycle encapsulated transformer.

• VERSATILITY - Simple adaption to projection welding

OPTIONAL EXTRAS

• High lift system.

• Soft Touch Safety system.

• Water-cooled lower arm.

• Reversible arms for angled electrodes.

• Closed circuit water-cooled system.

• Analogue PV valve.

• MFDC Transformer / Weld Control.

• Serra controls with optional Colour Touchscreen HMI.

MFDC OFFERS THE FOLLOWING BENEFITS:

• Improved weld quality.

• Reduced Power consumption costs.

• Lower peak currents providing increased electrode life.

• 3-phase even load distribution. Ideal for welding coated materials and Aluminium.

• Weld times reduced through increased rate of heat input to work piece.

• Reduced weld splash owing to lower peak currents.

• Can be retrofitted to existing machines.

STRONGHOLD PROJECTION WELDER

British Federal Projection welders are designed to give optimum welding conditions covering a wide range of applications.

• FLEXIBILITY - Choice of 150, 250, 300 kVA AC Transformers & MFDC Transformers.

• TOOLING VERSATILITY - Fully adjustable platen gap and T-slotted platens.

• RELIABILITY - 50% duty cycle encapsulated transformer.

• HIGH QUALITY WELDING -Choice of state-of-the-art microprocessor weld control.

• OPERATOR SAFETY - Twin button initiation as standard.

• LINEAR BEARING HEADSLIDE

OPTIONAL EXTRAS

• High lift and or 160mm air cylinder.

• 150KVA , 250KVA, 300KVA single phase AC

• or 250KVA 3-phase DC Medium Frequency

• Transformer.

• Custom Built tooling.

• Closed circuit water cooled system.

• Integration of automatic nut and bolt feed machines.

• Light guard and peripheral guarding systems.

MFDC OFFERS THE FOLLOWING BENEFITS:

• PA2 projection welding machines are also available as inverter controlled medium frequency machines and offer the following added benefits:

• Improved weld quality.

• Reduced Power consumption costs.

• Lower peak currents providing increased electrode life.

• 3-phase even load distribution.

• Ideal for welding coated materials.

• Weld times reduced through increased rate of heat input to work piece.

• Reduced weld splash owing to lower peak currents.

• Can be retrofitted to existing machines.

ALFA 209 SPOT WELDER

• Pnuematic circuit with single pressure system

• I/O water valves 1/2”

• Air Inlet valve 1/2”

• Electric Pedal

• Isolator

• Adjustable hydraulic jack in lower arm

• Circuit breaker (incorporated in MF welders)

• Distance between arms 550 mm

• Servo driven head. Force 750 daN

• Pneumatic circuit with counterpressure system

• Proportional valve

• Flow meter

• Main Voltage

• Electrode Diameter (conical 10°) 19mm

(50Hz)

• Electrode Holder Diameter

• Arms Diameter

• Distance between arms min/max 140-450mm

• Cylinder Stroke 100mm

• Cycles Per Minute (10mm gap) 90m/min

- 3000 Medium Frequency Inverter with adaptive controller.

ALFA 314 SPOT WELDER

PNEUMATIC OR ELECTRIC DRIVE

MFC - 3000 Medium Frequency Inverter with adaptive controller.

• Pnuematic circuit with single pressure system

• I/O water valves 1/2”

• Air Inlet valve 3/4”

• Electric Pedal

• Isolator

• Adjustable hydraulic jack in lower arm

OPTIONS

• Circuit breaker (incorporated in MF welders)

• Servo driven head. Force 1500 daN.

• Proportional valve

• Flow meter

• Pneumatic circuit with counterpressure system

• Double stroke (80 + 40) for 750 daN

• Transformer 300 kVA (50 Hz)

TECHNICAL SPECIFICATIONS

• Main Voltage 400V (50 Hz)

• Electrode Diameter (conical 10°) 24mm

• Electrode Holder Diameter 40mm

• Arms Diameter 80mm

• Distance between arms min/max 140-450mm

• Approach / Welding Stroke 0/120mm

• Cycles Per Minute (10mm gap) 90min-1

BETA 214 SPOT WELDER

AC - MEDIUM FREQUENCY 1000 Hz

PNEUMATIC OR SERVO-DRIVE

• Pnuematic circuit with single pressure system

• Elastomer for head tracking

• I/O water valves 1/2”

• Air Inlet valve 1/2”

• Two hands start

• Force control

OPTIONS

• Circuit breaker (incorporated in MF welders)

• DIN throat depth 300 mm

• Daylight between platforms 650mm

• Proportional valve

• Flow meter

• Automation integration set

• Autonomous cooling set

• Adjustable and programmable stroke (accuracy + / - 0,1 mm)

• Thickness detection and welding program automatic selection.

• Machine stop in case of no detection of due thickness: bad bolt or nut placement, sheet absence.

• Head integration in automated applications (7° axis function).

• Seating control during weld time.

BETA 323 SPOT WELDER

• Pnuematic circuit with single pressure system

• Elastomer for head tracking

• I/O water valves 3/4”

• Air water valve 3/4”

• Two hands start

• Circuit breaker

• Isolator

OPTIONS

• Servo driven head

• Force 2500 daN

• Circuit breaker (incorporated in MF welders)

• Daylight between platforms 600 mm

• Proportional valve

• Flow meter

• Automation integration set

• Force controller

TECHNICAL SPECIFICATIONS

• Main Voltage

• Platform Dimensions

• Platform Slots 3nm

• Distance between slots 63mm

• Distance between platforms (min/max) 140-450mm

• Manoeuvres / minute (in 10 mm) 90min-1

SERIES GAMMA SEAM WELDING

• Lower arm (except longitudinal type)

• Electronic flow meter

• Increasement 220 V

• Wheel trimmer

• Double drive and differential

• Double peripheral drive

• Pneumatic circuit with single pressure system

• I/O water valves 1/2”.

• Air Inlet valve 1/2”.

FEATURES

• Current: AC/MF

• Power: from 100 to 200 kVA.

• Option: one or two anti-rotation cylinders for projection nut welding.

• Option: one or two guided welding heads with high performance effort tracking for annular projection welding.

OPTIONS

• Intelligent pin up system for nuts and/or bolts.

• Plinth 200 and 300 mm

• Electric cabinet AS-6, AS-4, AS-2MFC

• Separated RIP Panel with proportional valve and flowmeter

• Up to two transformers incorporated.

• AC or MF power sources.

• Choice of welding timer.

• Operator panel integrated on the side mounted electric cabinet. Includes the programming unit and display.

• Palm buttons and/or foot switch.

• Adjustable knee height.

TECHNICAL SPECIFICATIONS

WELDING GUNS

SERRA SIGMA SERIES

Welding guns are meant for welding large and complex assemblies which are more difficult to handle due to their weight and size. For ease of use and precise manipulation, the welding guns are equipped with a balancer. The welding guns can be delivered with pneumatic or servo drives, in various shapes, with a low-frequency transformer or a medium-frequency inverter.

• 2D/3D dedicated design

• Pneumatic compensation (7th axis)

• Supports 0º - 35º - 90º

• Cupper rounded arms (X100/C50)

ROBOT WELDING GUNS

• Manual tool charger

• Flow Meter

• Pressure Switch

• Field buses (except 7th axe)

• Kevlar cover

• Powers from 54 to 103 kVA

• “C” or “X” shape

• AC / Medium Frequency

• Operation options: – Pneumatic

– Double servo-electric drive

– Servo-electric drive controlled by the 7th robot axe

• Dedicated designs

• Optional Field Buses:

ProfiNet

Profibus DP

DeviceNet

Ethernet IP

InterBus FO

BF450 WELD CONTROL

The BF450 Programmable Welding Control allows the Parameters for Welding to be controlled in a wide range of Resistance Welding Machines. The Weld Control is designed for Panel Mounting in a Control Cabinet and is perfect for Spot & Projection Welding Applications.

PARAMATERS DATA

0 – Programmes 0-15 Internal or External

1 – Heat 1 0-99% (heat setting for Weld 1)

2 – Heat 2 0-99% (heat setting for Weld 2)

3 – Pre-Squeeze 0-99 Cycles

4 – Squeeze 0-99 Cycles

5 – Weld 1 0-99 Cycles

6 – Cool 0-99 Cycles

7 – Weld 2 0-99 Cycles

8 – Hold 0-99 Cycles

9 – Off 0-99 Cycles Used only in Repeat mode

a – Upslope 0-30 Cycles Only valid on Weld1

b – Repeat 00-off, 01-on

c – Half Cycle 00-off, 01-0n Half cycle weld of set cycle

d – EOS 00-off, 01-on

E – Ex/In Prog select 00= Internal, 01=External

F- Pulsation 1-9 Pulses

• Operates on 50Hz or 60Hz Supply

• 9 Inputs and 4 Outputs

• 16 Selectable Weld Programs

• Single Spot and Repeat Operation

• Two Weld Intervals in each Program

• Pulsation of 2nd Weld Interval (1 – 9)

• Upslope Function (1st Weld Interval)

• ½ Cycle Function

• Internal / External Program Selection

• Hi-Lift / Retract Function

• Second Stage Input

• 24VDC Valve Outputs

• Can be used on 230V & 400V Machines

LIGHT DUTY WELDING GUN

GUNS

• Ideal for all light duty spot welding applications where a hand held gun is essential.

• Sturdy construction for long reliable life.

• Operating handles positioned for easy use.

• Electronic timer with solid state switching. Model M230F/400F has time and current control with ‘FUZZY LOGIC’ intelligence.

• Supplied with 120 mm arm set. Various shaped arm sets available.

• Adjustable electrode pressure.

• Duty cycle - 3 spots per minute. WELDING

CT 2 TWEEZER

The CT2 welding tweezers fit naturally into the hand and may be operated throughout the day without undue fatigue. Lightness in both weight and control is the secret of their successful performance.

• Weld Pressure Control

• Over Run Stop

• Pressure Sensitive Initiation

• Fitted with 864mm Long Power Leads

• Fitted With 1.32 Electrodes As Standard

• Weight With Leads 380g

• Size 185mm × 55mm × 22mm

PW 500 POWER UNIT

The PW 500 power unit houses a 500VA welding transformer, solid state synchronous timer with phase shift heat control contained in a steel casing.

• 1 - 10 Weld Cycles

• 5-100% Phase Heat Control

• 500VA Transformer

• Illuminated ON/OFF Switch

• Mains Supply 240V AC 50Hz

• Weight 9kg

• Size 295mm × 290mm × 167mm

ACCESSORIES

Prospot has a range of accessories available to assist with your Micro-Welding Applications. These include:

The MERITUS MPW8 portable spot and seam welding machine is suitable for welding a wide range of thin gauge materials in mild steel and stainless steel. It is particularly suitable for fine mesh or gauze used in the filtration industry.

The MPW8 offers the end user maximum flexilbilty through the incorporation of the latest electronic technology. The timer and heavy duty welding transformer are all built into this compact unit enabling it to be used in the most confined areas.

TW3 TWEEZERS FITTED WITH Z9760/1 ELECTRODES

PGTPWC WATER COOLED POKE GUN

PGTP POKE GUN AND SEAM WELDING

WHEEL ASSEMBLY PRO-H0506ASSY SEAM WELDING WHEEL PRO-E0146 POKE GUN ELECTRODE PRO-E1312

FW2 & FW2P MICRO-SPOT WELD HEADS

• The FW range of Foot or Pneumatically Operated Micro-Spot Weld Heads have been designed to join a range of ferrous and non-ferrous materials, in both Production and Laboratory environments.

• The range of welding heads can be combined with a choice of AC / MFDC / CD Transformers and Weld Controls depending upon the application.

• For large volume production welding, semi or fully automated installations can be employed using standard or bespoke Prospot FW series Weld Heads. Custom machines as well as jigs and fixtures are designed and manufactured “In House” to meet customers exacting requirements.

ELECTRODE FORCE RANGE:

• 4.5N – 44N (1 – 10lbF)

• 4.5N – 133N (1 – 30lbF) - Standard

• 4.5N – 266N (1 – 60lbF)

ELECTRODE TRAVEL:

• 12mm – FW2/P19mm – FW2

ELECTRODE DIAMETER

• 6mm – Standard.

• Special Materials and Electrode Shapes / Sizes available.

HEAD WEIGHT:

• 4.5kg.

• Throat Depth:

• 153mm.

FW2/T & FW2/TP MICRO-SPOT WELD HEADS

• The FW range of Foot or Pneumatically Operated Twin Electrode Micro-Spot Weld Heads have been designed to join a range of ferrous and non-ferrous materials, in both Production and Laboratory environments.

• The range of welding heads can be combined with a choice of AC / MFDC / CD Transformers and Weld Controls depending upon the application.

ELECTRODE FORCE RANGE:

• 4.5N – 133N (1 – 30lbF) - Standard

• 4.5N – 266N (1 – 60lbF)

• Independent on each moving electrode

ELECTRODE TRAVEL:

• 12mm – FW2/ TP19mm – FW2/T

ELECTRODE DIAMETER

• 6mm – Standard.

• Special Materials and Electrode Shapes / Sizes available.

HEAD WEIGHT:

• 9kg.

• Throat Depth:

• 153mm.

FW2/T FW2/TP MICRO SPOT WELD HEADS

WELDER

The Meritus micro bench welding system utilises the MPW8PS AC power source which can be tapped from 8kva to either 4kva or 2kva. We can fit either manual or air operated precision weld heads and also have the option of connecting single sided poke guns and seam welding attachments or TW3 tweezer welders.

SEAM WHEEL ASSEMBLY

PRO-H0506ASSY SEAM WELDING WHEEL

PGTP POKE GUN AND SEAM WELDING

PRO-E0146 POKE GUN ELECTRODE PRO-E1312 TW3 TWEEZERS FITTED WITH Z9760/1 ELECTRODES

MPW8PS - AC POWER SUPPLY

The MPW8PS is an AC welding power supply and timer suitable for use with various heads. This is the most widely used power source as the design is simple, easy to use, reliable and cost effective.

The X-GUN and C-GUN series of pneumatic operated suspended guns are versatile, robust and easy-to-use. They ensure best welding results on any weldable metal and are the most ideal solution for any spot welding job.

X-GUN / C-GUN

• Welding control in a separate cabinet with circuit breaker with residual current device and cycle stop emergency button.

• Synchronous ignition SCR group with phase shift to eliminate any current transient.

• Reduced consumption.

• Water cooled transformer.

• Water cooled arms, electrode holders and electrodes.

• Gyroscope suspension on sealed bearings for easy gun rotation and manoeuvrability in any position.

• Adjustable working stroke.

• Temporary extra stroke to easily reach workpiece areas also getting over obstacles.

• High versatility in all applications thanks to all possible machine configurations.

• Self-lubricated pneumatic components to eliminate oil deposits and to safeguard the environment from contaminants.

- GUN VERSION (1) AND VERSION (2) – 200 TO 600 mm LENGTH (1)

X-GUN / C-GUN

SPOT WELDING GUNS WITH BUILT IN TRANSFORMER

DIMENSIONS

K - KP ROCKER ARM SPOT WELDER

Standard machine supplied with 455mm arms, but can be supplied with either 600mm, 800mm or 1000mm arms.

Machines are available with lower arm configurations suitable for jobs with restricted access. Available from 455mm - 1000mm

K KP

SET OF PIPES WITH ELECTRODES

• Lower round arm with adjustable height and lateral adjustment.

• Electrode holders with electrodes for spot welding and ability to easily fit barholders for projection welding.

• Lower arm holder can be adjusted for use with larger arm gap.

• Spot welding.

• Projection welding with bars for mesh.

UPON REQUEST

• Different length arms (Optional)

• Lower arms with pressed-in electrode (for welding pipes or similar) and longer electrode holder on the upper arm (Optional)

• Special version with platens only for projection welding (PPN 53)

• Lower platen adjustable in height and fitted with T slots, enabling quick assembly of barholders, electrodeholders or any dedicated tooling.

• Platens gap is quickly and easily adjustable without any intervention on the secondary circuit.

• Manual valve for upper head descent without pressure for cleaning, centering and ordinary maintenance of the electrodes.

• Upper head low friction driving system for precision welding (Except PPN 83.)

PPN 103 PPN 253

WSI 100 CONTROL PANEL BACKLIT GRAPHICAL LCD DISPALY

• Preheating, welding and cost heating currents, up and down slope.

• 64 Welding programs.

• Control up to 4 solenoide valves

• Current adjustment in percentage or constant current.

• Limit valve monitoring.

• Weld counter.

MF 1040

• Upper head low friction driving system for very precise welding.

• Secondary circuit low impedance to grant high welding currents with low consumption.

• BSW 50 and 100, with a platens adjustable in height and fitted with T-slots, enable the quick assembly of barholders, electrode holders and any dedicated tooling for a specific application.

BSW 25 is particularly suitable for precision spot welding. It is fitted with special accessories, so it can be used to weld small size parts, BSW 50 and BSW100, thanks to their rigid structure, allowing high quality projection welding.

BSW 25

Resistance butt welders N3, N12 & N20 are especially designed for wire drawing mills for joining steel, brass, aluminium and copper rods and are recommended for non heavy duty applications. The N22 butt welders are especially designed for wire drawing mills for joining steel, brass, aluminium and copper rods. They are recommended for light duty applications.

SQ/AS models are suitable for flash butt welding solid material, pipes, profiles and hollow sections by obtaining high quality joints. They are particularly suitable for mass production with fully automatic controls aiding speed and efficiency.

SQ/A 62, SQ/A 121 & SRT 11 butt welders are air operated with completely automatic cycle and allow high productivity. Making them suitable for welding wire manufactured goods.

MERITUS RAS & AS SERIES WELDERS

AIR OPERATED SPOT WELDING MACHINES FROM 30kVA TO 150kVA

AUTOFORGE Spot Welders

There are five standard sizes covering 30,50,75,100 and 150kVA. These machines are particularly suitable for high

All of the AUTOFORGE range of rocker arm spot welders are fitted with twin foot pedals with a HIGH-LIFT facility for improving welding access and speed of production. All machines have water cooled electrodes, holders, timers and transformers. Each machine is fitted with telescopic arms, enabling the machine throat to be easily adjusted without removal from the machine. Provision is made for both electrode holders to be set at an angle of 20 degrees from the vertical if required. All machines can be fitted with either standard multi-programme digital timer or a more sophisticated welding control with constant current control and other features.

Optional Extras

All versions can be fitted with variable speed motorised seam welding attachments for both circumferential and longitudinal seam welding, either upper or lower driven. Also available with MEDIUM FREQUENCY transformers and controls.

RAS30A5

AS75A5

MERITUS RAS & AS SERIES WELDERS

AIR OPERATED SPOT WELDING MACHINES FROM 30kVA TO 150kVA

LOWER DRIVEN CIRCUMFERENTIAL SEAM WELDER

UPPER DRIVEN LONGITUDINAL SEAM WELDER

UPPER DRIVEN CIRCUMFERENTIAL SEAM WELDER

Optional Extras

The FLEXIMAN is a modular series of semi-automatic crosswire (and spot welding) machines specifically designed and developed by meritus for maximum flexibility in welding flat or profiled panels using precut length wires.

Fleximan is a CNC controlled single or dual jig welder, ideal to replace manually operated pedestal bar and spot welders. Its flexible speed of operation and short set up time makes it very suitable for jobbing shop applications as well as small/ medium volume batch production of a wide range of products.

• Machines from 600mm wide × 1100mm long to 2400mm × 3000mm

• Single or double headed machines

• Single electrode/ twin electrode/ rotating electrodes

• CNC control with teach and touch screen programming

• Full colour screen

• Dual jig cross shuttle transfer

• Single/ repeat auto cycle

• AC servo drives

• Programmable weld pressures

• Multi schedule weld controls

• Medium frequency invertor system (optional)

• Shop merchandising equipment

• Animal Cages

• Oven & refrigerator shelves

• Display panels

• Fan guards

• Drainer & freezer baskets

• Barbeque grills

• Bed mesh

• Ventilator grills

• Higher efficiency output

• Consistent quality control

• Reduced operator fatigue

• Unit cost reduction

• Increased flexibility

• Rapid change over times

• Increased Safety

• JIT Production

• Flexibility to increase capacity by adding extra two head welding modules.

• Easy to convert from cross wire to spot welding.

• Can be built with either manual load - manual index or manual loadauto index.

• Welding parameters can be set on each pair of welding heads to facilitate varying wire diameters or metal thickness.

• Option to incorporate two jigs and a transfer cross shuttle system.

• Reciprocating knee to ensure clearance of the welding jigs during indexing allowing lower electrode to rise and fall.

• Programmable auto indexing system.

IDEAL FOR

The MULTIMAN welding system uses twin series welding head modules, which can be added to or reduced in number as required and connected to each other in series for automatic operation.

• Oven and Microwave Shelves

• Merchandise Display Shelves

• Supermarket Trolleys

• Shop Equipment

• Drainer and Freezer Baskets

• Refrigerator Shelves

• Barbeque Griddles

• Animal Cages and Pens

All the welding heads are simultaneously lowered and then electronically cascade weld in series or direct to minimise mails line demand, whilst maintaining maximum operational welding speed.

Each module has its own watercooled welding transformer, firing card, scr contactor and solenoid valve allowing different welding parameters on each pair of heads, to compensate for varying wire diameters or metal thicknesses when spot welding.

A modular resistance welding system developed for medium to high volume production, of flat or profiled panels using pre-cut length wire.

Single Phase and Medium Frequency welding machines are designed to meet the highest standards of resistance welding in the Aircraft and Aerospace industries.

British Federal offer spot and seam welding machines from 100kVA up to 600kVA. Also available are MFDC controlled machines that offer numerous advantages over less efficient single-phase versions.

THE FORCE SYSTEM

• The low inertia weld force system using double active frictionless diaphragm cylinders ranging from 20kN or 30kN.

THE MACHINE FRAME

• A robust fabricated machine frame with integral reinforcing elements designed to absorb loads whilst minimising deflection, vital for achieving precision welds.

MEDIUM FREQUENCY DC WELDING TRANSFORMER (MFDC)

The use of a MFDC Welding transformer carries several advantages such as:

• Reduced Transformer size

• Balanced 3 phase load distribution.

• High secondary current capability.

MEDIUM FREQUENCY INVERTER WELDING

• British Federal Offers ‘Medium Frequency Inverter’ welding system through Serra MFDC for our aerospace machines.

MEDIUM FREQUENCY WELDING FOR AEROSPACE MACHINES

The Serra MFDC Weld Control expands the functionality of the aerospace welding machines including features such as:

• 255 selectable programs.

• Reduced cycle time.

• Integrated PLC functions.

• Easy programming via CPC Software.

• Multiple programmable force profiles during cycle.

• Adaptive welding with the suite.

• Wizard Welding.

• Automatic generation of welding paramaters.

• Optimal System.

• Self optimization of welding paramaters.

• Adaptive quality control.

• Intuitive interface via the Serra HMI option

Refurbished British Federal Welding Machines

• Prospot has a comprehensive stock of completed refurbished resistance welding machines, welding guns and ancillaries. We also refurbish old stock to our Customers’ requirements. We have all types of machines available, including rocker arm machines, linear machines, projection welding machines, butt welders, nut feeders, manual guns, robot guns and multi headed welders.

• Prospot can also refurbish or upgrade your exisiting welding machine. All machines are fully reconditioned with new welding controls and come complete with a 12 months parts and labour warranty.

CLINCHING TOOLS

A FULL RANGE OF CLINCHING TOOLS BY PROSPOT

CLINCHING TOOLS AND CLINCHING MACHINE (SHEET METAL): THE CLINCHING TECHNIQUE.

• Clinching tools and Clinching machine (sheet metal): the clinching technique.

• The Clinching technique is an innovative process for the mechanical cold junction of sheet metal. It is based on the plastic deformation of the sheet metal you need to join, that is possible through the interaction between a punch and a die without the supplement of added material. The punch and the die, by punctual pressing of the sheet metals with a preconceived force that permits the penetration of the punch into the sheet metals, create a button that form the “point” of the junction and shape of which depends on the tool kit geometry.

PRINCIPAL OF FUNCTION (TYPES OF THE POINT)

• The sheet metals pressed between the punch and the die get deform forcing the material to extend laterally up till they create a button. The “point” can be of the trapezoidal type or of the round type which are realised, respectively, with a trapezoidal punch and die or round punch and die.

• Round point allows an hermetic join to be formed, with a resistance to uniform strain in every direction and with an excellent appearance.

• The trapezoidal point allows the union of the sheet metals even with a low ductility, moreover, can be applied to the union of more than two layers of the metal plates.

• Clinching tools for sheets of metal and hybrid materials junction.

Prospot are able to design and manufacture welding fixtures for all types of welding applications including spot, projection, seam, mig, tig, capacitor discharge and other joining processes.

MANUAL SPOT WELDING FIXTURE

MANUAL X - Y SPOT WELDING FIXTURE

HANGING GUN FIXTURE

MANUAL STUD WELDING FIXTURE

ROBOT MIG WELDING FIXTURE

WELDING FIXTURES & DESIGN

POKE YOKE NUT CHECKING SYSTEM

PROJECTION WELDING FIXTURE WITH PIN UP SYSTEM

TWIN HEAD COMP TOOL

TOGETHER WITH OUR IN HOUSE HIGHLY SKILLED MANUFACTURING CAPACITY AND OUR LCM FACILITY IN SLOVAKIA, WE ARE ABLE TO GIVE OUR CUSTOMERS THE BEST SOLUTION TO THEIR REQUIREMENTS.

ROBOT SPOT WELDING FIXTURE

X Y SERVO SPOT WELDING FIXTURE

• From Special Purpose Machinery to bespoke solutions, we provide highly innovative machine and system solutions with respect to operation, budget and longevity. Our engineering team have vast experience within numerous manufacturing sectors from Aerospace, Automotive, Oil and Pipe, Renewable Energy and Rail. Our tailor-made solution will help you to overcome your process and manufacturing problems

• If your requirement is simply to handle very specific material types we specialize in both Ferrous and non-Ferrous solutions and also difficult Ultra High Strength material such as Boron steels in Hot and Cold stamped versions. If you need varied joining processes we have extensive experience not only in resistance welding but also riveting, stamping, clinching and feeders.

• Special Purpose Machinery will drive economies within the Company. Our tailor-made solution to overcome your process and manufacture problems. Production is economical and often utilization and efficiencies will be high as cycle times will be focused and production rates maximised. In some cases leak testing and vision systems can be added to provide additional quality control.

• Prospot have many years of experience of the Design and Manufacture of Robotic Assembly Cells.

• Robots are ideal for applications such as Spot Welding, Arc Welding, Nut & Bolt Welding, Clinching and Sealing / Gluing.

• It is also possible to combine some of these processes into a single cell for more complex assemblies such as Automotive Sunroof Panels which typically include spot welded brackets as well as projection welded fixings, short cycle fixings and even brazed joints.

• Prospot can assist with developing the assembly process to meet exacting quality and volume requirements with our in-house Design and Technical Departments.

See our videos on

Prospot has a dedicated Service Department who are experts in the Service, Repair, Upgrade and Calibration of all types of Resistance Welding Machinery.

OUR RANGE OF SERVICES:

• Breakdown Repairs

• Machine Spares & Consumables

• Weld Control Upgrades

• Machine Refurbishment

• Machine Service – range of Service Plans available

• Training – Resistance Welding & Machine Operation

• Calibration to National Standards

• Calibration of WA1 and WA2 Weld Current meters

HOW CAN WE HELP YOU?

• Our engineers are time-served professionals, trained to service and install all makes and types of resistance welder. Whether you need a single machine repair or would prefer a full service to keep every machine on site running smoothly, we can assist you with all aspects at Prospot.

• Prospot has been supplying spares and servicing machines for over 25 years. We understand that capital assets are the heartbeat of your organisation. Reactive maintenance leads to unplanned downtime, which can have significant cost implications to the business due to missed deadlines and idle employees. Also, without regular maintenance machinery operates inefficiently affecting cycle time and output quality.

• Preventative maintenance focuses on preventing equipment failure, reducing the risk of costly emergency repairs, machine downtime and ensuring equipment runs efficiently.

• Prospot offers three service plans as we understand maintenance isn’t a one size fits all concept.

PREVENTATIVE MAINTENANCE PACKAGE COMPARISONS

PREMIUM PLUS

• Assistance with weld parameters

• Record and store weld parameters as benchmark against future comparisons.

• Additional service visit

PREMIUM

• Basic machine maintenance training package plus:

• 1 breakdown call out per year (excluding parts)

• Recommend, and perform if needed, corrections to existing malfunctions (excluding parts).

• Additional service visit

ESSENTIAL

• Complete inspection for damaged, worn, leaking and exposed components.

• Operational functions and positions checked

• Machine guarding and safety features checked.

• Comprehensive health status report, including recommendations how to maintain machine’s optimum performance package plus: