Online ContactKey Features
Supports drawn arc, contact and non-contact stud welding.
One main unit supports up to three welding channels with different gun and process configurations.
Applies a controlled current after capacitor discharge to slow cooling and help reduce thermal stress.
Calculates capacitor capacity after each welding cycle to identify aging and support equipment maintenance.
Compatible with servo and non-servo welding guns, including automatic, semi-automatic and manual servo configurations.
Integrated PROFINET and DeviceNet interfaces, with multiple Ethernet ports for PC, CNC and PLC communication.
Integrated oscilloscope, data logger and WeldNIC group control software support waveform analysis, process monitoring and equipment management.
Welding Process and Digital Control
The SAW-D9 supports three welding process categories: drawn arc, contact and non-contact welding. Servo-controlled guns provide precise control of stud movement and contact force, while non-servo configurations offer a simpler equipment structure.
Its post-weld tempering function maintains a current output of approximately 50–100 A after the main discharge, helping control the cooling process and reduce the risk of cracking under suitable welding conditions.
For equipment condition monitoring, the system records discharge voltage and current waveforms at a 100 kHz sampling rate and calculates capacitor capacity using an integration algorithm. This provides ongoing information about capacitor condition.
Digital Monitoring and Automation Integration
The SAW-D9 incorporates an X86 / Windows-based data logging platform with 1 TB or greater storage capacity and support for more than one million welding-point records. Welding data is stored in a MySQL database and can be exported in CSV format for further analysis.
Multiple Ethernet ports provide dedicated communication functions for PC monitoring, real-time data, data logging, Modbus TCP and CNC control. PROFINET and DeviceNet interfaces support integration with industrial automation systems.
Through WeldNIC group control software, up to 250 devices can be managed within one network, with functions including event monitoring, fault recording, parameter backup and historical data management. The system can also connect with MES and other production information networks.
Typical Applications
The SAW-D9 is suitable for capacitor discharge stud welding applications in:
- Automotive sheet metal and body components
- New energy vehicle structural parts
- Electrical cabinets and metal enclosures
- 3C electronic equipment housings
- Industrial sheet metal fabrication
- Automated stud welding production lines
Technical Specifications
| Category | Technical Specification |
|---|---|
| Model | SAW-D9 |
| Equipment Type | Digital Capacitor Discharge Stud Welding Machine |
| Welding Processes | Drawn Arc, Contact, Non-Contact |
| Welding Channels | 3 independent channels |
| Welding Gun Types | Servo and non-servo welding guns |
| Servo Gun Modes | Automatic, Semi-Automatic, Manual |
| Post-Weld Tempering Current | 50–100 A |
| Drawn Arc Current | 10–100 A |
| Servo Gun Lifting Distance | 0.5–5 mm |
| Non-Contact Position Holding Time | Approximately 20 ms |
| Capacitor Monitoring | Online capacity calculation after welding |
| Waveform Sampling Rate | 100 kHz |
| Industrial Fieldbus | PROFINET / DeviceNet |
| Ethernet Communication | Multiple ports |
| Ethernet Protocols | Modbus TCP, RTD and dedicated PC, data logger and CNC interfaces |
| Data Logger Platform | X86 / Windows |
| Data Storage | 1 TB or larger |
| Welding Data Capacity | More than 1 million welding-point records |
| Database | MySQL |
| Data Resolution | 10 μs |
| Data Export Format | CSV |
| Oscilloscope Resolution | 16-bit |
| Oscilloscope Channels | 16 channels (subject to final technical confirmation) |
| Group Control Software | WeldNIC |
| Network Management Capacity | Up to 250 devices per network |
| MES Integration | Supported |
For application-specific requirements, please contact Hongbai for technical consultation and welding process evaluation.
