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Resistance welding technology

WELTAC®

Assembly systems for resistance element welding create high-strength joints.

Flexible and process-reliable.


Contents
 

Flexible technology

WELTAC® is a process used in resistance welding technology.

It creates mechanically strong joints for modern multi-material car body design.

This product is made by Böllhoff

Method / principle

Resistance element welding is a further development of resistance spot welding.
Compared to the conventional procedure, a rivet-like resistance element is used as the auxiliary joining part made of a material which is compatible with the base sheet. In the first process stage, the punching of the WELTAC® welding element occurs in the upper material layer(s). Afterwards this component is welded to the lower steel material layer(s) in the second stage of the process.

Applications

The main field of application for WELTAC® is the automotive industry – in the body construction.

Product benefits
  • High-strength joints
  • Use of existing, conventional spot-welding equipment in the body construction shop possible
  • Wide application range regarding material qualities and thicknesses (aluminium and steel), incl. press-hardened steel

Product gallery

WELTAC® welding element and cross section of the joined element

Resistance element welding

WELTAC® resistance element welding for modern multi-material car body design

01:25

WELTAC® Automation EH with KUKA robot connection

Resistance element welding

Product benefits

There are many good reasons for using our products.

Strength and options.
Point by point.

Proven technology

In the first process stage, the WELTAC® Automation is based on the proven electric-hydraulic processing system RIVSET® Automation EH.

Modular and flexible

Due to the modular design predestined for applications in large-scale production.

High duration of life and minimum maintenance effort

These are important factors and basis for a successful production.

Use of existsing equipment

Already existing resistance spot welding systems of modern car body constructions can be used for the second WELTAC® process stage.

Detailed description

 

How does resistance element welding work?

In the first process stage, a rivet-like resistance element, used as the auxiliary joining part made of a material compatible with the base sheet, will be punched in the upper material layer (i.e. aluminium). Afterwards this component is welded to the lower steel material layer in the second stage of the process.

 

1. Process stage: punching-in the element

WELTAC® resistance element welding in the 2-step process – 1. Process stage: punching-in the element

1. Process stage of the WELTAC® resistance element welding: punching-in the element

 

2. Process stage: welding

WELTAC<sup>®</sup> resistance element welding in the 2-step process – 2. Process stage: welding

2. Process stage: welding

Böllhoff only supplies the WELTAC® elements and the WELTAC® Automation of the first process stage.

The core components of the WELTAC® Automation

Our resistance element welding WELTAC® is linked to our proven assembly system RIVSET® Automation EH.

Due to the modular design, the system is designed for applications in large-scale production with minimum flexibilty during production planning.

A high duration of life and minimum maintenance effort are important factors and basis for a successful production.

TOOL – Setting tool EH

  • Setting tool with electrical drive for setting force 10 – 35 kN
  • Pre-clamping force adjusted with pressure springs
  • Various mounting points on the setting tool for prefect position on the robot
  • and more
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C-FRAME

The modular system – with the new C-frame, you will have the possibility to generate a minimum number of base frames for a maximum number of setting tool variants.

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SETTING HEAD

  • Blow feeding and processing of WELTAC® elements via pneumatic-controlled transport into the duct bend
  • Ensures also the feeding of small WELTAC® elements (shaft Ø 4 mm, total length 2.6 mm), with or without clamping ring
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FEED – Element feeder

  • Minimum maintenance at maximum availability
  • Feeds approx. 45 elements/minute
  • Stockage of approx. 4,000 elements (optionally expandable)
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Downloads

Find out more: related downloads.

If you would like to know more, simply download the relevant brochures.

Title Language Version File Download
WELTAC®
Resistance element welding for modern multi-material car body design
English 05/2019 2636 kB / PDF
English 05/2019 2636 kb / PDF
Portable C
Electro-hydraulic setting tool for RIVSET® and WELTAC®
English 03/2020 755 kB / PDF
English 03/2020 755 kb / PDF

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