Task

An aluminum cable with a cross section of 50 mm2 needs to be welded to a nickel-plated copper terminal. To add a further challenging aspect, the weld needs to be as narrow as possible for construction reasons. The tensile strength and shearing load also have to meet specified values.

Solution

A linear MPX universal welding system was used for this application. An automatic stop makes sure the cable is in the right position. The clamping and positioning device for various terminal shapes and sizes is easy to adapt thanks to interchangeable components. The Telso®Flex process controller comes with a wide array of quality monitoring options and convenient touchscreen operation.

Advantages of this configuration

Thanks to its modular structure, the linear 20 kHz MPX welding system with a modern MAG generator has a high degree of flexibility when it comes to integrating with other machines and attaching additional components. A few simple steps are all it takes to set the machine up for other types of terminal and other cable sizes. This system is equally suitable for all commercially available terminal designs.