Dual-Servo Commutator Spot Welding Machine

Model BKD-SW-02

Servo-controlled electrode force and indexing weld every tang with the same energy and dwell, so joint resistance stays consistent across the commutator.

Cycle time: ≈ 6.5 s / 10 tangs
Wire diameter: Φ0.06–1.5 mm
Armature OD: Φ10–80 mm

Applicable armatures

Motor types: Brushed DC and universal motor armatures
Armature OD: Φ10–80 mm
Stack length: 10–80 mm
Shaft length: 30–250 mm
Wire diameter: Φ0.06–1.5 mm

Specifications

Performance
Parameter	Value	Unit
Cycle time	≈ 6.5 per 10-tang armature, incl. loading	s/pc
Output	≈ 550	pcs/h
Changeover	25	min
Electrode force	50–500	N

Precision
Parameter	Value	Unit
Weld energy repeatability	±2	%
Electrode force repeatability	±3	%
Indexing repeatability	±0.02	mm

Electrical & pneumatic
Parameter	Value	Unit
Power supply	AC 380 V +10% / 3 ph / 50–60 Hz
Rated power	10	kW
Air pressure	0.4–0.7	MPa

Dimensions & weight
Parameter	Value	Unit
Footprint (L×W×H)	≈ 1 500×1 000×1 500	mm
Weight	500	kg

Control
Parameter	Value	Unit
PLC	Mitsubishi FX5U
HMI	Weinview 7"
Servo axes	2

How it works

1The wound armature is clamped with the tangs referenced to the electrode.
2The servo brings the electrode to the programmed force.
3The weld pulse is applied and its energy is monitored.
4The armature indexes to the next tang.

Standard configuration

Servo drive package and safety guarding with interlocked doors
PLC with touch-screen HMI, recipe storage per armature model
One set of tooling for the armature model agreed at order
Operation and maintenance manual, recommended spare parts list

Options

Additional tooling sets for further armature models
Data logging with CSV export or MES interface
Automatic loading and unloading, conveyor for line integration
Spare parts package for 12 or 24 months of production

Video

All machines in this process

Station 06 + 09

Commutator Welding

Automatic Welding & Testing Machine

BKD-WT-01

Cycle time: ≤ 7 s
Hipot test voltage: 1.5 kV