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Flash Welding Machines IDEAL – Superior Reliability and Support from Our Company

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Flash Welding Machines IDEAL – Superior Reliability and Support from Our Company Flash welding machines IDEAL – superior reliability and support from our company In December 1923, the family company IDEAL – called “Elektro-Apparate-Bau GmbH” at that time – was founded in Lippstadt. Since then, the name IDEAL has been synonymous with con- stant innovation and quality in machine and plant enginee- ring. The core competency of the company – family-run in the third generation – is resistance and laser welding. Clemens Jungeblodt sen. Clemens Jungeblodt Eberhard Jungeblodt The product portfolio of IDEAL includes welding machines Our own distribution and service office in the United States for the joining of wire, stranded wires, wood saws and me- has been marketing machines and spare parts in North Ameri- tal band saws; for wire processing, the production of sheet ca and Canada since 1995. metal products; as well as coil joints and profile connections. The offer ranges from smaller series machines to modular In order to meet the requirements of a demanding internati- standard versions all the way to tailor-made, customer-orien- onal industrial customer base, we rely on fair teamwork with ted special solutions. customers, employees and suppliers. The consistent further development of the product program With their dedication, skills and close attachment to the com- and an excellent, problem-oriented consultancy have helped pany, our staff of about 240 employees make a significant us to reach a leading position in the market and made us a contribution to our mutual success. On the basis of our own reliable partner for the industry. In over 45 countries, we have hands-on professional training and continuous further trai- expert professional representatives who ensure proximity to ning, we secure in-depth knowledge and experience in the the customer on site. long run. The management: Dorothee Jungeblodt, Dipl.-Ing. Rainer Pumpe and Dipl.-Ing. Max Clemens Jungeblodt 2 3 Your reliable partner AS Flash welding machines Our headquarters in Lippstadt in Westphalia houses the ma- At the second site in Lippstadt, the machines are built in our In order to achieve a maximum tensile strength and the fulfilment of standard re- nagement, the commercial and technical departments such assembly shops; the hydraulic, pneumatic and electrical sys- quirements that this entails, type AS IDEAL flash welding machines are the perfect as Project Management as well as engineering and design tems are installed, and a function test is performed. This is choice. offices. Our mechanical production facility is equipped with also where the test run with customer materials is performed state-of-the-art machinery and provides high-quality individu- in order to prepare the acceptance procedure and training of • Top weld quality with metallurgically pure joints al parts of the highest precision. the customer’s personnel in the best possible way. • Short welding time • Low demands on the preparation of the workpiece ends • High level of reproducibility of the welding parameters • High dimensional accuracy IDEAL provides The technical details of the AS wel- ding machines at a glance • Customer-specific solutions – design of machines in • Upsetting force max. 15 - 500 kN collaboration with the customer • Implementation/testing out joining-specific applications • Transformer 30 - 1200 kVA in the test field • Weight 1,2 - 22 t • Support with the planning of a new factory or Customer orientation is fine – but we have a better name production plant for it: • Welding cross-sections • Construction of all mechanical machine parts and unalloyed steel 15 - 10.000 mm² supply components IDEAL Service alloyed steel, BSt 15 - 8.000 mm² • Design of the control unit, sequential programs and stainless steel 15 - 4.000 mm² communication interfaces Our experienced team offers professional advice and support aluminium 15 - 2.500 mm² • Manufacture of the mechanical and electrical – over the phone or directly at your premises: • Dimensions of basic machine machine sections Width 150 - 400 cm • Assembly and commissioning of all machine parts • Spare parts Height 170 - 280 cm • Testing of the machine and determination of the • Repairs Depth 120 - 250 cm welding parameters • Upkeep/maintenance • Dismantling, transport and installation at the • Remote maintenance customer’s plant • Upgrades • Commissioning and, if applicable, line connections at the • Conversions customer’s plant • Training • After-sales service and supply of spare parts Our qualified project managers are Typical applications available to you as contact partners at • concrete steel connections (Almost) unlimited possibilities of welding all times to discuss individual tasks at • drill extensions length and in depth as well as find a so- • wire items lution together with you. • wire frames • wire rings Forward-looking project planning leads • wire cables to developments and CE-certified desi- • moulded parts from round and gns that are matched to downstream profile wire work processes. This way, life cycle costs • household cutlery are reduced. • cable work • medicinal instruments With IDEAL machines, you can face the • steel cord connections demands of the market calmly. The ex- • PortaBand saw bands perience of many years on the part of • band knife our customers has been incorporated • coil-to-coil joints into the well-thought-out and sophisti- • rims cated basic equipment. Smart options Welded workpieces before and after deburring the weld. open up additional potentials for you, if needed. 4 5 Flash welding - the technology The perfect solution for every requirement The flash welding process is broken down into pre-heating, Then the upsetting begins, and the two surfaces are pressed IDEAL builds and develops not only welding ma- flashing and upsetting. together with great force to ensure a flawless joint. chines – IDEAL offers efficient and cost-effective welding solutions for nearly every requirement. A high current generates concentrated heat at the surfaces to The upsetting causes a thin, brittle welding burr. The burr can be welded. The metal melts at the contact point and splashes. be easily removed by grinding, milling or similar procedures. Whether small devices for perfect individual welds or The flashing of the surface material that starts as of a speci- Deburring is particularly efficient in the welding machine. It’s fully automated welding systems for high volumes fic temperature results in a smooth and clean joint. The eva- done either by a planing deburrer or a shear deburring device. with exactly reproducible welding parameters, IDEAL porating metal creates a protective atmosphere, so welding The deburring is done when the workpiece is still red-hot. De- is your partner for innovative and sustainable welding consumables like shielding gas are no longer required. The pending on the length of the weld seam, it takes no more technology “Made in Germany”. melting loss consists of molten and oxidised material. than a few seconds. Special solutions for the electrical mobility industry Preheating Flashing Upsetting Max. Rated power Welding Welding Welding Welding Weight of TYPE upsetting of transformer cross-section, cross-section, cross-section, cross-section, basic machine force unalloyed steel alloyed steel (BST) stainless steel aluminium (approx.) kN kVA mm² mm² mm² mm² kg AS0 015 15 70 50 - 400 up to 250 up to 120 15 - 80 1200 AS50 – manual solution for concrete bars and stainless steel/steel (black/white) joining AS15 V-D – for vertical connections AS0 025 25 70 150 - 800 up to 400 up to 250 40 - 120 1700 AS0 040 40 120 200 - 1300 up to 650 up to 330 50 - 200 2500 AS0 050 50 120 / (200) 250 - 1600 up to 800 up to 400 50 - 250 3000 AS0 100 100 200 / (400) 400 - 2500 up to 1600 up to 800 100 - 500 5000 AS0 160 160 500 600 - 4000 up to 2600 up to 1300 200 - 800 7000 AS0 220 220 800 800 - 5000 up to 3500 up to 1800 300 - 1100 11000 AS0 320 320 800 1000 - 6000 up to 5000 up to 2600 400 - 1600 14000 Doppel AS15 - AS0 500 500 1200 1500 - 10000 up to 8000 up to 4000 500 - 2500 25000 automated solution for concrete bars and stainless steel/steel joining 6 7 Wire and rings Profiles and flat material Speed, dimensional accuracy, reproducibility – these are the Profile-T or angle connections, coil joints, etc., pose great chal- demands and requirements our customers want from our lenges to individual and easily installable material feeds in or- welding machines. Whether structural steel joints, tool exten- der to provide a consistent and reproducible welding result. sions, chain links, lugs, rings – with our AS15 or AS25, you will be on the safe side when welding smaller cross-sections. Larger welding cross-sections make the AS40 to AS220 ideal for such tasks. An extensive range of accessories meets virtually all customer wishes – from a manual solution for small volumes up to fully automated systems. Cutting-edge PC with parameter setting, monitoring and logging of each individual weld Automatic deburring device AS160 for the welding of waggon connections Automatic material handling Ergonomically designed loading magazine and work surfaces Fully automated AS15 for steel stainless steel joints High level of productivity, supported by fast setup Feed and loading magazine AS220 for the welding of ship profiles 8 9 Rims, rings, wreaths Special solutions DD & WES Rims and rings demand a great deal from welding. Important Due to an additional upsetting shock, DD double pressure are, among other things: very flexible material clamping de- welding systems create connections with extremely high ten- vices that are also able to build up a targeted and high contact sile strength during the welding process, because the heat- pressure – with very small tolerances. affected material is almost completely pressed out of the welding zone. The result is a significantly finer grain structure Demanding and sophisticated industries, such as automotive of the material and an extremely high tensile and bending or medical engineering, are therefore working with welding strength.
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