Virdi Electric Works Pvt. Ltd.
Virdi Electric Works Pvt. Ltd.  
spot welding machines, precision spot welding machines Virdi Electric Works Pvt. Ltd.
Virdi Electric Works Pvt. Ltd.
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Welding Machines



Seam Welding Machines

Introduction :
Offered in 50 to 200 KVA capacity, available in longitudnal / circumferential and universal versions. Percision built, sturdy design and robust construction suitable for high production and uninterrupted service in the manufacturing of drums, barrels, silence, fuel tanks, transformer radiator, water heater & auto rims, etc.

These machines are always made to specific customer requirement with highly sophisticated & leak proof joints.

Standard Rating :
50,75,100,150 and 200 KVA

Seam Welding Machines
Construction :
The main frame of the machine is of heavy rigidly re-inforced & robust welded steel construction. It combines a compact streamlined appearance with maximum resistance to mechanical deflection. The welding transformer is enclosed in the main frame and is easily accessible, for inspection.

STANDARD THROAT DEPTHS (mm) :
280, 460 & 600 (other throat available on request)

Normal Working Height :
900 (mm)

WELDING TRANSFORMER :
Transformer of a special type, water cooled, having core of high grade electrical steel, primary and secondary coils of solid electrolytic copper of ample section, heavy duty class ‘F’ insulated, impregnated and tropicalised suitable for withstanding continuous temperature of 140º C.

CURRENT CONTROL :
Transformer primary coils provided with taps brought out to tap change links for adjustment for welding current in a 6 step from 50 to 100%. Tap change links are enclosed behind machine door and are easily accessible for variation of welding heat.

COOLING SYSTEM :
Transformer, secondary connections, arms and electrode wheels are water cooled. Internet water cooling piping with flow adjusting values for each circuit and discharge to an open drain pot for visual observation of flow are provided in the machine.

ELECTRODE :
Circular disc type top and bottom welding Electrodes.

ELECTRODE CONTROL SYSTEM :
Upper electrode is actuated by hand lever to provide electrode force.

ELECTRONIC CONTROLS :
Seam welders are provided with solid-state electronic controls housed in a well-designed sheet steel cabinet. The standard design of the cabinet is suitable for mounting it on the sidewall of the machine; floor mounting shall also be provided a request. The control knobs and panel are elegantly arranged, provided maximum convenience to the operator. The front panel is protected from misuse by providing a transparent guard door. All internal wiring is easily accessible for servicing. The circuit design is versatile enough for almost all type of requirements and consists of the following facilities.
  • A squeeze time control to select the delay between initiation of the foot switch and the start of the weld. Timing is adjustable from 2-25 cycles, continuous
  • Synchronous (digital) timing control of 1-9 cycles “ON” and 0-9 cycles “OFF” both in steps of one cycles each.
  • Heat control circuit based on phase shifted firing of thyristors which enable continuous adjustment of current between 10% to 100% of then value available from welding transformer.
  • High power switches device consisting of 2 Thyristors connected in inverse parallel mounted on water-cooled heatsinks. The sizes of the thyristors are chosen to watch the KVA of the transformer and the devices are of ample capacity to withstand momentary overloads. Protection devices for high voltage surges and a thermoswitch (for inhibiting the operation if the temperature of the thyristor pad rises above a preset limit) are incorporated.
  • Hold time to provide a delay between stoppage of weld and separation of electrode wheels. Range of adjustment is 1-9.
WELD INITIATION :
By means of operators foot switch connected to a low voltage safe initiating circuit.

MOTOR DRIVE SYSTEM :
Machine can be supplied with either A.C. or D.C. motor drive system as per customers choice.
  • D.C. Motor driven system consists of an infinitely variable speed, reversible D.C. Motor, variac, rectifier & protective fuses system with reduction gear unit to provide stepless speed variation.
  • A.C. Motor driven system consists 3-phase induction motor speed as constant.
Note : Machine shall be supplied with A.C. MOTOR DRIVE SYSTEM AS STANDARD UNLESS SPECIFIED otherwise by the customer.

SERVICE REQUIREMENTS :
Customer to provide the following service facilities :-
POWER SUPPLY :
  • For Transformer : 415 V, Single phase, 50 cycles (suitable for connection to 2 lines of 3 phase supply). Main supply cable for transformer connection. Disconnect switch with fuses of recommended rating.
  • For Motor : 415 V, 3 phase, 50 cycles or 230 V, single phase, 50 cycles or 230 V, single phase, 50 cycles for D.C. motor drive, depending on the drive system selected supply cable 1.5 sq. MM 4 core, TPIC switch fuse unit 500 V, 15 Amps, with fuses of 5 Amps for D.C. motor Drive system.
COMPRESSED AIR :
Supply of air recommended flow volume at minimum pressure of 5.6 kg/cm2 (80 psi) by the customer.

TECHNICAL SPECIFICATIONS :

MODEL
UNIT
VSM-50
VSM-75
VSM-100
VSM-150
Normal Rating at 50%
         
Duty Cycles
KVA
50
75
100
150
Continuous Rating Of Transformer
KVA
35
55
70
110
Supply Voltage 2 Phase
         
50 Hz.
V
451
451
451
451
Switch Fuse
A
100
150
200
250
Current Taps
Nos.
6
6
6
6
Throat Depth Std.
mm
280
460
610
610
Normal Working Heights
         
 
mm
900
900
900
900
Welding Capacity
         
Mild Steel
mm
1+1
1.25+1.25
1.6+1.6
2+2
Water Supply Required
         
 
LPM
15
20
25
30
Drive Motor A.C.
         
 
HP
1
1
1.5
1.5
Dimension Overall :
         
Heights
mm
1900
1900
1900
1900
Width
mm
900
900
900
900
Depth
mm
1050
1050
1200
1200
Weight Approx
kgs
700
850
1100
1250

Virdi Electric Works Pvt. Ltd.

Projection Welding Machines

  • Spot and nut projection possible on the same machine
  • Robust construction – less vibrations – no maintenance of controller broad / connectors.
  • Controlled delivery of welding current by made constant current feedback controller.
  • Quantity watch on every spot. Weak or faulty spot highlighted instantly.
  • Error and weak spot alarm buzzer.
  • Fused copper laminate flexible links for lifetime use
  • High speed cylinder operations gives better cylinder follow up.
  • Electrode movement made precise by LM bearing.
  • Engineered for minimum downtime.

Projection Welding Machines
TECHNICAL SPECIFICATIONS :

PROJECTION WELDER
Machine Specification
Unit
VEW35
VEW50
VEW75
VEW100
Rated power @ 50% Duty Cycle
KVA
35
50
75
100
Secondary Voltage
Volt
4.8, 6.4
5.9, 7.4
6.5, 9
6.7, 9
Welding Current Max
KA
12
13.5
15
20
Control Type
Secondary feedback constant current control
Time Setting Least Count
Millisecond
20
20
20
20
Throat Depth
mm
250-300
250-300
250-300
250-300
Arm Gap Max
mm
300
300
300
300
Electrode Force min - max
Kg
150 to470
150 to470
150 to470
150 to470
Free Air Consumption (@1 bar) for
 
100 Spots and 25mm Stroke
Liters
250
250
250
250
Strokes Per Second Max at No Weld
Nos.
6
6
6
6
Cooling Water Pressure
Kg/cm. Sq
2
2
2
2
Cooling Water Flow Rate Min
It/min
9
10
10
12
Welding Capacity (indicative comparisons only)
Sheet Metal CRCA
mm
2/2.5
2.5/3
3.3
4.4
Sheet Metal HR
mm
2/2.5
2.5/3
3.3
5.4
Sheet Metal SS
mm
1.2/1.5
1.2/2
2.2
2.5/2.5
Projection Nut Welding
mm
M8
M10
m12
m16
Dimensions Depth x Width
mm
1050 x 410
1050 x 410
1050 x 410
1050 x 410
Height
mm
1750
1750
1750
1750
Weight
mm
500
510
520
600
Note : Optional low cost voltage compensation control is also available.
Virdi Electric Works Pvt. Ltd.

Spot Welding Machines

  • High weld abilities are achieved with special type of transformer.
  • Ability to weld thick material at low speed using short length arms.
  • In Manually operated machine at low speed using short length arms.
  • Easy maintenance.
Construction :
The unit is of robust construction sturdy heavy rigidly reinforced welded steel construction. It combines a compact streamlined appearance with maximum resistance to mechanical deflection. The transformer enclosed in the main frame and is easily accessible, for inspection.

Spot Welding Machines

Welding Transformer :
Manufactured from high grade materials of copper strips and sections, water cooled with class ‘F’ insulation with standing continuous temperature rise of 140`C. The coils are impregnated and tropicalised.

Current Control :
By tap method with 8 tap adjustments on primary of the main transformer having current control from 50% to 100% in 8 steps.

Cooling system :
By tap link method with 8 tap adjustments on primary of the main transformer having current control Electrodes, Electrode holders, Arms, Transformer are all water cooled with one single water-cooling circuit.

Electrode Control System :
Upper electrode is actuated by foot lever or by air cylinder. The electrode force can easily be calculated in both systems. Air system is provided with gauge and manual system with calibrated spring. All air accessories such as filter, lubricator, regulator, gauge, solenoid valve and speed valve are incorporated.

Maximum Operating Speed :
Machine is mechanically capable of attaining 60 spots per minute.

TECHNICAL SPECIFICATIONS :

Machine Model No.
UNITS
VSM-7.5
VSM-10
VSM-15
VSM-20
KVA @50% Duty Cycle
KVA
7.5
10
15
20
Rated Input Voltage
V
230/415V
230/451V
230/415V
230/415V
Transformer Cooling
Water
Water
Water
Water
Water
Water Consumption
LPM
5
5
8
10
Arms-Diameter
(mm)
40
45
51
64
Main Supply Cable Size
(mm2)
10/7
12/8
16/10
16/25
Cu / Al
         
Main Disconnection
[Amps]
25/15
30/20
60/35
60/55
Switch / fuse
         
Current Taps
Nos.
8
8
8
8
Over All Size
         
{Approximately}[mm]
D=
410
460
460
510
 
W=
250
280
280
310
 
H=
1020
1150
1300
1400

Virdi Electric Works Pvt. Ltd.

Mig Welders

VIRDI's MIG welders are used universally in light and heavy fabrication workshops, shipbuilding & auto industries, in manufacture of stainless steel, mild steel, copper vessels & container in chemical and allied industries.

These VIRDI CO2/ MIG equipment are designed and engineered for CO2 welding of mild steel, low alloy steels and MIG welding of high alloy steels and light metals.

Salient Features :
  • Welds mild steel, stainless steel wires & bronze alloy wires
  • Suitable for solid wires as well as fluxed cored wires
  • Easy connection system for torch plug-in to wire feeder
  • Most reliable / easy / maintenance wire feeder with roll / quick release type
  • Adjustable spot time control available on request
  • Coarse / Fine controls for proper selection of voltage
  • Sleek & most flexible torch
  • Wire feeder units are normally supplied as separate unit to give greater area of operation & flexibility. However in-built version is also available (on request)
Technical Specification :
Mig Welders
 
POWER SOURCE
MIG 250
MIG 400
INPUT
Supply Voltage
415 Volts AC
415 Volts AC
 
Phase
3 Phase
3 Phase
 
Frequency
50 Hz
50 Hz
 
Max KVA Rating at 60%
9 KVA
17 KVA

 

Recommended Switch
   
 
Primary Current at the Rated
TP-20
TP-30
 
Output at 415 V Supply
13 Amps.
25 Amps.
OUTPUT
Open Circuit Voltage (Max.)
18-42 Volts.
20-52 Volts DC
 
Maximum Continuous Hand
250 Amos. DC
400 Amos. DC
 
Welding Current at 60% Duty Cycle
   
 
Maximum Continuous Automatic
180 Amos. DC
350 Amps. DC
 
Welding Current at 100% Duty Cycle
   
 
Voltage Control Steps
8 Steps
8 Steps
 
Insulation Class
F
F
 
Type of cooling
Forced air cooled
Forced air cooled
 
Weight (Approx.)
140 Kg.
185 Kg.
 
Dimensions LxWxH (mm)
715x480x650 mm
825x510x725 mm
 
WIRE FEEDER UNIT
Drive System
DC Motor 110 volt, Solid State, Thyrestoriesed, wire Drive system for stepless variable setting of wire speed. Three core wire control.
 
DC Motor 110 volt, Solid State, Thyrestoriesed, wire Drive system for stepless variable setting of wire speed. Three core wire control.
Feed mechanism
Double feed role, quick change over type Plug-in-PCB for easy maintenance & Service Fuse Protection for vital PCB components against over-load.
 
Double feed role, quick change over type Plug-in-PCB for easy maintenance & Service Fuse Protection for vital PCB components against over-load.
Weight (Approx.)
26 Kg
 
26 Kg
LxWxH Dimensions
560x305x380 mm
  560x305x380mm
Torch
250 Amps at 60% duty cycle
 
400 Amps at 60% duty cycle
 
CO2 Shielding gas
 
CO2 Shielding gas.
STANDARD SCOPE OF SUPPLY
* Power Source
1 No.
welding Cable- 1 Set of Earthing Cable- 5 Meters (e.a.)
* Gas Regulator cum
* Wire Feeder
1 No.
Flow Meter
* Torch
1 No.
* CO2 Heater Assembly with Core 1 No.
Virdi Electric Works Pvt. Ltd.

Hot-Staking Welders

  • Solid-state digital timer for precision time control.
  • Highly productive process (welds 60 Armatures of 24 segments within 60 minutes)
  • High weld abilities are archived with special type of transformer.
  • In manually operated machine special mechanism is incorporated in order to increase production by reducing fatigue to operator.
  • The joints are very strong, durable and can withstand upto 650`C (whereas solder joints can stand only upto 160`C to 200`C)
  • No need to clean enamel on winding wires.
  • Weld strength of each segment is same and quality of each weld is far superior than that achieved by soldering.
Hot-Staking Welders

SALIENT FEATURES OF THE MACHINE :
  • Precise control of time eliminates :
  1. Damage to inter segment insulation.
  2. Sparking or flashing of segment material.
  3. Damage to insulation of wire.
  • No automation and no air operation makes it virtually simple and facilitates every manufacturer to enhance production even manually.


ELECTRONIC TIMER SYSTEM :
Control of precision electronic timer, synchronous with power frequency giving exact number of cycle set on the dial. The timer heat control unit is completely solid state ageing type and having modular construction to replace the timer easily.

MACHANICAL SYSYTEM :
The construction is like simple bench drill machine. Pressure system is with calibrated spring and adjustable over wide range to suit the staking of various combination of wires and segments of machine.

Water-cooling is provided for electrodes. The system is of course a closed loop type with water inlet and outlet brought out for external connections where customer has to provide clean water through completely closed water tanks pumps etc.

Since commutators do not have slots exactly in center, the automatic indexing facility is not provided. But the position of armature is so adjusted that the manual synchronism of both hand movement provides indexing as fast as automatic. The staking time for one segment being as low as 0.5 to 0.8 secs and total cycle time for staking one armature of 24 segments being only 15 to 20 secs.

MECHANICAL :
Farce of Stake
120 Kgf
Electrode Cooling
Water
Operation
Hand operate


WORKING RANGE :
Armature dia. Min.
20 mm
Armature dia. Max.
130 mm
Commulator dia. Min.
7 mm
Commulator dia. Max.
60 mm
Winding Wire dia. Min.
015 mm
Winding Wire dia. Max.
1.2 mm * 2 Nos.


PRODUCTION RANGE :
Cycle Time to Hot Staking One Segment (Depending on operater)
0.8 second (approx.)
Cycle Time to Hot Staking One Commutator With 24 segment (max.)
20 second (approx.)


ELECTRICAL DATA :
KVA Rating @ 50% Duty Cycle
10 KVA
Primary Input
200/220 Volts, 1 Phase, 50 Cycle
Weld Time Adjustable
1 to 60 cycles
Current Adjustable (course)
8 Steps
Virdi Electric Works Pvt. Ltd.


ARC Welding


In arc welding, the intense heat needed to melt metal is produced by an electric arc. The arc is formed between the actual work and an electrode (stick or wire) that is manually or mechanically guided along the joint. The electrode can either be a rod with the purpose of simply carrying the current between the tip and the work. Or, it may be a specially prepared rod or wire that not only conducts the current but also melts and supplies filler metal to the joint. Most welding in the manufacture of steel products uses the second type of electrode.

Basic Welding Circuit :
The basic arc-welding circuit is illustrated in Fig. 1. An AC or DC power source, fitted with whatever controls may be needed, is connected by a work cable to the work piece and by a "hot" cable to an electrode holder of some type, which makes an electrical contact with the welding electrode.

An arc is created across the gap when the energized circuit and the electrode tip touches the work piece and is withdrawn, yet still with in close contact.

The arc produces a temperature of about 6500ºF at the tip. This heat melts both the base metal and the electrode, producing a pool of molten metal sometimes called a "crater." The crater solidifies behind the electrode as it is moved along the joint. The result is a fusion bond.

Arc Shielding :
However, joining metals requires more than moving an electrode along a joint. Metals at high temperatures tend to react chemically with elements in the air - oxygen and nitrogen. When metal in the molten pool comes into contact with air, oxides and nitrides form which destroy the strength and toughness of the weld joint. Therefore, many arc-welding processes provide some means of covering the arc and the molten pool with a protective shield of gas, vapor, or slag. This is called arc shielding. This shielding prevents or minimizes contact of the molten metal with air. Shielding also may improve the weld. An example is a granular flux, which actually adds deoxidizes to the weld.

Figure 2 illustrates the shielding of the welding arc and molten pool with a Stick electrode. The extruded covering on the filler metal rod, provides a shielding gas at the point of contact while the slag protects the fresh weld from the air.

The arc itself is a very complex phenomenon. In-depth understanding of the physics of the arc is of little value to the welder, but some knowledge of its general characteristics can be useful.

Nature of the Arc :
An arc is an electric current flowing between two electrodes through an ionized column of gas. A negatively charged cathode and a positively charged anode create the intense heat of the welding arc. Negative and positive ions are bounced off of each other in the plasma column at an accelerated rate.

In welding, the arc not only provides the heat needed to melt the electrode and the base metal, but under certain conditions must also supply the means to transport the molten metal from the tip of the electrode to the work. Several mechanisms for metal transfer exist. Two (of many) examples include:
  1. Surface Tension Transfer® - a drop of molten metal touches the molten metal pool and is drawn into it by surface tension.
  2. Spray Arc - the drop is ejected from the molten metal at the electrode tip by an electric pinch propelling it to the molten pool. (Great for overhead welding!)
If an electrode is consumable, the tip melts under the heat of the arc and molten droplets are detached and transported to the work through the arc column. Any arc welding system in which the electrode is melted off to become part of the weld is described as metal-arc. In carbon or tungsten (TIG) welding there are no molten droplets to be forced across the gap and onto the work. Filler metal is melted into the joint from a separate rod or wire. More of the heat developed by the arc is transferred to the weld pool with consumable electrodes. This produces higher thermal efficiencies and narrower heat-affected zones.

Since there must be an ionized path to conduct electricity across a gap, the mere switching on the welding current with an electrically cold electrode posed over it will not start the arc. The arc must be ignited. This is caused by either supplying an initial voltage high enough to cause a discharge or by touching the electrode to the work and then withdrawing it as the contact area becomes heated. Arc welding may be done with direct current (DC) with the electrode either positive or negative or alternating current (AC). The choice of current and polarity depends on the process, the type of electrode, the arc atmosphere, and the metal being welded.
ARC Welding
Virdi Electric Works Pvt. Ltd.


DC Welding Rectifier/Tig Welding

VIRDI series of welding rectifiers are forced air-cooled, silicon type and are designed to provide a DC Welding current where 3 Phase, 50 Hz AC mains power is available at voltage ranging from 380 to 440. Arc welding is one of several fusion processes for joining metals. By applying intense heat, metal at the joint between two parts is melted and caused to intermix - directly, or more commonly, with an intermediate molten filler metal. Upon cooling and solidification, a metallurgical bond is created. Since the joining is an intermixture of metals, the final weldment potentially has the same strength properties as the metal of the parts. This is in sharp contrast to non-fusion processes of joining (i.e. soldering, brazing etc.) in which the mechanical and physical properties of the base materials cannot be duplicated at the joint.
VIRDI series of welding rectifiers are suitable for manual arc welding particularly for the welding of :

DC Welding Rectifier
Technical Specification :
  • Pipes in all positions.
  • Non-ferrous metals.
  • Low alloy, corrosion, heat and creep.
  • Mild steel and low alloy steel at site where welds of high radiographic standards are required.
  • Mild steel and low alloy steel is lighter gauge resisting steel i.e. stainless steel.
VIRDI sets are also suitable for argon arc welding where DC is necessary and are supplied with built in high frequency suppressor.600 FC welding rectifier is suitable for arc gouging also.


MODEL
VEW-R300 A
VEW-R400 A
VEW R600 A
INPUT
     
Supply Voltage
380/415/440 V
380/415/440 V
380/415/440 V
Primary Current at Max. Output
30A
40A
68A
OUTPUT
     
Open Current Voltage
85
85
85
Max. Continuous Current at 100% Duty Cycle
225
300
420
Max. Continuous Current at 60% Duty Cycle
300
400
600
KVA- Max. Continuous
15
20
30
KVA-Max.
19.5
26
43.2
Welding Current Range (in two ranges)
30-300A
40-400A
60-600A
Specn. To Which Conforms
IS: 4559
IS: 4559
IS: 4559
GENERAL
     
Max. Ambient temp. To which rating apply
40ºC
40ºC
40ºC
Class of Insulation
E
E
E
Type of Cooling
Forced air cooled
Forced air cooled
Forced air cooled
Approx. Dimensions (LxWxH) mm
640x850x710
640x850x711
1066x711x889
Approx. Weight (Kg.)
305
355
450


VIRDI series of welding Rectifier are forced air-cooled silicon type. Combination of well-designed rectifier & transductor unit gives smooth and steady arc with minimum spatter & excellent weld bead. It gives ideal DC power source for Manual Metal Arc and Tungsten Inert Gas (TIG) Welding.



Virdi Electric Works Pvt. Ltd.
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