Introduction

Ideal-Werk C+E Jungeblodt GmbH & Co KG, Germany, is a leading manufacturer of resistance welding machines for the wire and cable industry worldwide. The company provides a wide range of butt welding machines for use in wire drawing, cable manufacture, and wire fabrication. Its butt welders accommodate steel and nonferrous wires in the range 0.1 to 20mm Ø. A wide range of Ideal-Werk accessories for coil joining is also available, as are devices for annealing the weld joints in carbon steel wire.

A flexible welding system

Ideal-Werk mesh welders are designed for high productivity and quick set-up and changeover, and are equally suitable for big or small runs. AC-servo drives make it an easy task to accommodate various cross wire spacing, even in the same mesh panel, with highest precision. Programming is by means of a user-friendly PC dialogue system. New products are programmed while the welder is producing the previously programmed job. Programmes are stored in the PC hard drive or on floppy disks. CIM integration into a computer network is available as an option.

Photo 1: Triple line wire loading device for automatic loading of line wires with different lengths/diameters

Automatic wire loading and feeding

Ideal-Werk can provide welding machines in which wires are loaded by manually stacking magazines or by means of an automatic loader into V-type magazines. With manual loading the wires are stacked in the magazines while the machine is in operation, ensuring continuous production. Each stacking magazine is suitable for the entire range of wire diameters. With automatic wire loading (Photo 2), the line loader moves over the V-type magazines (Photo 3), dropping a wire into the designated magazine. The wire loader feeds wires in both directions of travel. It can be “parked” in position for easy changeover, for manual loading of wires, and for the production of shelves with frames.

Photo 2: Wire feeding with automatic wire loader

Both stacking magazines and V-type magazines are easily set up for various line wire spacing. An ingenious template system with a factory-set zero position guarantees accurate line wire spacing and a completely square mesh. After changeover, the first mesh panel will already have been produced to tolerance. Cross wire loaders/feeders are designed for large wire capacity. Cross wires are first separated by means of a motor-driven sorting wheel, then fed into the gap-type mechanism for precise feeding and positioning in the welding position. Changeover for different diameters and/or lengths is fast and easy. Dual or multiple-track production is possible. A second cross wire loader/feeder for different diameters and/or lengths of cross wires within one mesh panel is an optional accessory.

Photo 3: Automatic double line wire loader and V-type magazines

Quick set-up and changeover

Ideal-Werk mesh welders are designed with Jop Shop features as well as for quick set-up and changeover (Photo 4).

Photo 4: Machine in open set-up position for good accessibility

The company’s mesh welding machines can also be equipped with DC weld modules (Photo 5). This is very advantageous in welding wire to flat stock or mesh with very small spacing. DC welding also guarantees highest welding quality and a flat mesh product. DC technology is recommended to reduce electrical loads.

Photo 5: Programmable weld module to produce conical mesh as used in shopping carts

Latest developments

Flexible mesh welder for vertical processing application
Ideal-Werk recently introduced a highly flexible mesh welder, Model GAD 512/06-12-20, designed for vertical processing applications. It can be set up for a variety of wire products; changeover times are short. The machine’s linear pull-out system provides easy programming and reliable programme memory.

Photo 6: Mesh welding machine Model GA 516

The DC welder provides perfect flatness of product and a high-quality of welded joint. Using automatic distributors for round line wire and flat steel bars, the machine will weld panels in sizes up to 1,600mm wide x 2,000mm long, made of steel wire 2 to 10mm Ø. The welding portal is equipped with six transformers of 100kVA each and 12 welding cylinders, producing a maximum weld force of 3.5kN at 6 bar air pressure. The extremely versatile machine lends itself to frequent product changes. It can weld a wide variety of mesh configurations.

Photo 7: Type GA0 516 mesh welder, showing opened machine frame

Model GAD 512 is available with such optional accessories as additional transformers, a positioning device for stainless steel wires, pneumatic or hydraulic trimming units for eliminating cross wire overhangs, a second cross wire loader/feeder for single or multiple track production, automatic line wire loaders/feeders, automatic mesh stacking systems, bending units, and automatic coining.

Automatic mesh welding machine for industrial wire mesh
Ideal-Werk also recently introduced its latest automatic mesh welding machine, Model GA 500, designed for any type of industrial wire mesh. The machine features a new automatic quick-change loading system for pre-cut line wires, flat stock, and cross wires, minimum changeover time required. Suitable for line and cross wire in diameters up to 10mm, the unit is available with AC or DC power packs and with options for simultaneous welding of three layers of wire. The GA 500 is suitable for mesh widths of up to 3,600mm.

Photo 8: Input table of Model GAD 512 Ideal DC mesh welding machine

Conclusion

Ideal-Werk has been active in research and development for the resistance welding industry worldwide since 1923, and provides the industry with butt welders, automatic frame bending and welding machines, semi-automatic and automatic T-welders, automatic positioning and welding systems, basket welders, and dedicated manufacturing/welding lines. Its years of experience and close collaboration with its customers have made the company, already known as a dependable partner, into a market leader. The Ideal-Werk team of qualified engineers is always available to work closely with customers to create better solutions. Modern manufacturing facilities and highly motivated personnel guarantees a state-of-the-art product line. Reliable technical support, on-site service, and affordable spare parts enable Ideal-Werk to guarantee customer satisfaction.