Stud Welding System operates with single digit ppms.

Press Release Summary:



Computerized Servo-Electric Welding System includes servo-operated weld gun, Model KSE 100, with intelligent referencing mechanism that allows gun to account for exact physical position of base material. Feedback system and linear motor drive control arc length, lift and plunge velocity, and depth penetration of each stud weld. Model N3 Inverter monitors all parameters of weld cycle, while automatically-controlled FSE 100 Feeder compensates for changing variables.



Original Press Release:


Nelson Introduces Innovative Servo-Electric Welding System Proven to Operate With Single Digit PPMS


New Servo-Electric Welding System by Nelson Proves Superior in Reliability and Repeatability

CLEVELAND, (Oct. 26, 2004) - Today, at the 2004 FABTECH International metal forming and fabricating trade show in Cleveland, Nelson. Stud Welding introduced the Servo-Electric Welding System, which fuses traditional stud welding applications with servo-electric technology to serve the industry's increased need for quicker, easier and higher quality welding.

Specifically benefiting short-cycle stud welding that's suitable for welding to light gauge materials and applications that require high-speed automation (in particular the automotive industry), the Servo-Electric Welding System is comprised of three key components - the KSE 100 servo-electrical weld gun, the FSE 100 feeder and the N3 inverter welder power supply - which work together to significantly enhance the reliability and repeatability of the welding process.

"Nelson's new Servo-Electric Welding System encapsulates all of the improvements in the welding process that our customers are looking for," said Doug Phillips, product manager of equipment, Nelson. "Currently, most stud welding systems operate mechanically lending to numerous inefficiencies. Nelson's new Servo-Electric Welding System is computerized, allowing for a faster, more intelligent system that operates with record-low single digit PPMs."

Servo-Electrical Weld Gun (KSE 100)

The KSE 100 servo-operated weld gun has an intelligent referencing mechanism that allows the gun to account for the exact physical position of the base material - eliminating the need for a stop-pin and pneumatic slide. In addition, a feedback system and linear motor drive in the weld gun precisely control the arc length, lift and plunge velocity (a patented feature by Nelson), and depth penetration of each stud weld.

The gun's intelligence and control provides the user with increased application speed, improved access to tight weld locations, simplified set-up and maintenance, better weld consistency, and more accurate stud placement.

Welder Power Supply (N3 Inverter)

Through DSP technology (i.e. digital control of all critical functions), the N3 inverter welder monitors all parameters of the weld cycle, including precise and consistent weld current, lift/plunge compensation, adaptation to changing plate conditions, and diagnostics. Additionally, the KSE 100 features a fully programmable pulse-welding mode to enhance the welding of aluminum studs.

Utilizing computer software, all weld information is analyzed in real-time and archived so the user can view current and past performance, track suspect welds and more easily pinpoint failures - making the system 100 percent reliable. Ethernet connectivity is available for those users interested in remotely monitoring or programming the system through their LAN.

Feeder (FSE 100)

Parameters for the timing of the feed sequence and adjustment for air feed time are eliminated with the automatically controlled intelligent FSE 100 feeding option. The new FSE 100 is capable of compensating for variables such as changes in air pressure, damaged feed hoses and sticky loading pins. And, the shortest feed time is determined for each welding position, thereby guaranteeing optimum cycle time for the robot station.

Moreover, the front load hopper has a capacity of over 10,000 studs allowing the user to spend far less time replenishing the feeder then previous models.

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