Servo Inline Tabletop Welding Machine For Copper Wire Terminal Forming And Welding
2026/10/08
Servo Inline Tabletop Welding Machine for Copper Wire Terminal Forming and Welding
Copper wire terminals look like a small part, but the requirements on them are not small at all. For an electronics components manufacturer whose products serve communication equipment, automotive electronics, smart terminals and industrial control, PDKJ built a customized inline tabletop welding machine that forms the wire end into a square section and welds it - holding the dimensions to within plus or minus 0.15 mm, with a cycle under five seconds. The machine has been delivered and is strengthening the customer's terminal production.
Application Overview
| Item | Details |
|---|---|
| Application | Forming (sizing) and resistance welding of copper wire terminals |
| Industry | Electronic components (communications, automotive electronics, smart terminals, industrial control) |
| Workpiece | Copper wire terminals, 0.75-6 mm2 wire range |
| Process | Square-section forming by four-sided servo sizing, then precision welding |
| Accuracy | Dimensional tolerance within plus or minus 0.15 mm |
| Machine type | Customized inline tabletop welding machine with four-direction servo sizing and an 80 kVA welding transformer |
| Cycle time | Under 5 s per cycle (feed - clamp - discharge - unload); 0.1 s clamping |
| Changeover | Approx. 5 minutes |
| Process control | 15/31 stored schedules; three-stage heating (pre-heat, weld, post-heat) |
| Footprint | 1200 x 1200 x 1700 mm with movable worktable |
Customer Requirements
Customer Background
The customer has worked in electronic components for years, with a product range serving communication equipment, automotive electronics, smart terminals and industrial control. Wire terminals are a critical supporting part: their welding accuracy and stability directly affect the reliability and service life of the end products.
Project Background
To meet the strict requirements of multi-market products, the customer defined three core welding needs: form wire terminals of 0.75-6 mm2 into a precise square section with the tolerance held within plus or minus 0.15 mm; keep pressure stable and positioning precise through welding so defects never reach the end product; and rely on a dependable clamping mechanism so finished parts stay consistent and durable. After comparing suppliers, the customer chose PDKJ's customized solution.
Why This Part Is Hard
A copper wire terminal combines two operations that fight each other: it must be squeezed into an exact square, and it must be welded - both on the same part, both within a fraction of a millimeter. Any play in the mechanism, any pressure drift, shows up immediately in the dimension report or in the joint.
The Servo Inline Tabletop Welding Machine
1. Four-sided servo sizing, dimension under control. The machine pairs a four-direction servo sizing mechanism with an 80 kVA welding transformer. Working in displacement mode, the servo uses pulse counts to control the travel precisely, holding the formed terminal within the plus or minus 0.15 mm tolerance across the full 0.75-6 mm2 wire range.
2. A cycle under five seconds. The optimized motion sequence - feed, clamp, discharge, unload - completes in under five seconds, and the left-right clamping action takes just 0.1 s. The upper clamp cylinder speed adapts to the wire gauge, pushing efficiency more than 60% above conventional equipment and carrying large-scale production easily.
3. Five-minute changeover. Changing to another wire specification takes about five minutes of adjustment, so mixed production and urgent orders do not stall the station.
1. Programmable, visual, operator-friendly. The visual interface supports 15/31 stored welding schedules, with the three-stage heating process - pre-heat, weld, post-heat - freely definable, and welding current, time and pressure precisely adjustable. Recipes are recalled with one touch, so ordinary operators come up to speed quickly.
2. Durable materials and thermal management. The sizing electrode uses tungsten alloy for wear resistance, and the left-right clamping blocks are insulating material. A built-in chiller and complete water and air circuits control the working temperature and extend the machine's service life.
3. Compact, safe, layout-friendly. The 1200 x 1200 x 1700 mm frame with a movable worktable fits varied cell layouts, and a transparent protective cover with insulating limit blocks guards the working area.
How the Machine Solves the Customer's Needs
1. Precision forming and welding in one station. Servo displacement control and a stable clamping mechanism keep both the square dimensions and the weld within specification on every part.
2. Speed that survives mixed production. A sub-five-second cycle plus five-minute changeovers mean small batches and model switches cost almost nothing.
3. Consistency by recipe, not by feel. Stored schedules with three-stage heating give every terminal the same thermal history.
4. Service life protected by design. Tungsten alloy electrodes, insulated clamping and active cooling reduce wear and unplanned downtime.
Why Choose a Customized Tabletop Welding Machine?
Off-the-shelf welders weld; they do not form, and they rarely hold a 0.15 mm tolerance across a 0.75-6 mm2 wire range. Combining four-sided servo sizing with resistance welding in one tabletop machine is what makes this terminal process both precise and productive.
Key Advantages
- Four-direction servo sizing with displacement-mode control to plus or minus 0.15 mm.
- 0.75-6 mm2 wire range; 80 kVA welding transformer.
- Cycle under 5 s, 0.1 s clamping, efficiency up 60%+ over conventional equipment.
- 5-minute changeover; 15/31 stored schedules with definable three-stage heating.
- Tungsten alloy electrode, insulated clamping, built-in chiller, 1200 x 1200 x 1700 mm footprint.
Potential Applications
The same approach covers precision forming-plus-welding of small conductive parts: wire terminals, connector pins, sensor lead ends, brush and contact assemblies and other copper or plated components where square forming and a sound weld must happen together.
Delivery and Results
The machine has been delivered and put into production. Its high-consistency, high-reliability welding process has strengthened the customer's competitiveness in the electronic components market and won recognition from downstream customers - a further example of PDKJ's customized welding solutions for precision electronics.
PDKJ continues to provide customized laser welding and resistance welding solutions based on different materials, workpiece structures, welding requirements, and production applications.
Related Products
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- DTB-80 Industrial Vertical Medium Frequency Inverter Spot Welder
- Medium Frequency Row Spot Welding Machine
Contact PDKJ
Need small conductive parts formed and welded within a tight tolerance? Send us the part drawing and wire range - PDKJ will evaluate a servo sizing plus welding solution, with sample parts before you commit.
WhatsApp: +86 136 1279 3248
Email: pdkj101@gd-pw.com
Website: https://www.spotlaserwelding.com/contactus.html
Address: 1-2F, Building 3, Qichen Industrial Park, No. 26 Luxi 1st Road, Liaobu Town, Dongguan City, Guangdong Province, China
Guangdong Pudian Automation Technology Co., Ltd (PDKJ) - 20 years in resistance spot welding machines, laser welding machines and automated welding equipment.
