Electrode Orientation refers to whether the electrodes approach from above, or from both sides of the work piece.  Opposed designs have a bottom and a top electrode.  Typically the bottom electrode is fixed, and the top electrode moves and provides the down force.  Some types of heads like the Avio NA-43 have the electrode oriented horizontally instead of vertically.  Parallel designs have both electrodes approaching from the same side, typically from the top.  Parallel designs are further broken down into Parallel and Series weld heads.  True Parallelheads hold both electrodes in a fixed relationship to each other, meaning that the electrode tips must touch the work piece at the same time under the force of a single spring.  These type of electrodes can be bonded together with an adhesive insulator, or free such that the electrode holder sets the height relationship between the left and right electrodes.  Series type weld heads have double springs, such the the left and right electrodes are independently spring loaded.  This allows each electrode to come to a resting point on the work piece under their own pressures, compensating for varying work heights.  Most battery tab welding is done with this type of head.

Both Opposed and Parallel heads come in a variety of actuation configurations.  Air operated heads are actuated by a foot switch that fires a solenoid, which applies compressed air to an air cylinder, which in turn drives the head downward.  As the head is driven down, a switch fires the weld sequence when the head achieves the correct down force.  Then afterward the solenoid releases the air valve, which retracts the upper electrode.   Manual actuated heads have a mechanical foot switch that the operator uses to pull the  upper head down.  When the head senses that it has achieved the correct pressure, it fires the weld cycle.  The operator then releases the foot switch, allowing the head to retract.  Servo actuated heads use a servo driver and servo motor to drive the head down to a set position each time.  These are used for greater speed and control over the welding process.  For example, a servo head can rapid very quickly to the work piece, decelerating a millimeter before the electrodes touch, and then applying pressure softly as the electrode contact the work piece.  Monolithic heads are typically either manual or air operated. 

Electrode holders also have options for what type of electrode they can hold.  Some electrodes, mostly the parallel design, are square or rectangular bodied.  Other types are round bodied.  The round body electrodes typically come in 1/16", 1/8", 1/4", or 1/2" diameter designs, or their metric equivalents in the case of Avio electrodes. 

How We Can Help You

AVIO Welders

These AC spot welders are  most suitable for welding thick plates and copper stranded cable, as it can adjust the weld time through a wider range than other stored energy type of welders.  The lower peak current is less affected by dirt or stain on the work piece.  These are very suitable for integration with automation.  AIT builds all of our own electrodes for use in these and other welders that we provide to our customers.  We can provide custom electrodes and solutions for your welding applications.

Suitable weld heads and other accessories are available for all the welders featured below.  It is best to contact us and describe your welding application in detail, and allow our technician to work with you in determining the best power supply, weld head, and electrodes for your specific applications.

Sunstone Welders

These AC spot welders make use of an internal transformer that provides ample power for many applications, making them ideal for resistance spot welding and seam welding.  Both of these welders also make use of a microprocessor that allows easy setup and programming for complex welding sequences, such as linking different weld schedules together within the same job.  Either of these AC spot welders are capable of welding thicknesses up to 0.1 inch.

Advanced Modes:

• Dual Pulse Welding
• Multi-pulse Welding
• Seam Roll Spot Welding
• Seam Welding
• Temper Function

The seam welding function of these AC welders make them very popular.  The internal micro controller allows for complex seam welding sequences.

Features:

• Simple, User-Friendly Interface
• 110 V Single Phase
• Internal AC Transformer
• 4 Line Character Display
• Foot Pedal
• Single Pulse, Dual Pulse, Multi Pulse, Seam, and Rolling Spot Modes
• Up To 180 Welds per Minute
• Pulse length range excluding seam weld mode ( 16.67ms to 1.65 sec )
• Save up to 100 Programmable Schedules
• Size: 13.25" x 10" x 5.5" - 32 lbs
• Possible Applications: Brazing, battery pack assembly, resistance seam welding, resistance soldering, and general resistance welding.

• The favorite for welding micro wires and components

• Consistent and precise welding by high speed linear control

• 3 Feedback modes (constant current, voltage, or power)

• High speed welding (up to 5 shots / second)

• Pre-weld check function reduces spark problems

• Simultaneous graph of voltage, current, and power wave forms

Transistor welders are also known as Linear DC welders. In a transistor welder, energy is stored up in capacitors and released through transistors. This produces a result similar to the high frequency inverter power supplies. The output is in the form of clean square waves with very fast rise time. The transistor welders made by AVIO are closed loop designs, utilizing transistor controlled feedback with extremely fast response time, which are able to monitor the condition of the weld using one of three feed back modes, "constant current", "constant voltage", or "constant power". These feedback modes offer great advantages such as better process consistency between multiple weld stations, reduced number of bad welds, and real time automatic adjustment for variations in part thermal loading and plating. Linear DC welders do not use a transformer. These power supplies have the best low energy control, making them the favorite for welding micro wires and then foils. The major limitation is that the duty cycle is typically much less than one weld per second.

The Avio welders we are offering here are premium quality Japanese made welders. We stand by these welders and guarantee our customers support and assistance when you buy an Avio welder from us. All electrodes are manufactured by AIT in our facility in the United States. We can respond quickly to your inquiries or questions.

AVIO Inverter Welders 

• High speed and precise control of wave form

• 3 Feedback modes (constant current, voltage, or power)

• Pre-weld check function

• Up to 3 second weld time

• LCD graphic display of welding wave form

• Multi Transformer System
  

Welding power supplies come in two broad categories, "closed loop" and "open loop". Open loop designs are capacitive discharge welders and most direct energy, or AC power supplies. These essentially offer no feedback, meaning that a weld command or pulse is sent out, but there is no circuitry to verify how that pulse responds when it hits the point of welding. Closed loop welders are inverter type (high frequency inverter) and transistor type (linear DC) welders. These type of welders are able to control the shape of the welding wave form and monitor the condition of the weld using one of three feed back modes, "constant current", "constant voltage", or "constant power". These feed modes offer great advantages such as better process consistency between multiple weld stations, reduced number of bad welds, and real time automatic adjustment for variations in part thermal loading and plating.

Inverter welders use pulse width modulation to control weld energy. Through a series of rectifiers and switches, the resulting output current is in the form of DC current with an imposed low-level AC ripple. The time of each piece of a cycle can be controlled in sub millisecond increments. Inverter welders have high repetition rates, making them particularly useful in industrial automation.

The Avio welders we are offering here are premium quality Japanese made high frequency inverter welder. We stand by these welders and guarantee our customer support and assistance when you buy an Avio welder from us. All electrodes are manufactured by AIT in our facility in the United States. We can respond quickly to your needs and build custom electrodes to help resolve any welding issues you encounter. Contact us today to see how AIT can make your next welding project a success.