Welding Equipment

The robust air cooled AC arc welder have been used for decades as power source for most of manual metal arc welding jobs. These welders are ideal for Rolling Mills, Cement, Plants, Thermal Power Projects, Shipyards and other industries.

Forced air cooled welders are used as a power source for argon gas shielded arc welding tungsten electrodes (tig) for the welding of aluminum & aluminum alloys. These welders are also available in Double Operator Model-EC (D/O).

» Construction
The set consists of heavyweight transformer with Turbofan Cooling for high duty cycle at all amperage. Wounded with copper wire, the transformer is housed in heavy steel frame covered with ventilated M.S. Sheets mounted on rubber wheels. Front wheel of the arc welders are fixed and rear wheels are swiveling type which allows great mobility. The current is controlled by air gap between Primary & Secondary coils with a magnetic shunt.

» Transformer
Doubled copper wound transformer conforming to IS:1851 standards (1975), having core of high grade electrical steel primary & secondary coils.

Coils are of electrolytic copper strips & wires covered with fiber glass and insulated with class 'F' duly vacuum impregnated.

Ideal for both ferrous as well as non ferrous metals, DC welding rectifiers are extensively used as power source for manual metal arc welding (MMAW) jobs with bare & coated electrodes. These welders are also used as alternative to DC welding generators. The welding rectifiers have no moving parts except the cooling, which ensures greater stability and low maintenance cost. Both main & control rectifier protected against surges by semi conductor devices for positive protections. M.C.B. is provided for protection of the current controller. The on-off switch on the front panel provides greater added safety to the users.

DC Welding Rectifiers can also be used as power source for plasma arc cutting gas shielded arc welding & for Tungsten Electrode (TIG) welding for welding of stainless steel copper alloys. Also suitable for special welding applications such as submerged arc welding and carbon air arc gouging.

Sterco also offers optional accessories with the welding set such as remote control with required cable length, voltmeter, Amp. meter and a set of welding accessories etc.

» Transformer
The heavy duty transformer with core of high grade electrical steel Welding current conforms to IS : 4559 1993. Rectifiers have a 3 phase full waive bridge circuit for higher efficiency and steady form. Rectifiers are mounted on three solid rubber wheels (Front wheels swiveling & steerable type by means of draw bar) for easy mobility, bye bolts have been provided for lifting the machine.

» Advantages
- Energy efficient operation.
- Does not create unbalanced voltage fluctuation on the other load connected simultaneously.
- Starts immediately even with low current.
- Low running and maintenance cost.
- Extremely low ripples in the output.

» Specifications
Rectifiers of higher ratings up to 800 - 1000 amps. with higher O.C.V (Open Circuit Volt) and multi - Operator welding rectifiers can also be made available on demand.

We offer precision gamut of spot welder (PEDAL) that is fabricated using finest quality raw material. Our electronic control system comprises of STERCO SOLID STATE CMOS INTEGRATED WELD TIMER having timing range 5-99-199 cycles, adjustable in step of one cycle by means of Thumb wheel switch along with heavy duty electromagnetic contactor for switching purpose. Tap changing switch in 8 steps from 50 to 100% for adjustment of welding current. A mechanism coupled switch provided in the machine which initiates the weld only after preset pressure is built up.

» The Electrode System
The rocker arm mechanism coupled with foot pedal is specifically used to attain the electrode force. The force can be varied by adjusting the nut provided on the back-rod below the compression spring of rocker arm mechanism.

» Cooling System
Arms, electrode holders, electrode etc are water cooled. Water cooled transformers can be availed at an extra cost.

» For Fine Control
Thyristor can be used to control heat current from 5 to 95% of the available current. Weld time is also adjustable from 1 to 99 cycles in step of one cycle each. A pair of thyristor can be used for switching purpose instead of electro magnetic contactor at an extra cost.

Features :
» Rocker Arm Type Spot Welders
The international standard machine is viable for mass production as it required less operational efforts. These machines are designed and developed to meet the demand of various metal fabrication shops.

» Advantages
Besides spot welding the machine can also be used for Electrobrazing, Cross wire welding and resistance heating.

» Salient Design Features
The machine is highly demanded for its rugged body and easy maintenance. A heavy machined bracket is provided on top of the frame for Rockering the upper arm holder. "T" stotted face plate allows both vertical and horizontal adjustment of lower arm. Special electrode holder clamping system provides an increased current carrying section. These are available for maintenance of electrical, electronic and mechanical components.

» Welding Transformer
With special design technique adopted to offer, maximum efficiency of the transformer, confirming to latest IS/4804 part I. It is Air/Water cooled, sandwitch construction of coils having core of high grade electrical steel. Class 'F' vacuum impregnated transformer helps to withstand higher temperature.

Rocket Arm Pneumatically Operated Spot Welder are ideal for mass production, where less operational efforts are required. Specially designed for sheet metal fabrication shops, this model can be used for electro brazing, cross wire welding, projection welding & resistance heating.

Features:
» Construction
The rugged construction of the machine with least moving parts ensures hassle free use along with minimum maintenance. A heavy Gun Metal bracket is provided on top of the frame for Rockering the upper arm holder. "T" slotted face plate allows both vertical and horizontal adjustment of lower This special electrode holder clamping system works to increase the current in the carrying section.

» Electronic & Electrical Control System
"STERCO" make SOLID STATE C-MOS INTEGRATED WELD TIMER with heavy duty electromagnetic contractor for switching purpose.

Timer consists of squeeze (Range 0-250 cycles, step less control), Weld Timer (Range will be 5-99-199 cycles adjustable in step of one cycle)and to adjust the welding. Current from 50 to 100%, one tap changing switch of 8 steps had been provided on the machine.

» Cooling System
Arms, electrode holders, electrodes etc. are water cooled. Water cooled transformers can be provided at an extra cost.

» Pneumatic System
The pneumatic system comprises of a pneumatic double acting cylinder, solenoid valve of 4 ways 5 port, filter, lubricator, regulator gauge and foot operated initiating switch for solenoid coil.

» Electrode System
The electrode force is attained through the rocker arm mechanism coupled with the pneumatic cylinder. This system provides easy adjustment of the electrode force with the help of Air regulator.

» For Fine Control
A pair of thyristor can be provided for switching purpose in place of electromagnetic contractor at an extra cost. By using thyristor, Heat Current can be controlled from 5 to 95% of the current available. Weld time is also adjustable from 1 to 99 cycles in step of one cycle each.

» Additional Features
Additional ARMS AND ELECTRODE HOLDERS are provided at extra cost.

Micro Wire Butt Welder suitable for butt welding of ferrous and non ferrous wires from 0.3 mm to 2.5 mm. Easy to operate, the table top model can withstand subsequent drawing of the wires.

» Welding Process
Micro Wire Butt Welder automatic welding machine has a set value of 10 for welding current and the initial upset gap. The upsetting pressure can be set according to the size of the wire. Special quick acting clamps are used to hold wire for perfect alignment of the ends to be welded. Welding is simply initiated by a press of button and the complete cycle is automatically completed with built in controls.

Wire Butt Welders are used for butt joining of wires/rods of mild steel, carbon steel, steel alloy copper, aluminum and brass etc. The clamping of the machines bring the end of the rods or wires together under pressure for welding. The end parts are welded by applying short circuit current to the joints. The jaws of the machines are arranged in such a way that it facilitates welding of wires over a wide range of diameters of specially shaped cross sections. The same Jaws can be used for annealing with extended jaws.

The mechanical timer provided with the system is automatically tripped, after the job is done. Welded joint can withstand high tensile and can be easily drawn upto minimum size.

» Transformer
The transformer of the welding system conforms to national and international standard specifications. Primary and Secondary wounding of th e coil are of solid electrolytic copper of ample section, suitable for withstanding continuously temperature of 155°C. The transformer is fitted in a light welded framework.

» Regulator
A regulator is provided on the primary side with 8 different stages to control the current based on the demand of the application.

» Additional Facilities for annealing at extra cost
- Extended annealing jaws from 4" to 10".
- Separate heat regulator for annealing with foot switch.
- Annealing time will be control automatically by providing an electronic timer.
- Lighting lamp with flexible stand.

Sterco Band Saw Butt Welder is the result of many years of experience, research and development. It is the most modern method of joining Band Saw Blades giving a joint strength 25% higher than that of the base metal strength. It eliminates the old process of overlapped brazing. Resistance welding is quick and automatic, thus eliminating human error and giving a perfect and strong joint.

The mechanical timer provided with the system is automatically tripped, after the job is done. Welded joint can withstand high tensile and can be easily drawn upto minimum size.

» Welding Process
The Band Saw Blades are cut straight exactly at right angles and free of burrs. Welding current, upsetting pressure and upsetting way are set according to the blade width the blade ends being rigidly clamped by special quick acting jaws. By Depressing the welding lever the automatic welding cycle starts. The two ends are heated upto forging temperature in a few seconds, then automatically forged (upset) and current switches off.