Welding solutions for automotive customers

Welding solutions for automotive customers

For many years, we have been an accepted partner of the automotive supplier industry.

Our customers in the automotive sector are national and international companies.
We offer them automated welding machines and robot solutions based on resistance welding technology.

Programmable NC-controlled multi-spot or projection welding machines are available to produce a wide range of joints.

Typical automotive applications for our resistance welding machines are:

  • Rims for motorcycles, cars and utility vehicles
  • Starter rings
  • Stabiliser bars
  • Nut and bolt welds
  • Reinforcement profiles on doors or chassis
  • Seat frames produced from sheet metal, tube or wire
  • Lumbar supports
  • Aluminium frames for sunroofs

Furthermore, we also design special solutions, such as a production line for particulate filters, for our automotive customers.

On all machine types, the compact and robust machine design with intuitive operator guidance is oriented towards industrial usage in production.

When designing the machines, the operator was the main focus. For this reason, particular emphasis was placed on easy and ergonomic operation.

Used around the world, IDEAL welding machines have been proving their quality and reliability on a day-to-day basis and have been doing so for decades.

Read the list of the most important features of

  • Type AS
  • Type VPS
  • Type CSR 102 Versaweld™

See also:

  • Solutions for the » joining of steel, aluminum and copper wires
    » Learn more
  • Option » dual force welding (DD) process for the processing of non-ferrous metals
    » Learn more
  • Series production of wire products in large quantities
    » Learn more

Some application examples:

A wide range of products in the automotive sector can be processed on the resistance welding machines.

Get to know our solutions:


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IDEAL is a pioneer in the design and development of flash butt welding machines. Flash butt welding machines of type AS are used in the automotive sector in particular for the economical welding of rims, rings and starter rings.

They are characterised by high welding quality and strength, short welding times and high reproducibility of the welding parameters.

With the use of the most diverse, practically oriented options, the modular constructionof the machine enables the individual implementation of the customer and therefore product-specific requirements..

Max. upsetting force [kN] 15 – 500
Nominal transformer power (alternative) [kVA] 30 – 1200
Weight of basic machine [kg] 1.200 – 22.000
Welding cross-section, unalloyed steel [mm²] 15 – 10.000
Welding cross-section, alloyed steel [mm²] 15 – 8.000
Welding cross-section, stainless steel [mm²] 15 – 4.000
Welding cross-section, aluminium [mm²] 15 – 2.500
Width dimensions [cm] 150 – 400
Height dimensions [cm] 170 – 280
Depth dimensions [cm] 120 – 250

Flash butt welding is utilised in a wide range of applications in the automotive sector due to its productivity and reliability in the attainment of a robust and consistent welding result.

With this resistance welding process, the energy is transferred to the parts to be joined in particular through resistance heat.

The workpieces are positioned opposite each other. The flash butt welding process is broken down into preheating, flashing and upsetting.

Preheating takes place under low welding pressure. By allowing a large amount of current to flow through, concentrated heat is generated at the contact point between the two surfaces lying against each other. The effect of this heat melts and splashes the metal at the contact point. When the welded joint has been heated up to a certain temperature, the flashing begins and the surface material is burned off. This leads to an even and clean connection surface. The melting loss consists of molten and oxidised material. After flashing off, upsetting begins and the two surfaces are pressed together with high force to create a faultless joint.

The upsetting causes a thin, brittle welding burr. Its size is dependent on the respective cross-section. The burr can be easily removed by grinding, milling or similar processes. Deburring in the welding machine is particularly efficient. Plane deburring machines and shear deburring devices are used for this purpose. The deburring takes place after an adjustable cooling time, whilst still red-hot. The deburring process is automatic and takes just 1 – 4 seconds depending on the length of the seam to be deburred.

  • Machine housing as a welded steel structure
  • Drive for welding carriages
  • 2 welding transformers, water-cooled
  • Hydraulic unit with oil tank and valve linking
  • Hydraulic clamping device
  • PLC controller in a separate control cabinet

Dual force butt welding machine

Welding solutions for starter rings in the automotive industry and steel rings in heavy industry

The equipment of the machines type DD0 can be supplemented with various annealing processes (according to the requirements of the material to be processed) and deburring devices as well as machines and devices for welding seam preparation and post-processing.

With the double pressure welding machine DD0 200 from IDEAL-Werk, the heat-affected material made of ferrous or non-ferrous metal is almost completely pressed out of the welding zone after the welding process. This improves the mechanical properties and the construction of the weld. With the DD0 type series, a high welding quality and enormous strength can be achieved. At the same time, the machine is characterized by high reproducibility of the welding parameters and low-spatter welding.

The IDEAL solution for your areas of application in the automotive industry.

IDEAL Dual Force Upset Butt Welding Machine type DD0 200 S-K

For serial welding and deburring of steel rings, radial and axial aligned, clean and dry, shotblasted surface, ring ends in cut quality – manual loading and unloading of rings by operator – Barcode scanner (4.0) as an option.

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Product specification    
Section of rings ~400 – 1.200 mm²
Width of rings ~24 – 55 mm
Height of ring ~18 – 22 mm
Inner diameter of ring ~345 – 450 mm

Special production line solution for particulate filters

Working together with our customer’s product development department, we developed the production line for particulate filters as an individually tailored solution.

It was necessary to pay particular attention to the extremely high requirements for product quality, the reproducibility of the product characteristics and the detection of primary material and production defects.

We would be delighted to assist you with the production-oriented product development.

Filtermaterial/day 12 500 m
Coils/day 70
Product weight/Tag 2.500 kg
Power consumption/day 5000 KW
Switching operations/day 20.000.000
  • Sucheinheiten für Fehler kleiner 0,1 mm
  • Linearmotoren
  • Roboter
  • Schweißeinheiten mit 1 MW Leistung
  • Abcoilanlagen mit Richtwerken
  • Oberflächenkontrollsysteme
  • Markiereinheiten
  • Stanztechnologie mit Servohydraulik
  • Umlaufspeichereinheit
  • Schweißtechnologie mit 3-phasigem Gleichstrom mit Stromüberwachung
  • Rotierende Vollbiegeeinheiten
  • Ausschleusstationen mit Fehlteilkennzeichnungen

JIG resistance welding machines of type CSR 102 Versaweld™

Die Maschinen vom Typ CSR 102 Versaweld™ können dank ihrer enormen Flexibilität in einer Vielzahl von Anwendungen eingesetzt werden. Der modulare Aufbau mit unterschiedlichsten Optionen erlaubt die individuelle Anpassung an produktspezifische Produkt- und Produktionsanforderungen. Mit der CSR 102 Versaweld™ fertigen Sie hocheffizient dreidimensionale Produkte mit einer Produkthöhe bis 400mm.