Since our foundation in 1923, IDEAL has been characterised by ever-growing success. This is the result of the continuous technical further development and quality of our machines and systems.
The special machines, which are developed in accordance with the individual needs of our customers, are an important mainstay of IDEAL. After determining the customer’s problem or issue, our design department seeks and identifies the optimum technical solution, and then designs, manufactures and tests the machine until it is ready for operation. Flexibility and tailored, customer-oriented solutions are the roots of our high innovative strength here.
On all machine types, the compact and robust machine design with intuitive operator guidance is oriented towards industrial usage in production.
When designing the special machines, the operator is the main focus. For this reason, particular emphasis is 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.
A wide range of products are manufactured using customer-specific special machine solutions from IDEAL.
Starter ring weld seam
Automotive rim weld seam
Welded motorcycle rim
The resistance upsetting machine shown on the left is used to produce bolster-upsetting on professional knives.
The machine was designed and developed by IDEAL as a special machine in accordance with customer requirements.
The material pre-heated by the machine in advance is upset in the next process step.
The clamping pressure and jaw distance can be adjusted to the material to be upset.
|Max. upsetting force [kN]||50|
|Clamping force [kN]||50|
Nominal power at 50% duty cycle
2 x 100 = 200 kVA
The upsetting machine heats the material and compresses it in a controlled process.
The blanks are inserted by the feed unit and clamped with a clamping device.
The parameters must be set to the material to be welded.
After pressing the “Start welding” button, the set machine functions run automatically.
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.
Hydraulic vertical clamping device.
Thyristor-controlled automatic annealing system, type GAP for automatically annealing high carbon steel - consisting of:
Stacking magazine for accommodating the blanks
Pneumatic vacuum gripper for transporting the flat bars out of the magazine transfer position into the clamping device.
Central electronic control unit and data storage (for double system)
The following phases of the machine operation can be adjusted:
Upsetting pressure through proportional pressure reducing valve:
Fault diagnostics with clear text display
The ball stud welding machine from the machine series type VPS is an automatic machine for welding ball studs. These welding machines are used to weld balls onto the end faces of studs fully automatically.
The automatic filling of the bins with balls and studs enables many hours of unattended production. Counting the finished products takes place fully automatically in the containers provided.
The medium frequency welding and monitoring system delivers a stable process with low fluctuations and very high precision.
The geometry of the welded ball studs is checked by a camera system, the data is evaluated and stored on a continuous basis, and faulty products are separated.
The annealing process after welding guarantees the maximum in fatigue strength and operational stability.
The cooling section establishes the best preconditions for optimally joining the welds, ideal for the requirements of the automotive sector.
The VPS machine series with an extensive range of machine types has been used for many decades in a wide variety of companies and industries, so we are able to draw on a wealth of experience. This means we can offer you the best possible solution for your needs and deliver the right tool for your end product with the best quality.
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.
|Filter material / day||12,500 m|
|Coils / day||70|
|Filter material / day||2,500 kg|
|Current consumption / day||5,000 KW|
|Switching operations / day||20,000,000|
- Search units for errors smaller than 0.1 mm
- Linear motors
- Welding units with 1 MW power
- Decoiling systems with levellers
- Surface control systems
- Marking units
- Stamping technology with servo-hydraulics
- Circulating storage unit
- Welding technology with 3-phase direct current with current monitoring
- Rotating full bending units
- Discharge stations with defective part identification
The machines of type CSR 102 Versaweld™ are characterised by their diversity, as well as a high degree of flexibility. With the use of the most diverse, practically oriented options, the modular construction of the machine enables the individual implementation of the customer and therefore product-specific requirements. With the CSR 102 Versaweld™ you can manufacture highly efficient three-dimensional products with a product height of up to 400mm.
We are there – no matter how far away you are. You invest a great deal in a new IDEAL machine. This is why it is clear to us: We continue to be there for you after the purchase – as long as you wish.
We want to meet your expectations even after the purchase so you become a long-standing, satisfied IDEAL partner.
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