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Type CSR 102 Versaweld™ jig welding machines

For the flexible production and combination of different wire and sheet metal products.

Intelligent machine design combined with ergonomics and user-friendliness the new CSR 102 jig welding machines combine maximum flexibility with minimized downtimes thanks to modularity and intelligent smart jig design. The combination of different machine modules into a single system enables a complete product manufacturing in one operation. The possibilities of integrating “pick and place” as well as stud welding systems make this machine unique.

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Process all product variants and material combinations

  • Shelving systems in wire and sheet metal construction

  • Baskets and drawer systems up to a height of 400 mm

  • Three-dimensional applications such as fan protective grating and kitchen corner cupboards

  • Shopping trolleys and shop construction

  • White goods and various material combinations (wire, sheet metal, flat bar, etc.)

CSR protective grating
  • Reinforcement profiles for the stiffening of sheet metal panels

  • Sheet metal cabinets for changing rooms or tools

  • Switch cabinets and server racks

  • Weld studs/weld nuts for the installation of mounted parts

  • Car body parts

  • Sieves for agricultural machinery/combine harvesters

Advantages in order to make your production and processing faster and more affordable

  • Highest degree of flexibility due to the modular design

  • Perfect welding results by means of the 1,000 Hz medium frequency technology

  • Angled applications by means of programmable rotating electrode (continuously rotatable from 0° to 360°)

  • Vertical applications with freely programmable welding tongs (continuously rotatable from 0° to 360°)

  • Innovative solutions for any task, such as the quick procedure with the newly developed NC servo cylinder

  • Product heights of up to 400 mm

  • 9 servo motor axes for a maximum degree of precision and speed

  • Optimised setup and standstill times in combination with the tool changer

  • Combination of different materials by means of a tool changer with up to 8 different tools

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Down to the smallest detail: The CSR 102 Versaweld™ jig welding machine

Taking a closer look at the details of the CSR 102 Versaweld™ is worth your while. Here, you can see the

  • Technical data
  • Typical areas of application
  • Accurate information on the technology

of the CSR 102 Versaweld™ jig welding machine and you will learn why IDEAL utilises modular mechanical engineering in order to fulfil your requirements and expectations.

Working surface up to 3.000 x 1.200 mm as a rotary table version
Working height up to 400 mm
Medium frequency welding with 1.000 Hz technology
Available welding current 30 kA welding current
Welding tongs for vertical applications continuously rotatable from 0 – 360°
Servo motor welding cylinder up to 5 kN
Tool changer up to 8 different tools

IDEAL jig welding machines are used by leading manufacturers for the welding of wire goods for various products. Among others, they are used in the production of

  • Shelving systems in wire and sheet metal construction
  • Baskets and drawer systems up to a height of 400 mm
  • Three-dimensional products such as fan protective grating and kitchen corner cupboards
  • Shopping trolleys and shop construction
  • White goods
  • Pull-outs and fittings
  • Products for the automotive sector
  • Decorative fences
  • Gabions
  • Dishwasher baskets
  • Industrial mesh
  • Oven and stove grates
  • Rolling containers
  • Switch cabinets
  • Protective grating
  • Press-welded gratings
  • Safety equipment
  • Animal cages
  • Products for transport and logistics applications
  • Display stands and display articles
  • Fence panels.

Here, diverse material combinations such as wire, sheet metal or flat bars can be processed.

Depending on the particular welding task and requirements, alternating current, direct current or medium frequency technology is used. As a result of the concentration of the current to the respective cross point, straight, distortion-free and dimensionally accurate grates are achieved. Furthermore, with the programmable cascading of individual welding areas, the use in production facilities with limited power supply is also possible.

Extensive experience with resistance welding technology and a close, cooperative collaboration with our customers, the cooperation with technical universities and research institutes as well as an instinct for technology trends form the foundation of our high innovative strength. The basis of our development work lies in the continuous further development of our well proven machines with a focus on the best customer benefit and maximum efficiency. The CSR 102 Versaweld™ jig welding machine can be adapted to your specific application with practice-oriented and proven accessories. Particular attention is paid to the versatility and flexibility of the machine – to your benefit. In order to meet the requirements of your product, you can choose from a wide range of accessories. These options can even be retrofitted later on. Thus the welding machine is equipped for future tasks.

An overview of the CSR 102 Versaweld™ jig welding machine

The CSR 102 Versaweld™ jig welding machines are characterised by their versatile application possibilities and their easy handling. Products made of wire and/or sheet metal are inserted in jigs on the manually operated rotary table. While the products are fabricated on one side of the jig table, the operator loads or unloads the other side; this enables an optimal utilisation of the machine and minimises standstill times. Both table sides can be programmed independently from each other. Product changes and new set-ups are possible within the shortest time due to the intuitive programming method as well as the use of corresponding jigs.

IDEAL offers a wide selection of different table variants and loading devices. The shape and dimensions of the product mountings can be adapted individually to the requirement. With the use of NC-controlled axes, the machine can be programmed and controlled in X, Y and Z direction with an accuracy of tenths. In this manner, a maximum degree of precision and the best possible welding results are achieved.

IDEAL_CSR102_3D

The requirements of our customers as well as the market – in connection with continuous new and further development – form the basis for the accessories of our jig welding machines. Our machines are the embodiment of modular construction and can be adapted to your specific requirements with corresponding practice-oriented and proven accessories. With our wide range of accessories, you can adapt your jig welding machine individually to the respective fabrication process – also in future.

The various accessory elements can also be retrofitted at a later stage, giving the certainty that the welding machine will be equipped for future tasks. You will achieve investment security and the ability to respond to your market requirements in a flexible manner with the expansion or conversion of your system. In addition to traditional software updates, we also offer an upgrade of the switch cabinet components and electronics components.

Can be replaced and supplemented in a modular manner

Special solutions: Individual machine solutions for your specific requirements

Based on the proven machine concept CSR 102 Versaweld™, we facilitate special solutions – for the individual adaptation to the needs and requirements of our customers. Due to our knowledge, comprehensive solutions and production lines are also realised in an economical manner in the various dimensions.

Our competent team of engineers, design engineers and technicians will be happy to provide help and advice for the realisation of your project. The requirements are determined and planned in close cooperation with our customers. In the course of more than 90 years, we have acquired extensive knowledge in the field of welding technology and we have developed and constructed a corresponding large number of special machines.

The special solutions : Customized jig welding machines

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