Electronic Components
Copper Wire Welding
In the realm of electronic-component manufacturing, the weld quality of transformers and inductors is a direct determinant of end-product reliability, while the ability to handle multiple product families is pivotal for raising production efficiency. Recently PDKJ supplied and commissioned a DTB-160 vertical medium-frequency inverter DC spot-welder for a Dongguan electronics processor. The machine not only cracked the tough job of welding transformer copper wire, but also seamlessly accommodates downstream products such as on-board transformers and all kinds of inductors—making it an “all-round weapon” on the customer’s line.
I. Project Background
The customer, a seasoned welding subcontractor based in Dongguan, has long provided joining services for magnetic components and power-supply products to the new-energy, photovoltaic, electronics, telecom and automotive sectors. Because its portfolio is so broad, the company insists on extreme welding accuracy, repeatability and cross-product adaptability. It urgently needed a single machine that could deliver pinpoint precision on one material yet switch effortlessly among many product families.
II. Production & Welding Requirements
Copper-wire welding on transformers is the customer’s core process. Traditional equipment had reached its limits: joint oxidation and deformation hurt both conductivity and cosmetics, and low throughput could not keep pace with volume orders. Worse, the upstream product mix is vast—planar transformers, DC-DC converters, low-frequency transformers, boost inductors, common-mode chokes, PFC inductors, differential-mode inductors, integrated inductors and more. Legacy machines required constant parameter tweaks or even hardware swaps, crippling overall efficiency.
The customer’s core requirements are clear: first, to completely resolve the quality and efficiency issues of transformer copper-wire welding; second, the equipment must offer broad adaptability, covering the welding needs of all types of transformers and inductors from upstream manufacturers; third, it must be easy to operate and run stably, ensuring consistency and reliability in large-scale production.
III. PDKJ Welder Highlights & Advantages
To answer the customer’s three core demands, the PDKJ team carried out on-site investigations and process validation, and finally chose the vertical medium-frequency inverter DC spot-welder as the solution. Its key advantages map one-to-one to every pain point:
1. Copper-wire welding finely optimized
Medium-frequency inverter DC technology delivers closed-loop current control with millisecond response; output is ripple-free. Tailored to copper’s high conductivity, it produces strong welds while drastically reducing oxidation and deformation, securing both electrical performance and cosmetic finish.
2. Universal compatibility, zero stress
The machine covers an exceptionally wide welding window. Beyond transformer copper wire, it handles auxiliary-source transformers, DC chokes, transformer + resonant inductors, common-mode chokes, PFC inductors, differential-mode inductors, and more—without frequent parameter changes. One unit covers every specification the upstream lines produce.
3. High speed, high stability, lower cost
Welding speed is >30 % faster than conventional equipment, easily meeting high-volume deadlines. A pure-copper transformer plus multi-channel water-cooling keeps the system running continuously at low energy, cutting long-term operating costs.
4. Plug-and-play operation
A color touch screen supports Chinese/English switching and stores multiple welding schedules. New operators can achieve consistent, category-spanning weld quality with almost no training.
Welding Machine Parameters
IV. Win-Win Cooperation: Make Metal Welding Easy for the World
Today, the PDKJ DTB-160 vertical medium-frequency inverter DC spot-welder is running stably on the production line of this Dongguan electronics company, fully resolving the customer’s core pain points: transformer copper-wire welds are smooth and strong, and repeated performance tests confirm that electrical conductivity is fully compliant; welding speed has risen sharply, cutting bulk-delivery lead times dramatically.
What pleases the customer even more is that the machine has successfully adapted to every transformer and inductor product from upstream suppliers—whether copper-wire welding on transformers or precision spot welding on inductors—completing all tasks efficiently without any extra equipment, greatly boosting production flexibility and service capability.
Centered on “Precision, Efficiency, Compatibility,” the PDKJ vertical medium-frequency inverter DC spot-welder moves from transformer copper wire to every kind of inductor, from single-material welding to multi-product adaptation, precisely solving the welding pain points of the electronics-manufacturing industry. Whether your company needs to conquer welding challenges with specific materials or faces multi-category welding demands for transformers, inductors, and more, PDKJ can provide a professional solution and truly Make Metal Welding Easy for the World!
Purchase Invitation
If welding issues with three-phase motor lead-out wires, automotive solenoid valves, on-board inductors & transformers, inductors, power adapters, or power cords are keeping you up at night, reach out to Guangdong PDKJ Automation Technology Co., Ltd. Our dedicated technical team, premium welding equipment, and full-coverage service system will deliver the most suitable joining solution for your needs. Let PDKJ become your trusted partner on the welding journey—together we’ll conquer every joining challenge, upgrade product quality and production efficiency, and propel your business forward. PDKJ, the welding expert always at your side, looks forward to cooperating with you!
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If you have welding machine requirements, please contact Ms. Zhao
E-Mail: pdkj@gd-pw.com
Phone: +86-13631765713
