Water Cooled Kickless Cables
Kickless Cable
Kickless Cable Assembly Process
Alternate Polarity separated by Separator
Hose Crimping for Kickless Cable
Resistance Checking of the Kickless Cable
Specification of Water Cooled Kickless Cable :
Design of Cable as per Customers Specification with very less tolerance.
Special type of rubber hose with the High flexibility, more than 10 Kg/cm2. Capacity and to protect to high temperature water for safe operation. Excellent cooling effect even in continued welding operation.
Copper wire size is 33 Gauge for 300 MCM & 400 MCM as per standard of RWMA.
Accurate copper straight lugs or copper bend lug with 99% conductivity of Electrolytic Copper. Little Impedance & little Reactance drop.
Fantastic water testing units with Pressure 10 to 12 Kg/cm2, each and every Cable are tested.
Good Quality product with Long Life and very competitive rate. Long cable life reduces cable cost per weld - the true measure of cost cable.
We have good team of engineers with more than 10 Years experience in same field.
Strict Quality Control during production, delivery as per schedule.
Easy for check & replacement & maintenance.
We have own Quality Assurance Plan of our products.
Maximum current available with different cable on different Transformer:
EMC : Eletromech kickless cable
First numeral : Normal sectional area of conductor.
Second numeral : Length of cable
• a) With a sub-cable 150 mm2 × 650 mm long + 1200 mm electrical Throat Depth × 200 mm Throat Gap gun
+ kickless cable.
• Tip to tip current is given.
Unique Technical Features:
Extra operations on each end of Electromech Kickless Cable.
These operations are necessary where wires are crimped in an exclusive male and female pattern to position the wires to achieve the best alternate polarity design. This ultimately results into less Kick in Kickless Cable without any shorting of inside wires while in weld operation and hence increases the life by two to three months.
Operation 1 & 2 : Copper strip using for Wire crimping in Hydraulic press & then soldering on both end lugs.
Operation 3 & 4 : Blanking of Non magnetic S.S. sheets - 2 times (One Male & One Female).
Operation 5 & 6 : Forming of straight Pipe (male) and taper Pipe (female)
Operation 7 & 8 : Spot Welding straight pipe (male) and taper Pipe (female)
Operation 9 & 2 : Crimping into male type and other into female type.
Operation 11 : Covering the male pipe with high quality imported heat shrink sleeve.
Secondary Welding Cable (300 MCM) Technical Parameter Chart :
Flexibility of Rubber Hose and Star separator is 48 to 50 Sour A. Over all finished Cable flexibility check by the Coiling around Wooden Former.
Flexibility of Rubber Hose and Star separator is 48 to 50 Sour A. Over all finished Cable flexibility checked by the coiling around wooden former.
• Little impedance and little reactance drop.
• High flexibility for good working efficiency.
• High resistance to repeating kicks and bending caused by electro-magnetic force induced by welding current and welding operation, and accordingly long life.
• Excellent cooling effect even in continued welding operation.
• Easy check, replacement, and maintenance.
• Covering of good pressure resistance, heat resistance, and wear resistance.
• The kickless cable is consumable part and required to be inexpensive.
• Long cable life reduces cable cost per weld - the true measure of cable cost.
Secondary cables for portable Spot Welding Machine
1. This specification consult to JIS C 9318
2. Ours secondary cable mainly include Kickless cable and single conductor cable.
1) Kickless cable: A low-reactance water cooled flexible cable composed of 2 separate conductors insulated mutually and braided into a single hose.
2) Single conductor cable: A water cooled flexible,in which each of go-and-return path conductors is braided into a hose,usually making a set.
3. Specifiction
4. Cable Model:
A. Kickless cable model:
Usually,we have 3 kinds of cross section 150sqmm*2, 160sqmm*2and 200sqmm*2,the satandard length is 2.4m.Also,we can make different length cable accroding to clients’ needs.
B. Single conductor cable,Aid cable:
We have 150/160/180/200/250sqmm cross section cable, the length is according to customers' needs.
The HTRF Cover hose was developed to combat the primary cause of water-cooled cable failure: wear through of the outer cover. Often a hose wears through due to abrasion on the welding equipment or production components. WATTEREDGE-UNIFLEX has developed a super high abrasion compound which can outlast other materials 40 to 1 against failure due to abrasion. This compound is integrated into the HTRF cover hose, which is available for all kickless cables and also for water cooled jumpers up to 600 MCM in size.
Also available is a high abrasion thin wall sleeve, which can be mounted over the standard kickless cable hose.
DC Cable / 500 and 650 MCM
Opposed polarity cables for high amperage, direct current applications.
These heavily reinforced, two conductor water cooled cables are primarily used on heavy duty spot welding stations for joining aluminum panels. This cable is designed to operate at welding currents typically in the range of 45,000 to 55,000 amps D.C.
Several design features maximize cable life and are exclusive to these WATTEREDGE-UNIFLEX cables:
Stranding is press welded to the terminal to provide the lowest possible electrical resistance properties and a virtually indestructible bond. (Patent # 4,640,982)
Opposed polarity for optimum efficiency.
High strength, high temperature teflon reinforced retaining rings throughout the entire cable length.
High pressure, impact resistant cover hose.
1/2″ or 3/8″ NPT water port
21/32″ diameter mounting hole