Coil Joining Solutions

Taylor-Winfield Technologies has the solution
to your welding needs and more. Choose from our
complete line of Coil Joining Welders.

WHY OUR CUSTOMERS PARTNER WITH
TAYLOR-WINFIELD TECHNOLOGIES

As a Capital Equipment Manufacturer, we provide standard & custom engineered parts production solutions, all under one roof. From concept through engineering, assembly and test, we have the expertise, resources, and commitment to ensure quality equipment & total “life” support for all the equipment we manufacture.

Research & Development Laboratory

The Research and Development​ Center can help improve part quality, quantify existing processes, create reliable parts production expectations, and establish machine performance criterion.

Aftermarket Spare Parts & Copper Products

Taylor-Winfield’s Aftermarket Spare Parts & Copper Products Group provides “life support”, parts and ancillary equipment for existing machines worldwide.

Worldwide Field Service and Support

Taylor-Winfield’s technicians have mechanical, electrical, & programming skills, enabling them to provide timely, quality service, and to supervise or perform on-site machine evaluations, repairs, & upgrades.

Laser Welding

Pushing Boundaries. Upholding Tradition.

Taylor-Winfield’s new Eclipse X1 is the most technologically advanced laser welder for metals finishing and galvanizing lines to date, eclipsing all other current systems on the international market. Made in the USA, the Eclipse X1 joins steel grades from LCS through AHSS and UHSS, as well as other metals such as aluminum and copper. Our laser welding system overcomes variation in strip shape and presentation and offers real-time feedback to ensure the highest weld quality.

Taylor-Winfield has a long and substantial history of providing the highest quality coil joining welding machines to the metals processing industry. Our new Eclipse X1 solid-state fiber laser welder is no exception. The development of this machine evolved from our vast experience manufacturing coil joining welders and the shortcomings we have seen from laser welding machines on the current market. After collaborating with the world’s top laser welding experts on its technical design, the Eclipse X1 is the most modern fiber laser welding system for coil joining applications.

Strip Material Specifications:

  • Steel Grades: Cold & Hot Rolled Steels (LCS, AHSS, UHSS, SS & Silicon)
  • Other Materials: Aluminum, Copper & Titanium (grades evaluated per inquiry)
  • Strip Thickness: 0.41mm to 4.00mm (0.016” – 0.160”)
  • Strip Width: 850 – 1930mm (33” – 76”)

Download the Exclipse X1 brochure here

ECLIPSE X1 LASER WELDER

  • Servo Controlled Carriage Drive for Laser Welding & Cutting Head Arrangements
  • Entry Clamp with Horizontal and Longitudinal Movement
  • Exit Clamp with Vertical Height Adjustment
  • Laser Cutting and Welding Heads with Integral Gas Shielding Delivery Systems
  • Modular Quick-Change Welding & Cutting Laser Heads
  • Servo controlled Upper and Lower Planish Rolls (selectable on/off)
  • Laser Weld Identification Hole Cutting 
  • “No-Touch” Scrap Handling System
  • Induction Heating Pre and Post Weld Heat Treatment Power Supplies, Coils & Support Structure (Optional)
  • Real-Time Weld Quality Monitoring System, Weld Profiling and GOOD/BAD Weld Quality Feedback
  • Dual Screen HMI Operator Station with Live Video Feed
  • Machine Operation and Verification System with Data Acquisition, Analysis and Reporting; Industry 4.0 Ready
  • Programmable Logic Controller (PLC) for Machine Sequences
  • Connectivity: Profinet & I/O Link
  • Live Online Remote Machine Monitoring Support via TWConnect

Spot Welders

STANDARD CIRCULAR & LONGITUDINAL

Spot welding is the most basic and generally, the most economical of all resistance welding techniques and lends itself to many forms of mechanization and automation. It can be used where speed is not a critical factor, double-thick lapped joints are acceptable, and normal electrode maintenance time is tolerated.

Min. Max.
Coil Width 80” (2030mm)
Coil Thickness .250” (6.3mm)
spot-welder-coil-joining_265x265
spot-welder-coil-joining

The top 3 types of spot welders are listed below:

Forces

The forces required for flash-butt welding are established by the forge strength of the materials being welded. The strength classifications of steel are:

  • Low Forging Strength: (10,000 psi) SAE-1020, 1112, 1315, NAX9115, along with trade names such as Cor-Ten, Yoloy, Ductiloy, Cromansil, etc.
  • Medium Forging Strength: (15,000 psi) SAE-1045, 1065, 1335, 3135, 4130, 4140, NE- 8442, 8640, 9440, 9540, 9640, etc.
  • High Forging Strength: (25,000 psi) SAE-4340, 4640, Stainless steel of the 400 series (13% CHROMETYPE), 300 series stainless steel (18% CHROME-8% NICKEL), high speed steel, Sil-Chrome, special tool and die steels.
  • Extra High Forging Strength: (35,000 psi) Any special steel having extra high compressive strength at elevated temperatures. NOTE: Hardenable steels may require pre/post-heating either in the welder or a furnace.

The selection of a standard machine or the design of a special welder will be determined by the upset forces, along with the necessary clamp forces required as a result of the sectional area of the material being welded.

Construction

Flash welders consist of the three main sections each of heavy duty construction.

The MAIN FRAME is made of heavy duty welded construction and designed for maximum accessibility for ease of maintenance and adjustability. Mounted to the frame are the welding transformer, upsetting mechanism, upset slide/clamp, stationary clamp, four sealed main bearing boxes with precision roller bearings.

The WORK CLAMPING MECHANISMS are normally vertically operated pivoting lever-arms mounted integral with the fixed and movable platens. Each consists of steel clamping levers on heavy duty hardened and ground pivot pins and bushings. The ends of the pivot-pin bearings are sealed to protect them from weld flash. Lubrication of the bearings is through single point Alemite fittings.

The clamp levers are usually operated by double acting direct cylinders, either pneumatic or hydraulically operated. The piston rods are protected by sewn leather bellows. Depending on the application, these clamp levers are designed to provide from .5 to 2.5 times the upset force. Other types of clamping mechanisms are available optionally as required.

The Upper Electrodes are recessed in the clamping levers. They can be arranged for adjustable/fixed or self-equalizing alignment with the lower dies/work piece.

The Lower Electrodes are often supplied so that the electrode on the movable platen is adjustable horizontally and the electrode on the stationary platen is adjustable vertically. This allows precision alignment of the welded parts.

UPSETTING MECHANISM: The motor operated device for controlling the flashing and upset movement of the upset slide is a gear box mounted Flashing Cam on which a steel roller runs. The cam shaft is supported by an outboard anti-friction bearing with the flash/upset cam located between the outboard bearing and the first bearing in the gear box.

A variable speed 3 phase, 60 hertz, 230/460 volt motor provides a flashing time range of approximately 3 to 1. The cam shaft carries timing cam switches to turn off and on the welding power and stop the motor after each weld cycle. The upset slide is returned to the load die position by a single acting air cylinder.

When welding non-ferrous materials the upsetting action may be controlled by the addition of necessary pneumatic devices between the flashing cam and the upset slide to increase the upset speed for greater control of the forging force.

The flash and upsetting action may also be controlled hydraulically by use of a double acting hydraulic cylinder in place of the motor driven gear box and flash cam. An electro-hydraulic servo control with provisions for multiple welding programs and data recovery is available.

All welders are provided with control interlocking features to provide maximum safety to the operator and to prevent damage to the welder or work spoilage because of improper operator actions.

Welding Power Supply

These welders may be provided with one of three types of power sources.

SINGLE PHASE welder transformer rated at 50% duty cycle per RWMA standards selected for KVA rating based on power required for welding and production considerations.

SINGLE PHASE D.C. power pack with silicon diodes arranged for full wave rectification of the weld transformer secondary current.

THREE PHASE D.C. power pack with silicon diodes arranged for full wave rectification of the weld transformer secondary current.

The power supplies are mounted at the rear of the main frame and are sealed to prevent flash particles from entering the power supply area. They are connected to the stationary and movable platens by heavy water-cooled copper buss bars and flexible band connectors. Transformer primary tap switches are included for a wide range of welding applications.

Welder sizes range from the B-2.5 Butt welder for band saws, providing 2.5 KVA, 1 phase transformer and 1200 pounds upset force, to the B-1600 Butt welder with 1600 KVA transformer and 1 million pounds upset force for aircraft landing gear.

Machine frame sizes are standardized according to upset force such as 5000, 10,000, 20,000, 40,000, etc.; the electrical rating varies proportionally with the power required and the duty cycle of the machine.

Taylor-Winfield’s heavy-duty, power traversed spot welder has found wide acceptance in heavy gauge processing lines. The welding gun is moved by a manually controlled motorized drive. The operator thus controls spot spacing and the quality of spots.

 

Seam Welders

STANDARD CIRCULAR & LONGITUDINAL

Taylor Winfield Technologies’ seam welders deliver high performance and efficiency for your operation with a wide range of welding techniques to achieve any joint configuration.

SEAM WELDER MACHINE TYPES

MACHINE UPGRADES

  • Post Weld Induction Annealing- Inline & free-standing systems
  • Weld Seam Monitoring
  • Welder Control Systems
  • Weld Testers/ Weld Wheel Dressers
  • Machine Reconditioning Service
  • Punching/Notching Machines

Seam Welders

The main frame of these seam welders is of heavy, rigidly reinforced welded steel construction for a minimum of mechanical deflection but a maximum of accessibility and neat appearance. The lower conductor support or knee is a heavy steel fabrication keyed to the frame for accurate vertical adjustment. The upper conductor is insulated from the frame, while the lower conductor is grounded to the frame, therefore work support tables or conveyors can also be grounded.

In addition, we stock a complete inventory of replacement parts and in-stock components can be shipped within 24 hours of order receipt. When you buy from Taylor-Winfield, you get sound technical advice, competent service and continued performance backed by single source responsibility.

• Heavy, reinforced welded steel construction with current collector bearings.

• Straddle type bushing bearings are provided for longitudinal configuration.

• Tapered roller bearings carry the weld force load with absolute minimum friction and maintain   precise alignment.

• Oil bath for lubrication and heat dissipation with water cooled shaft and copper housing; provide high welding capacity at high duty cycle with a minimum of maintenance

• Exceptionally low friction air cylinders.

• Highly efficient water cooled welding transformer with Class F (155°C)

• Insulation made in accordance with RWMA specifications.

• Speed control valves to control ram movement.

• Upper head adjustable for in/out wheel alignment.

• Tap switch for multiple steps of transformer secondary voltage.

• Two stage foot switch with pressure switch interlock.

• Bushing type secondary current bearings; class 2/class 3 alloy combination.

• Variable speed D.C. motor for wheel drive.

• Single gear, single knurl or single friction drive.

• Pair of wheel electrodes, RWMA Class 2.

• Single phase AC or three phase MFDC.

• Weld force chart, force vs. cylinder air pressure.

• Open drain water system with inlet manifold and flow adjusting valves.

• One set of instruction manuals and standard flint gray paint.

Circular - wheels are perpendicular to the welder throat and are the most popular for making long seams in flat sheet or around flanges, as in fuel tanks or around a cylinder.

Longitudinal - wheels are parallel to the welder throat and the lower conductor is usually an unsupported round horn which allows clearance in welding the longitudinal seam of a cylinder or barrel.

Universal - Capable of conversion to either circular or longitudinal rotating the upper weld head and replacing the lower arm. Two lower arms would be provided

Flash Butt Welders

STANDARD CIRCULAR & LONGITUDINAL

Flash-Butt Welding is an ultra-fast joining process with fusion occurring over the entire weld area simultaneously. It is the only resistance welding technique in which surface scale has little or no effect on the weld quality and consistency — a major reason for its use in pickling lines. After trimming, flash-butt welds are as thin as the strip itself and pass readily through subsequent reduction and forming equipment. In most cases, the welds lose their identity and continue on into the consumer product. Flash-Butt Welders predominate in pickle lines, but are also used in heavy-gauge Coil Preparation, Shot Blasting, Side Trimming and Slitting Lines, and Welded Tube and Pipe Mills. Combination Flash-Butt Welders, appropriately named because they have a built-in, draw-cut weld trimmer which, in one stroke, removes the excess metal extruded to the surfaces of the strip during the upsetting (forging) portion of the welding cycle. A transfer mechanism successively moves the joint to the trimming station and other optional work stations, which include an edge punching or notching station and/or induction post-heating system. The latter minimizes costly strip breakage by tempering the heat-affected zone in alloy steels susceptible to treatment.

CFBW Features

Min. Max.
Coil Width 52″
1320mm
100″
2540mm
Coil Thickness .046″
1mm
.375″
9.5mm
Coil-Joining-264x264

Weld Description

Weld equals parent metal thickness

Weld equals parent metal thickness

Forgiving welding process compared to Laser and other joining processes.

  • Skilled Trade personnel do not need extensive training to operate and maintain the welder.
  • No need to release tension in your mill to pass the weld -creates a “Rollable Weld”.
  • Less concern about weld breaking when moving across strip support and tension rolls.
  • In many applications, the weld does not have to be removed before subsequent processing coating, annealing, or galvanizing the strip.
  • No damage to seals, rolls or bearings when passing the weld through the line.
  • Less waste and scrap.
  • Lower initial investment, operating and maintenance costs than TIG, MIG or Laser welding systems.
  • Fast cycle time – typically less than 60 seconds for the maximum width and thickness.
  • Rugged “O” frame configuration.
  • Hydraulic entry and exit clamps with quick change clamp liners.
  • Precision linear motion control of welding platen.
  • AC or DC weld current available.
  • Automatic weld parameter set-up with “Upper Level” computer communication.
  • Various PLC’s available – GE Fanuc, Siemens, Rockwell Automation (Allen Bradley).
  • “Upper Level” computer communication via Profibus, Ethernet, or TCP/IP protocol.
  • Matrix or algorithmic weld parameter adjustment control.
  • Close-coupled transformer, secondary bus bar and welding electrodes – highest weld current density for any flash welder and lower energy usage!
  • Automatic centering guides
  • Automatic strip cross alignment
  • Closed loop water chillers
  • Notchers for trimming strip edges
  • Weld quality “bulge” tester
  • Weld temperature monitoring
  • Weld wheel dresser

Arc Welders

STANDARD CIRCULAR & LONGITUDINAL

Arc Welding is the most versatile of all strip welding processes. It is applicable to almost all ferrous and non-ferrous metals in a broach range of thicknesses and offers a wide selection of parameters to meet a precise requirement. It is often used when a butt-type joint is mandatory, and occasionally when a rollable weld is needed.

The most popular types of fusion (Arc) welding processes are:

  1. Plasma Arc Welding
  2. Submerged Arc Welding (SAW)
  3. Gas Tungsten Arc Welding (GTAW) (TIG)
  4. Gas Metal Arc Welding (GMAW) (MIG)

ARC Welder Features

Min. Max.
Coil Width 24″
610mm
84″
2135mm
Coil Thickness 0.45mm (0.018”) 25mm (1.0”)

Weld Description

GTAW- Weld near parent metal thickness

GMAW- Weld near parent metal thickness after inline trimming

Forgiving welding process compared to Laser and other joining processes.

  • Skilled Trade personnel do not need extensive training to operate and maintain the welder.
  • No need to release tension in your mill to pass the weld -creates a “Rollable Weld”.
  • Less concern about weld breaking when moving across strip support and tension rolls.
  • In many applications, the weld does not have to be removed before subsequent processing coating, annealing, or galvanizing the strip.
  • No damage to seals, rolls or bearings when passing the weld through the line.
  • Less waste and scrap.
  • Rugged frame configuration.
  • High precision pneumatic or hydraulic single or dual resquaring shear with four sided cutting blades available.
  • Pneumatic or hydraulic entry and exit clamps with quick change clamp liners.
  • Urethane clamp inserts to prevent strip slippage and separation.
  • Precision linear motion control of welding carriage.
  • Automatic scrap removal.
  • Automatic weld parameter set-up with “Upper Level” computer communication.
  • Various PLC’s available – GE Fanuc, Siemens, Rockwell Automation (Allen Bradley).
  • “Upper Level” computer communication via Profibus, Ethernet, or TCP/IP protocol.
  • Matrix or algorithmic weld parameter adjustment control.
  • Automatic centering guides
  • Automatic strip cross alignment
  • Closed loop water chillers
  • Notchers for trimming strip edges
  • Weld quality “bulge” tester
  • Weld temperature monitoring
  • Weld “tip” dresser

Post Weld Heat Treatment

STANDARD CIRCULAR & LONGITUDINAL

Many of today’s “automotive grade” Advanced and Ultra High Strength Steels (AHSS and UHSS) including Dual Phase, TRIP, high boron and other complex phase steels require post-weld induction annealing to temper the weld interface and restore ductility for subsequent processing in the production line.

Screen Shot 2019-01-04 at 12.45.09 PM
Screen Shot 2019-01-04 at 12.45.15 PM

POST WELD INDUCTION ANNEALING FEATURES

New and existing seam, flash and laser welders can be upgraded to include post-weld induction annealing. Taylor-Winfield’s Induction Heating Product Group and trained field service personnel are dedicated to providing power supplies, coils and fully integrated systems to customers worldwide. We have been supplying post-weld induction annealing systems for coil joining and other applications since the 1960’s.

Taylor-Winfield can assist with your welding challenges. Contact us today to discuss your machine upgrade needs and options available. Upgrades are available for other manufacturer’s welders.

Post-weld induction heating can be fully integrated into an existing welder with complete operator interface through an HMI or provided as a free-standing system with independent operation and control. All systems include weld temperature pyrometer control and power supplies with automatic load tuning that adjust the heat input based on feedback from the pyrometer.

Solid state IGBT based microprocessor control Kilowatt range sized to application, machine and cycle time requirements Pyrometer controlled temperature regulation Automatic load tuning “Upper Level” communication capability available Full machine integration available, including: Annealing temperature control Welder and Annealing system compatibility Single Operator HMI Interface Welding parameter matrix updated to include annealing temperature control Full system diagnostic capability Interactive display for initial set-up, tuning and maintenance of power supply Power supply screen will display: Start Stop Ready Power Voltage Current Frequency Energy All fault conditions (individually specified) Pyrometer annealing temperature reading.

Welder Rebuild & Upgrades

STANDARD CIRCULAR & LONGITUDINAL

Existing coil joining welders can be upgraded to optimize welder performance and expand the range of materials capable of being joined by an installed machine. Modernizing and upgrading an existing machine with new welding controls, machine PLC control functions and other mechanical and electrical upgrades can add years of performance to an installed machine.

MACHINE UPGRADES

  • Post Weld Induction Annealing- Inline & free-standing systems
  • Weld Seam Monitoring
  • Welder Control Systems
  • Weld Testers/ Weld Wheel Dressers
  • Machine Reconditioning Service
  • Punching/Notching Machines
  • Cross-Cut Flash Trimmers

Forgiving welding process compared to Laser and other joining processes.

  • Skilled Trade personnel do not need extensive training to operate and maintain the welder.
  • No need to release tension in your mill to pass the weld -creates a “Rollable Weld”.
  • Less concern about weld breaking when moving across strip support and tension rolls.
  • In many applications, the weld does not have to be removed before subsequent processing coating, annealing, or galvanizing the strip.
  • No damage to seals, rolls or bearings when passing the weld through the line.
  • Less waste and scrap.
  • Rugged frame configuration.
  • High precision pneumatic or hydraulic single or dual resquaring shear with four sided cutting blades available.
  • Pneumatic or hydraulic entry and exit clamps with quick change clamp liners.
  • Urethane clamp inserts to prevent strip slippage and separation.
  • Precision linear motion control of welding carriage.
  • Automatic scrap removal.
  • Automatic weld parameter set-up with “Upper Level” computer communication.
  • Various PLC’s available – GE Fanuc, Siemens, Rockwell Automation (Allen Bradley).
  • “Upper Level” computer communication via Profibus, Ethernet, or TCP/IP protocol.
  • Matrix or algorithmic weld parameter adjustment control.
  • Automatic centering guides
  • Automatic strip cross alignment
  • Closed loop water chillers
  • Notchers for trimming strip edges
  • Weld quality “bulge” tester
  • Weld temperature monitoring
  • Weld “tip” dresser