Products

Our products - Modular design for standard or tailor-made concepts

Stud welding has now become a highly sophisticated technology. This specialty in automotive engineering places the highest demands on equipment, bolts, welding processes and metallurgy.

We have been mastering all these demanding requirements for decades and have the right products for all applications for our customers on offer - of course with all associated services such as commissioning, training, maintenance, service and spare parts supply. And all of that worldwide.

Stud welding systems from AVISTUD with redundant system monitoring fulfill the performance level “d” according to the requirement of the European Machinery Directive. A power source can be used for stud, TARC- and TARC-nut welding and operating up to 5 feeders. With the optional feed monitor up to 6 positions can be tracked and individually configured. The Power-Safe Mode allows low power consumption during idle state. The Weld Impedance Control warns when the maximum welding circuit impedance is exceeded.

With the different types of welding heads, every welding task can be fulfilled.

Power Sources

For the power sources, special requirements exist today in stud welding.

The different materials used in body construction require a high degree of flexibility and modern interface communication at maximum duty cycle in multi-shift operation.

Just the right requirement for our key products N4s and N4s-AC.

N4s INVERTER — universal and flexible

  • For all known studs of the short cycle drawn-arc stud welding method
  • Customer-specific interfaces to robots/transfer lines (parallel interface, InterBusS, DeviceNet, EtherNet/IP, ProfiBus, ProfiNet, )
  • All AVISTUD FSE feeders and the related welding tools from the N4s-System can be combined and used (standard polarity or reverse polarity for up to 5 feeders and/or welding tools)
  • Only one power source for stud welding, TARC welding and TARC nut welding
  • Multiple possibilities of networking and PC-supported quality monitoring

N4s-AC

  • The N4s-AC generates regulated DC and AC currents from 150A to 1800A.
  • With the new AC module, up to 5 welding heads can be operated
  • It generates a square-wave alternating current with a frequency ranging from 0 to 500 Hz using the regulated direct current of the N4s welding device.
  • This alternating current can be set separately in the frequency as well as in the level for the positive and negative half-wave.
  • By using the 1000s AC module, any standard N4s welding machine can be retrofitted as an AC source

AVISTUD feeders work quietly, economically and reliably.

Due to the modular design, tailor-made system configurations of single or multi-point systems are possible. Each feeder can easily be converted to another type of stud by changing the feeder unit as requirements change.

FSE 1000s

The new stud feeder FSE 1000s is a further development of the proven and frequently used stud feeder FSE 100.

  • ECO conveyer concept
    • New seperator for all current stud variants
    • High air consumption savings
    • Reduction in noise level
  • Performance Level „d“
  • Straightforward changing of the stud-specific conveyor module

FSE 5000s

The new stud feeder FSE 5000s is a further development of the proven and frequently used stud feeder FSE 500 for seperating and feeding T-studs.

  • Modular design
    •   Provides a high level of flexibility and serviceability
    •   The servo modul can also be used as a control box for other welding tools
    • Up to 5 feeders and bunker units can be operated from one control box
  • Performance Level „d“

TARC Welding

The innovation from the leader in stud welding technology

  • TARC welding offers the possibility to weld non rotation- symmetric components in one step on the base material.
  • A robot moves the welding head, which controls the handling of the component and the TARC welding process itself.
  • The component is welded frontally on the base material different from spot welding. This reduces the weight of the total assembly group and saves costs
  • of material.

AVISTUD offers the right type of welding head for every welding job.

The modular and robust construction is service-friendly and allows fast cycle times. All connections and media hoses are compactly integrated in the head connection. The head connection is positioned within the interference edges and allows a quick change. Due to the compact anodized aluminum housing, the use of a protective cover is not required.

AVISTUD welding heads do not require a support leg due to the servo-electric path monitoring and reach thereby also complicated component geometries, such as beads, radius, concave or convex surfaces.

KSE 1000s

  • Modular, short and robust construction
    • Shorter than the KSE 100 (approx. 50 mm) / Up to 80 mm shorter depending on the
      loading head variant
    • Base body consists of one part -> No build-up of production tolerances
    • The stud-specific parts are identical to those of the KSE 100 model
  • Plugable feed hose with quick connect
  • Cable outlet on head connector
    • straight, lateral left, lateral right and 90° downwards (within the projecting edges)
  • Feed hose request via safety switch (Performance Level „d“)
    • High contribution to risk reduction

KSE 1055s

  • Modular, short and robust construction
    • Shorter than the KSE 100 (approx. 50 mm) / Up to 80 mm shorter depending on the
      loading head variant
    • Base body consists of one part -> No build-up of production tolerances
    • The stud-specific parts are identical to those of the KSE 100 model
  • Plugable feed hose with quick connect
  • Cable outlet on head connector
    • straight, lateral left, lateral right and 90° downwards (within the projecting edges)
  • Feed hose request via safety switch (Performance Level „d“)
    • High contribution to risk reduction

 

 

KSE 1055 LSPs

  • Stud welding head for welding up to four studs with only one welding head
  • Modular, flexible and robust construction
    • Particulary suitable for welding at locations that are hard to access, such as tunel-shaped metals, bent edges or narrow cavities.
    • Housing consists of one part -> No build-up of production tolerances
    • Improved latch area for increased accessibility
  • Cable outlet on head connector
    • straight, lateral left, lateral right and 90° downwards (within the projecting edges)
  • Feed hose request via safety switch (Performance Level „d“)
    • High contribution to risk reduction

KSE 2000s - The world's smallest weld head

The Welding Head for the Smallest Construction Spaces

For welding on hard-to-reach points, such as tunnel-shaped sheets, curved edges or small-dimensioned hollow spaces.

  • Modular, short, sturdy
    • 30% shorter than the KSE 1000s
    • Single piece base body -> no addition of production tolerances possible
  • Quick-connect device for the entire head (including supply of media)
  • Infinitely variable Nelson robotic axis optional (7th axis on the robot)
    • In order to increase the variance (accessibility) in narrow spots
    • Head position freely programmable in the space (0° to 90°)

P NS 40 SL

  • Manual feeding of the welding studs
  • Suitable for all welding studs used in the automotive industry
  • Easily convertible to other types of studs
  • Freely adjustable lift dimensions
  • Also applicable for unusual bolt geometries such as W-Top, collar studs or T-studs
  • Can be directly connected to an N4s System for single-station use

PSE 1000s

  • Automatic feeding of the welding studs.
  • Servo-electric drive with digital control.
  • Freely adjustable lift-off dimensions (programmable via the user panel of the welding machine).
  • Constant lift-off, even when welding on a concave or convex surface.
  • Optionally, welding with inert gas.

Various accessory components make your AVISTUD stud welding system unique.

Whether the wear reduction for robot-guided systems with the AVISTUD supply hose separation unit or welding similar studs with a welding head and two feeders with the AVISTUD stud switch: We make it possible.

The AVISTUD Speedport reduces the feeding time by pre-storing the next stud during the welding process close to the welding head.

For the robot installation of the hose packages, we also offer different solutions depending on the requirements and robot type.

Speedport

Acceleration of the conveyor process

  • Feed speed can be reduced (reduction in wear and tear) without loss of cycle time
  • Reduction of feed hose wear and tear
  • Up to 60 welds per minute possible
  • New stud already loaded when the R-position is reached

ARM – AVISTUD Robot Module

Extension module for all stud types. The module functions as the 7th robot axis.

  • Stud supply in any position
  • Rotation execution of stud canal
    • No movement on the feed hose
  • Rotation execution of head cable
    • No movement on the feed cable

Cleaning Station

The cleaning station is used in an automatic stud welding or Tarc welding machine to clean the welding heads.
By using inert gas, weld residues can accumulate in the gas bell, which must be removed regularly.
For this, the welding head is moved to the cleaning station and cleaned with rotating knives.
The welding residues are sucked off automatically.

Test and Calibration System

  •  Measurement of welding current and arc voltage at all stud welding units
    • Welding currents up to 2000 A, arc voltages up to 100 V
  • Automatic calibration of N3, N4 and N4s
    • Automatic comparison of welding current and process control
  •  Linearity control of N3, N4 and N4s
  • Fatigue test of N3, N4 and N4s

Control Box

Control box for the connection of 5 welding tools

  • The NTC 5 SL control box increase the flexibility of the N4s stud welding unit by the connection of up to 5 hand welding guns.
  • The control box features five welding outputs and five individually adjustable welding pro-grams.
  • Each welding output is equipped with an angle position function.
  • Besides the standard polarity (plus pole on the workpiece), the „Reverse Polarity“ version is available.

AC-Module 1000s

AC-Module 1000s – To generate square-wave alternating current

  • It generates a square-wave alternating current with a frequency ranging from 0 to 500 Hz using the regulated direct current of the N4s welding device.
  • The AC module 1000s is available as an add-one module and as a stand-alone solution
  • The AC add-on module 1000s is a component of the welding device N4s.
  • By using the 1000s AC module, any standard N4s welding machine can be retrofitted as an AC source

AVISTUD creates automotive Connections

The challenges in the material mix of modern lightweight construction vehicles are increasing and are subject to the highest quality standards.

AVISTUD offers all current welding studs as a solution for a holeless connection with the carrier material. Welding on special materials such as sandwich panels, aluminum or high-strength steels are used here. Full-surface connection, high strength and minimized corrosion are essential quality features.

Bolts of different size and shape are an ideal mounting aid for components and provide a task-ready, durable solution.

AVISTUD offers a wide range of different types of bolts. This concerns both the base material as well as the desired application and mounting options. Of course, we are also your partner when it comes to the new development of special bolts for your individual application.

If your desired bolt is missing in the existing versions, please contact us; we look forward to developing your bolt together with you.

Fir Tree Studs (Studs with coarse thread)

Studs with coarse thread, also called fir tree studs, are designed for various fastening solutions, such as clips, cables and wires or other fastening components. Quick fastening of the plastic elements by simply pressing. It always creates a secure attachment that remains easy to dismantle.

SC-Z 5FL 8 L16

This standard 5 x 16 mm fir tree stud is mainly used to fasten plastic clips and nuts.

SC-Z 5FL6 L20

This standard 5 x 20 mm fir tree stud is mainly used to fasten plastic clips and nuts.

SC-Z 5FL6 L9

This standard 5 x 9 mm fir tree stud is mainly used to fasten plastic clips and nuts. Due to the length of only 9 mm it is possible to realize a low overall height.

Large-Flange Studs

Large flange studs are mainly used for components that require a large contact collar when mounting. The used torques are on the bolt and not on the base material. Deformation in the basis material is avoided.

W-Top-MG

Large flange bolt M6 with large contact collar for torque requirements.

Ground Studs

Very good current flow is essential in modern vehicles. By a paint-tight nut a connection to the body part is made, which allows a high currents flow through a safe and paint-free installation.

SC-KRB M6

Ground stud M6 for optimal ground connection to all body parts

SC-KRB MG OMM

Ground stud M6 for optimal ground connection to all body parts with optional nuts

SC-KRB yellow cap

Ground stud M8 with plastic cap for paint-free mounting of ground cables

SC-KRB white cap

Ground stud M6 with plastic cap for paint-free mounting of ground cables

T-Studs

For exact positioning fastening of clips in space-constrained environments. Different materials for different applications and high strength.

T-Stud 3*5.4

The T-stud is mainly used for attaching trim strips, seals and clips at low height.

T-Stud 5*10

The T-stud 5×10 is mainly used as an assembly aid for modules.

Internally Threaded Bushings

Welding stud with internal thread for special applications such. Fastening of oil filters, but also component fixtures as a special solution and bearing-tight parts.

SC-I M5x9 CU

Internal thread M5x9x1x13 for fastening oil filters

SC-I M5x9

Internal thread M5 for the fastening of holed rail

Non-Threaded Studs (Straight Pins)

Studs as positioning and mounting aid for larger modules. Perfect fitting during assembly. Reliable centering.

Weld Pin

This stud with mounting tip is used as centering pin.