Benlong 
Silberpunkt + Kontakt automatische Schweißmaschine
Automatische Silberpunkt-Lötmaschine mit Servodruckregelung und Mittelfrequenzumrichter. Zwei Vibrationsförderer, optionale Lötpastendosierung. Gleichmäßige, niederohmige Lötverbindungen für Relais, Schalter und Leistungsschalter. Kundenspezifische Vorrichtungskonstruktion.
Automatic Silver Dot & Stationary Contact Welding Machine
This silver dot contact automatic welding machine has been manufactured to create high precision resistance welds between silver contacts and static (stationary) contact heads. The machine utilizes a servo motor controlled welding pressure system allowing for programmed weld force application precision; medium frequency inverter welding power supply provides stable energy output characteristics; and automatic solder paste dispensing system applies flux or paste to the surfaces to be welded before every weld. The machine is made specifically for mass production of electrical contacts for use in relays, switches and circuit breakers.
This setup is designed to use two separate vibratory feed systems (one for feeding silver dots to be welded, and another for feeding stationary contacts to be welded) and automatically feed components to the designated welding locations. The user-friendly design is such that the operator only needs to set parameters at the HMI, pour parts into their respective vibratory feeders, press start to begin operation, and the machine is completely automated and will discharge parts either via an exit conveyor or collection bin at the end of the cycle.
The welding pressure is controlled by servos ensuring consistent strength and flash when joining parts. Medium frequency welding technology is superior for the production of repeatable welds at a fast pace with reduced electrode wear.
Standard delivery: 30-45 days | Custom fixture design | Solder paste dispensing optional
What is a Silver Dot & Stationary Contact Automatic Welding Machine?
A silver dot contact automatic welding machine is a specialized resistance welding machine that is used to attach a small silver alloy contact (silver dot) to a fixed contact terminal (static contact head). This assembly is essential in low‑voltage switching devices such as relays, contactors and circuit breakers since low contact resistance and high mechanical strength are necessary. The machine utilizes a medium frequence inverter power supply (typically 1,000–4,000 Hz) to produce an accurate welding pulse. The welding head is driven by a servo motor, so programmable force profile options (i.e., soft touch, high force, dwell) are available. An optional automatic solder paste dispenser applies flux or paste to the welding interface for improved wetting and reduced oxidation. The machine can be fed by either vibratory bowls or tape feeders and is able to continuously run in an unattended mode. As this is a non-standard custom solution, we will design the electrode geometry, fixture design and feeding system specifically for your silver dot and contact dimensions.
Programmable force profile (pre‑press, weld, hold) for consistent joint quality.
Fast rise time, minimal spatter, and extended electrode life.
Pre‑applies flux/paste to welding surfaces for improved wetting and reduced oxidation.
Automatic orientation and feeding of silver dots and stationary contacts.
Welding Process & Key Features
Technische Spezifikationen
| Welding application | Silver dot (Ag, AgSnO2, AgNi) to stationary contact (copper, brass) |
|---|---|
| Welding power supply | Medium‑frequency inverter DC, 1,000 – 4,000 Hz, energy range programmable |
| Welding pressure control | Servo motor driven, force range programmable (typically 50–500 N), accuracy ±5% |
| Automatic solder paste | Pneumatic or peristaltic dispenser, programmable volume (microliters), optional |
| Fütterungssystem | Two independent vibratory bowls (silver dot feeder + stationary contact feeder) |
| Welding cycle time | Approx. 1.5 – 2.5 seconds per assembly (depending on part size) |
| Electrode dressing | Automatic or manual dressing station (optional) |
| Steuerungssystem | PLC (Siemens/Mitsubishi) with HMI, recipe storage for 20+ product types |
| Datenausgabe | CSV / MES via Ethernet; weld energy, force, and cycle count logged |
| Strom- und Luftversorgung | 380V ±10% 50Hz | Compressed air 0.5-0.7MPa (for feeders and dispenser) |
Detailed Process Flow (Operator & Machine Sequence)
The automated welding process follows these steps:
- Parameter setup The HMI and the operator determine the applicable welding parameters (e.g., force, energy, time, and paste volume) for the specific type of product based upon the specification requirements provided for that product.
- Component loading – Operator pours silver dots and stationary contacts into their respective vibratory feeders.
- Start – Operator presses the start button; the machine begins automatic operation.
- Feeding & orientation – Feeders orient and separate components; they will either be presented for pick-and-place by the operator or will slide into a welding nest for support.
- Solder paste application (optional) – A dispenser applies a precise amount of flux/paste to the welding interface.
- Component placement – The silver dot is placed onto the stationary contact (or vice versa) in the welding electrode.
- Welding – Servo motor applies programmed force; medium‑frequency power supply delivers welding pulse.
- Qualitätsüberwachung – Optional weld energy and displacement monitoring; rejects detected.
- Unloading – Finished assembly is ejected into a collection bin or onto an exit conveyor.
- Cycle repeats – Continuous automatic production.
Technische Kernvorteile
Servo‑controlled welding pressure
Unlike pneumatic systems, servo pressure provides precise, programmable force profiles (e.g., pre‑press to avoid part movement, then high force during weld, then hold pressure). This eliminates impact bounce and ensures consistent joint strength.
Medium‑frequency inverter welding
MFDC (medium‑frequency direct current) offers fast rise time (less than 1ms) and constant current output, independent of line voltage fluctuations. Results in less spatter, lower electrode wear, and better weld consistency than AC or capacitive discharge.
Automatic solder paste dispensing
Pre‑applying flux or paste to the silver‑to‑copper interface improves wetting, reduces oxidation, and lowers required welding energy – especially important for silver alloys with high contact resistance.
Dual feeder flexibility
The machine can handle a wide range of silver dot sizes (1‑8mm diameter) and stationary contact shapes. Quick‑change tooling allows changeover between product families in under 20 minutes.
Kundenerfolgsgeschichte
An automotive relay manufacturer needed to join silver-tin oxide contacts to brass fixed terminals. The company produced 2,500 assemblies each shift. The previous pneumatic welding system produced inconsistent forces and electrodes often wore out quickly. By upgrading their production process with our fully automatic silver dot welder with servo control and MFDC technology, the manufacturer has experienced the following benefits:
The machine paid for itself in 7 months through reduced rework and lower electrode costs.
Applications and Typical Components
Kundenspezifische Entwicklung & Lieferung
Request a Custom Silver Contact Welding Quote
Please provide us with your silver dot and stationary contact samples for analysis by our engineering team to assist you in determining the best servo pressure profile, MFDC parameters, and dispensing of solder paste required (if applicable) with a detailed return-on-investment analysis.
WhatsApp: +86 150 5837 0007 | E-Mail: xsb@benlongkj.cn | Support in Englisch und Chinesisch
Why Choose Benlong for Silver Contact Welding?
- Mehr als 15 Jahre Erfahrung im Designbereich silver contact welding machines for electrical components
- Proven servo pressure + MFDC technology for consistent, low‑resistance welds
- In‑house feeder and electrode fabrication – quick turnaround
- Optional solder paste dispensing for difficult‑to‑weld alloys
- Weltweiter Service und Ersatzteilsupport
Eine typische Sondermaschine umfasst:
1-year warranty; Reject bin; Safety enclosure; Custom welding electrodes; Siemens PLC w/HMI; OPTIONAL automatic solder paste dispenser; dual vibratory feeders (silver dot + stationary contact); medium frequency inverter power supply; Servo driven welding head w/force sensor.
Häufig gestellte Fragen
Programmable force profiles (soft touch, high force, dwell time) are available for servo control along with the ability to measure servo-generated forces. In comparison to pneumatic systems, servo controls eliminate impact bounce, thus prolonging the life of electrodes and improving the consistency of joint strength through multiple cycles.
The MFDC offers quick-rising constant current pulses that will not change with line voltage fluctuations. Users benefit from less spatter, more penetration, and an increase in electrode life while welding with DC current than they would while using AC or Capacitor Discharge welding methods.
Most silver-copper joints can be soldered without paste. However, the use of paste will enhance wetting and require less energy when working with high oxide content silver alloys (like AgSnO2) or when soldering to heavily oxidized copper. Each sample you provide will be tested to evaluate whether or not paste is necessary for that specific application.
Weld Energy Monitoring (WEM) (optional) compares actual weld energy (based on voltages & current) to the profile it has on file. Its displacement and force sensors can detect missing parts or parts incorrectly placed.
The machine will typically be able to work with dot sizes ranging between 1mm and 8mm in diameter. For larger diameters or rectangular shapes you will need custom electrode and feeder tooling for those applications.
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