Secondary welding cables

Our range of secondary welding cables is designed for the industrial operation of robot and manual welding guns and for power supply in mechanical engineering. High flexibility due to specially stranded copper wires and crimped lugs, good heat abstraction through a perforated inner jacket as well as effective cooling are just some of the characteristics of these cables.

Comparison between water cooled jumpers and kickless cables:

Both are generally used on separate transformers for spot welding applications in order to transport the current from the source (tranformer) to the tool (welding gun). The water cooled jumper has only one polarity, the kickless cable has both current polarities in one cable (less kicks during current load).

The choice between these technologies is in general based on two parameters:

  1. The type of terminal on the tool and/or on the source
  2. The ergonomy of the work station (manual ergonomy or robot movement)

Technical characteristics kickless cables

  • Cables are protected by either a rubber or polyurethane jacket. Polyurethane is an excellent electrical and thermal insulator. Other advantages include its self-extinguishing quality plus excellent resistance to abrasion, welding sparks, weak acidic or base solutions.
  • The fine stranded copper wires are made of high grade electrolytic copper and are structured and positioned to increase flexibility and to reduce abrasion factors.
  • The copper strands are crimped to the lugs ensuring the best electrical contact without altering or overheating the copper.
  • Different standards of lugs are already available, new types can be developed according to customers specification.
  • The rubber and polyurethane jackets are crimped onto the lugs with a protective steel ring, which ensures the water tightness of the jumper.
  • A perforated inner sheathing provides interior insulation and contains the inner cores. The patented system significantly reduces abrasion and minimizes the generation of wire fragments which can cause watercooling restrictions.
  • The polarity construction of the kickless cable can be:
    ➔ Opposite: Recognized by mechanical resistant on heavy duty applications.
    ➔ Alternate: Recommended when high output is required due to lower impedance and for manual station due to lower reactance.

Application example of the installation of a kickless cable and watercooled jumper cable

Detail of the connection to the transformer
 

Examples of nominal cross sections 160 mm², 200 mm² and 250 mm² – other terminals on request.

Nominal cross section 160 mm²

Nominal cross section 200 mm²

Nominal cross section 250 mm²

Technical characteristics air-cooled jumper cables

Cables are protected by either a rubber or polyurethane jacket. Polyurethane is an excellent electrical and thermal insulator. Other advantages include its self-extinguishing quality plus excellent resistance to abrasion, welding sparks, weak acidic or base solutions.

  • The fine stranded copper wires are made of high grade electrolytic copper and are structured and positioned to increase flexibility and to reduce abrasion factors.
  • The copper strands are crimped to the lugs ensuring the best electrical contact without altering or overheating the copper.
  • Different standards of lugs are already available, new types can be developed according to customers specification.

Installation of an air-cooled cable

Examples

Technical characteristics water-cooled jumper cables

Cables are protected by either a rubber or polyurethane jacket. Polyurethane is an excellent electrical and thermal insulator. Other advantages include its self-extinguishing quality plus excellent resistance to abrasion, welding sparks, weak acidic or base solutions.

  • The fine stranded copper wires are made of high grade electrolytic copper and are structured and positioned to increase flexibility and to reduce abrasion factors.
  • The copper strands are crimped to the lugs ensuring the best electrical contact without altering or overheating the copper.
  • Different standards of lugs are already available, new types can be developed according to customers specification.
  • The rubber and polyurethane jackets are crimped onto the lugs with a protective steel ring, which ensures the water tightness of the jumper.

Example of jumpers, other versions possible
 

Robotics catalog 2012, Kickless, 2006 self created BU Robotic Solutions,

Application example of the installation of a kickless cable and watercooled jumper cable

Examples of lugs

Conical lug female

Conical lug male

Cylindrical lug

45° bent lug

90° bent lug

Flat lug