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Tube Insert Resistance Welding Machine: A Tool for Improving Industrial Efficiency

The tube insertion resistance welding machine is an essential and important tool in industries such as HVAC (Heating, Ventilation & Air Conditioning) and automotive that require high precision and durability. The machine connects copper heads to aluminum condensers and evaporators to ensure stable and high-performance connections. 

It has adjustable welding parameters that can be adapted to different tube diameters, making the welding process easier and more efficient. These features make the Tube Insertion Resistance Welder an excellent performer in improving productivity and product quality, making it a great addition to the industrial manufacturing sector.

Resistance Welding Overview

Resistance welding is a process in which welding is accomplished by the resistive heat generated when an electric current is passed through a metal part. The technique originated in the late 19th century and was first introduced by Elihu Thomson in 1885. 

The basic principle of resistance welding is that when an electric current is passed through a metal joint under pressure, resistance generates heat, causing the metal to melt and form a strong joint. Due to its high efficiency, reliability and ease of automation, resistance welding is widely used in various industrial fields.

Welding machine components

Welding machine components

Tube insert resistance welding machines consist of several key components, each of which plays an important role in the welding process. Understanding these components helps to better operate and maintain the machine.

1. Welding electrodes

The welding electrode is one of the core components of the tube insertion resistance welding machine. Electrodes are usually made of highly conductive and heat-resistant materials, such as copper alloys. Their main function is to conduct current through the workpiece, generating heat at the point of contact between the electrode and the workpiece to form a weld.

2. Electrode arms and electrode tips

The electrode arm and electrode head are responsible for holding the welding electrode in place and applying the necessary pressure. The electrode arm is usually mechanically or hydraulically actuated and can precisely control the pressure on the electrode to ensure a quality weld.

3. Current transformers

A current transformer adjusts the voltage and current of the input power source to a level suitable for welding. It converts high voltage and low current to low voltage and high current to provide enough energy for welding.

4. Control systems

The control system is the "brain" of the welding machine, which is responsible for monitoring and regulating the welding parameters, including current strength, energizing time and electrode pressure. Modern control systems are usually computerized, capable of storing and recalling preset welding programs to meet different welding needs.

5. Cooling system

Due to the large amount of heat generated during the welding process, a cooling system is essential. It usually consists of a water or air cooling system to cool the welding electrodes and other critical components to prevent overheating damage.

6. Workpiece fixtures

Workpiece fixtures are used to hold the tube to be welded and ensure that the workpiece does not move during the welding process. The design and material of the fixture have a significant impact on the quality of the weld and should be customized to the specific shape and size of the workpiece.

7.Operator interface

Operator interface

The operator interface usually consists of buttons, a touch screen or a control panel for the operator to set and adjust welding parameters. Modern welding machines are user-friendly and intuitive and are often equipped with digital displays and programmable logic controllers (PLCs) for precise control and quick start-up.

Application of resistance welding machine

Tube insertion resistance welding machines have been widely used in many industries for their high efficiency, reliability and adaptability. The following are specific examples of its application in different fields:

1. Automobile manufacturing

In the automotive manufacturing industry, tube insertion resistance welding machines are widely used for welding bodywork, chassis and exhaust systems. Its high precision and strong connection capability ensure the safety and durability of automotive components.

     ● Body assembly: Welding of doors, roof, frame and other components to ensure the robustness of the body structure.

     ● Exhaust system: connects the exhaust tube and muffler to ensure the sealing and durability of the exhaust system.

2.HVAC systems

HVAC systems

In Heating, Ventilation and Air Conditioning (HVAC) systems, tube insertion resistance welders are used to connect copper tubes and aluminum fins to ensure system tightness and heat transfer efficiency.

     ● Condenser and Evaporator: Welded copper heads with aluminum condenser and evaporator ensure efficient heat exchange performance.

     ● Air conditioning piping: Welding of various piping to ensure efficient operation and long-term reliability of air conditioning systems.

3. Appliance production

In the production of home appliances, tube insertion resistance welding machine is used to weld the internal structure of refrigerators, washing machines, air conditioners and other equipment to improve product quality and production efficiency.

     ● Refrigerator: Welded refrigeration lines to ensure efficient operation of the refrigeration system.

     ● Washer: welded internal piping and components to ensure stability and durability of the washer.

4. Manufacture of electronic components

In the manufacture of electronic components, tube insertion resistance welding machines are used to solder small electronic components, ensuring reliable and conductive electrical connections.

     ●Circuit board assembly: Soldering various connectors on the circuit board to ensure the stability and reliability of the circuit.

     ● Sensors and Connectors: Soldered sensor and connector assemblies ensure accurate data transfer and stable connection performance.

5. Aerospace

In aerospace, tube insertion resistance welding machines are used to weld high-strength, lightweight metal parts to ensure the performance and safety of aircraft.

     ● Fuselage construction: Welded fuselage frames and skins to ensure the strength and weight reduction requirements of the vehicle.

     ● Fuel Line: Welded fuel piping system to ensure safe and reliable fuel transfer.

6. Medical equipment

In medical device manufacturing, tube insertion resistance welding machines are used to weld a variety of precision metal parts to ensure the accuracy and reliability of the device.

     ● Surgical Instruments: Welding high-precision surgical tools to ensure their safety and effectiveness during use.

     ● Medical Piping: Welding medical piping used to transport liquids and gases ensures no leaks and durability.

Advantages and limitations

Advantages and limitations

Tube Insertion Resistance Welding Machines offer a variety of advantages, but there are some limitations. These machines increase efficiency and precision, but may be limited depending on the material used.


      1. high efficiency

          ● Resistance welding is very fast, usually taking only a few seconds to complete a joint or seam, making it ideal for high-volume production.

     2. high reliability

          ● Since resistance welding allows precise control of welding parameters such as current strength, energizing time and electrode pressure, the quality of the weld is stable and reliable.

     3. High degree of automation

          ● Resistance welding is easy to integrate with automated equipment, enabling a highly automated production process that improves productivity and consistency.

     4. energy conservation and environmental protection

          ● Resistance welding process heat concentration, energy loss is small, and do not require filler material, reducing the waste of resources and environmental pollution.

     5. Good welding quality

          ● Resistance-welded joints have high strength and durability and can withstand large mechanical loads and long periods of use.

     6. Wide range of applications

          ● Suitable for welding a wide range of metal materials and different thicknesses, especially suitable for joining thin metal plates.


     1. High equipment costs

          ● High-precision resistance welding equipment and automation systems are more costly, with larger initial investments.

     2. High demands on material surfaces

          ● The surface of the material to be welded must be clean and free of contamination to ensure a quality weld. Oxides, grease or other contaminants will affect the welding results.

     3. Limited weld thickness

          ● Resistance welding has a limited ability to weld thicker materials and is usually suitable for welding medium to thin plates.

     4. Electrode wear

          ● Electrodes wear out gradually during the welding process and need to be replaced or maintained periodically to ensure weld quality.

     5. heat affected zone

          ● Resistance welding creates a heat-affected zone (HAZ) around the weld, which may alter the mechanical properties of the material and affect the overall performance of the welded joint.

     6. Difficulty in welding complex shapes

          ● For parts with complex shapes or difficult access, resistance welding may not be possible and other welding methods are required. 

By understanding the advantages and limitations of the tube insertion resistance welding machine, you can better utilize its advantages and avoid its shortcomings to achieve the best welding results and productivity.

Advances in welding technology

Recent advances in welding technology have had a significant impact on various industries. These innovations have not only improved the precision and efficiency of the welding process but have also significantly increased operational safety.

Development of the fusion welding process

Modern fusion welding processes focus on optimizing weld deposition rates and environmental protection. By improving the heat cycle during the welding process, these improvements result in excellent welding characteristics and higher process reliability.

BOBO Machine's Resistance Welding Machine for Copper and Aluminum Tube Insertion

BOBO Machine's Resistance Welding Machine for Copper and Aluminum Tube Insertion

BOBO Machine's Copper and Aluminum Tube Insertion Resistance Welder is a technological breakthrough that enables the connection of copper heads to aluminum condensers and evaporators. With adjustable settings for different tube diameters, it is easy and stable to operate.

Key Features:

     ● Adjustable electrode base calibration system: This patented technology ensures high welding quality. Variability during the welding process is reduced by the welding stroke control instead of the traditional time-based control.

     ● High-performance welding transformer: Specialized welding transformer produced by Russian technology with stable performance. The secondary welding current is adjusted by the thyristor in eight levels, adapting to various tube diameters.

     ● Advanced control system: Equipped with PLC system and touch screen to simplify operation and setup and improve reliability and ease of use.

     ● Strict Pressure Test: Each machine undergoes a strict pressure test to ensure the integrity of the weld. Welding parameters are adjustable to ensure stable machine performance.

These technological advances have significantly improved the efficiency and reliability of the welding process, bringing higher-quality welding solutions to a wide range of industries.

Reach a verdict

Tube Insertion Resistance Welding Machines provide efficient and reliable welding solutions for a wide range of applications where robust joints are required. Factors such as power requirements and ease of operation need to be considered when choosing the right machine. 

BOBO Machine's copper and aluminum tube insertion resistance welding machines significantly improve welding accuracy, efficiency and safety through innovative technology. Contact us to learn more about our resistance welding machines for copper and aluminum tube insertion and discover how to enhance your welding process.