The exact alignment of components is crucial in resistance welding. Whether body components or fastening elements such as a welding nut - they must be positioned in relation to each other with millimeter precision before they can be joined.
For this, MEGATRON AG relies on the ModulMaster, a modular welding device from DOCERAM. With the help of a ceramic centering pin, the nut is guided precisely to the sheet metal hole. In combination with integrated sensors, the entire process can be monitored in real time - reducing rejects and rework to a minimum.
The device is compatible with almost all common projection welding systems in the automotive industry. Its sophisticated, modular design allows easy adaptation to different component geometries, cycle times and production requirements - for greater safety, repeat accuracy and efficiency in the production process.
Efficient welding - with the ModulMaster Pro from DOCERAM
More cycles, fewer rejects: The ModulMaster Pro stands for economical welding with maximum process stability. The intelligent device impresses in nut (configuration N) and stud welding (configuration S) with its precise positioning and fast adaptability.
Thanks to its modular design, the system can be flexibly integrated into almost all common projection welding systems in the automotive industry. Three integrated sides with threaded holes allow easy mounting of sensors, supports and accessories - for maximum design freedom.
A particular highlight: The revised design of the centering pins, sleeves and exchangeable electrodes enables extremely short changeover times - ideal for series processes with a high number of variants.
The ModulMaster Pro was developed for maximum efficiency and process reliability in nut and stud welding. The fully retractable centering pin enables fast and safe component changes, supported by an integrated return spring for automatic positioning.
One system, many possibilities: A single holder covers all standard centering pin sizes for weld nuts from M4 to M12 as well as 7/16″ UNF. Fixing is precise and repeatable via a stainless steel union nut.
The direct water cooling on the device ensures a long service life, which significantly reduces wear on the exchangeable electrode. Robust metal connections for cooling and compressed air guarantee reliable operation in continuous use.
More control in the process: The integrated sensor system detects the position of the centering pin in real time - can also be optionally combined with the ModulMaster compact controller from DOCERAM to ensure quality before each welding process.
Thanks to its compact design, large piston diameter (32 mm) and generous contact surface of the exchangeable electrode, the ModulMaster Pro is also ideally suited for high loads in series production processes.
Free threaded holes on three sides offer space for sensors, supports or individual extensions - for maximum flexibility in your production.
The top-of-the-range DOCERAM welding fixture, the ModulMaster Pro Type-N, combines precise mechanics with integrated sensors for maximum process reliability. The integrated distance measuring system detects potential sources of error during positioning - before the welding process begins.
As standard, the device is equipped with a high-precision analog sensor from Turck*, which is characterized by its insensitivity to interference fields - ideal for industrial environments with strong magnetic fields.
For simpler applications, a variant with a digital sensor from Balluff** is also available, e.g. for detecting end positions in the positioning process.
A sequence controller is required to connect the sensors. If your system does not have its own PLC, MEGATRON AG offers the compact CRU-2 control unit - a fully integrable system that is compatible with all standard resistance welding machines.
With the DOCERAM CAD portal, the ModulMaster Pro welding fixture can be configured quickly and conveniently online. By entering your application parameters, you will receive a customized configuration in just a few steps - perfectly tailored to your welding process.
The model is then available for you to download in all standard CAD formats - for direct integration into your design or project planning.
In addition to the ModulMaster, you will also find other DOCERAM components in the CAD portal, such as:
Positioning and dowel pins
Locating bolt
Insulating bushes
Of course, you can also request your configuration directly from MEGATRON AG - we will be happy to support you with technical advice and design it for your application.
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