Precision, efficiency and control: digital welding technology takes the entire welding process to a whole new level. The combination of sensor technology, intelligent regulation and precise current control makes welding processes both more stable and reproducible. Digital welding systems now record and control every phase of the welding process in real time - a clear advantage in terms of quality and energy utilization. Find out here how digitally controlled welding systems work, what they are made of and what you should consider before buying one.
What are digitally controlled welding systems?
Digitally controlled welding technology means that all relevant process variables, from welding current to voltage, wire feed speed and travel speed, are recorded by sensors, shown on the digital display and regulated in real time by a microcontroller. The result is reproducible welding results that score highly in terms of accuracy and safety.
Whether MIG/MAG, TIG/TIG with Lift TIG or flux-cored wire welding - digitally controlled systems conveniently map the respective function as a „process profile“. Users can simply select the desired mode via a clear menu, then specify the material and the wire or welding electrode, and the control system automatically suggests the appropriate welding parameters such as amperage and voltage. This shortens set-up times, increases welding speeds and even reduces any operating errors. All of this pays off, especially with changing jobs, materials and weather conditions. Digital welding machines make everyday work much easier.
IGBT technology - The heart of digital welding machines
At the heart of modern welding power sources are inverters based on IGBT transistor technology. Compared to MOSFET or transformer devices, they are lighter, more compact and have a high duty cycle with a stable arc. For you, this means less weight, a more mobile welding machine, precise control and significantly better energy efficiency.
Power electronics in comparison
| Technology | Properties | Advantages | Typical application |
| IGBT inverter | High switching frequency, digital control | Precise parameters, high duty cycle, compact | MIG/MAG, WIG/TIG |
| MOSFET | Older inverter generation | Solid performance, more affordable | Easier work |
| Transformer (conventional) | Large and heavy, analog | Robust, simple technology | Stationary basic applications |
MIG and MAG welding
In MIG/MAG welding, the welding machine works with a constant welding current, while the wire feeder automatically regulates the amount of welding wire. This combination creates a stable arc that melts the material evenly. Here too, digital technology simplifies this process considerably: digital welding systems have so-called synergic programs that automatically coordinate the type of material, wire thickness and the shielding gas used, such as M21. The device then optimally adjusts the voltage and amperage to each other and sets both - the welder therefore has to make fewer manual corrections.
Advantages of digital MIG/MAG welding
- Automatic programs: Depending on the material, such as steel, stainless steel or aluminum, the appliance selects the appropriate parameters.
- Stable seam quality: A regulated open-circuit voltage creates a uniform seam root and controls the arc length.
- Convenient start and end functions: Adjustable lead times, crater filling, hot start and arc force improve the ignition and ending of the welding process.
- Process control and traceability: Modern devices record all relevant data automatically - perfect for quality assurance and documentation.
Flux-cored wire welding: reliable in wind and weather
Flux cored welding (FLUX) is a particularly robust process that - depending on the wire type - does not require shielding gas. This makes it ideal for working outdoors, in windy, draughty or changing weather conditions. The self-protecting wire forms its own gas bell during melting, which stabilizes the arc. When it solidifies, a layer of slag is formed which provides additional protection for the seam.
In contrast to classic shielding gas welders, FLUX systems therefore do not require a gas cylinder - a clear advantage for assembly work, on construction sites or in areas that are difficult to access.
When flux-cored wire welding is the best choice
- Outdoors: In windy, draughty or changeable weather, where protective gas bubbles can easily be blown away.
- For contaminated or coated workpieces: For example, galvanized or painted materials, but only with a suitable wire type.
- For fast, deep seams: The process enables a high penetration depth and rapid material application.
Tip for pole connection:
DCEN, a negative pole on the torch, is recommended for most self-protecting FLUX wires. Gas-protected cored wires (FCAW-G), on the other hand, often run with DCEP, a positive terminal on the torch. Before starting, always check the manufacturer's instructions for the connecting mandrel, contact tip and wire feed-through for safe and stable results.
Lift-TIG: Precise ignition without high frequency
With the Lift TIG process, the ignition of the arc is particularly controlled. The TIG process starts by gently touching and lifting the electrode and without high-frequency ignition (HF). This significantly reduces electromagnetic interference (EMC), making the process ideal for Class A environments such as workshops with sensitive electronics.
Advantages of Lift-TIG at a glance:
- Clean ignition without spatter or material inclusion
- Finely dosed heat input; is perfect for thin-walled components and stainless steel
- Compact device equipment: Often with WP-17V burner, earth cable and matching basic accessories
- Integrated additional functions such as Anti-Stick, Hot-Start and Arc-Force
This means that even fine visible seams or precise repair work can be carried out with maximum control.
Digital display and control
A modern digital welding machine has more to offer than just the display of current and voltage: The digital display now guides the user clearly through all settings and menus. Parameters such as amperes, voltage or wire feed are shown here in real time and can be adjusted or saved as required.
Typical features of a modern control system include
- overheating protection and intelligent smart cooling for a longer service life,
- several process modes such as 2T/4T, spot, synergy or pulse mode,
- the display of duty cycle, protection class and mains frequency and
- Interfaces such as USB or LAN for data transfer and integration into larger systems.
This allows welders to keep an eye on all relevant welding parameters at all times and document or adjust them as required. A real plus point for consistent quality and efficiency in operation.
Accessories and consumables
Even the best welding machine can only achieve perfect results with the right accessories. This is because high-quality components improve the welding properties on the one hand and extend the service life of the entire system on the other.
Important accessories for MIG/MAG welding include welding torches with a suitable contact tip, nozzle holder, gas nozzle and connecting mandrel as well as suitable wire thicknesses from 0.8 to 1.2 mm. TIG welding is best supplemented with suitable clamping sleeves, ceramic nozzles, gas lenses and a protective cover for hosepacks and cable routing. Depending on the process, it is also important to use the right shielding gas mixture or the right cored wire. With the right accessories and consumables, you are guaranteed to work precisely, safely and economically over the long term.
Selection and design - the right way to find the right welding machine
The choice of the right welding machine always depends on the application, the material properties and the desired seam quality. Although digital devices are highly convenient, they should be configured to suit the actual requirements.
Important criteria before buying
Process selection
- MIG/MAG - universal and fast, ideal for series production
- TIG/Lift-TIG - precise, for high-quality seams
- FLUX - robust, ideal for outdoor areas
Performance
The required welding current should match the material. For 3 - 6 mm steel, 160 - 200 amps is usually sufficient, with some reserve for future requirements.
Operation
Pay attention to the actual duty cycle for your ampere class, the protection class such as IP23 and Class A EMC certification for industrial use.
Periphery
High-quality wire bushings, contact tips, earth cables and the right shielding gas composition or cored wire type ensure consistent results. Make sure you have a switchable pole connection if you want to switch between processes.
Service and delivery time
Good manufacturers provide you with a fast spare parts service, detailed documentation and clear information on delivery times as well as interfaces for automation or data management. At Schnelldorfer Maschinenbau, you will find customized and holistic solutions: from individually configured digitally controlled welding systems to custom-fit process integration and technical support - with us, you get everything from a single source and with a focus on reliability, precision and your requirements.
Schnelldorfer Maschinenbau - Digitally controlled welding systems with a system
Schnelldorfer Maschinenbau stands for high-precision, digitally controlled welding systems that have been specially developed for industrial applications. The company produces PLC and HMI-controlled systems for longitudinal and corner seams, tailor-made special solutions and complete welding cells - all including intelligent control, recipe management and automatic documentation. For example, you will find welding systems from the LINEARWALD and CORNER series, but you can also look forward to custom-made products or powerful complete systems on request.
All systems are of course always designed to meet the requirements of your modern production: from quality assurance and process monitoring to full integration into Industry 4.0 structures. In addition, we configure each system individually according to the material, geometry and your production requirements. We take a holistic view of everything and are happy to clarify what you need in a personal meeting.
Anyone who relies on digital welding technology from Schnelldorfer Maschinenbau benefits from:
- Maximum process reliability thanks to automated parameter control
- Reproducible quality with every weld seam
- Efficient use of energy and modern IGBT technology
- Complete traceability thanks to integrated data recording
Would you like to increase your productivity, reduce rejects and rework and document your processes digitally? Then Schnelldorfer Maschinenbau is the right partner for you: We provide you with practical advice, plan the integration into your production and deliver on time, guaranteed - with transparency, experience and the highest level of technical expertise.
Don't hesitate to contact us - we look forward to hearing from you!
Frequently asked questions (FAQ)
What are digitally controlled welding systems?
Digitally controlled welding systems automatically regulate welding parameters such as amperage, voltage and wire feed speed via a digital controller. They work with IGBT technology and are known for their precise welding results and high efficiency. This makes them ideal for modern industrial applications.
What are the advantages of IGBT technology for welding equipment?
IGBT transistor technology is rich in advantages: It creates stable welding currents, a low weight and is highly energy efficient. Compared to MOSFET or transformer devices, IGBT inverters also achieve a longer duty cycle, finer control and consistent welding quality.
When is flux-cored wire welding the right choice?
Cored wire welding is particularly suitable for outdoor work, as it delivers stable results even in windy or changing weather conditions. With self-protecting flux cored wire, the process works entirely without shielding gas, making it robust and flexible in operation.
What is Lift-TIG and how does it differ from other TIG processes?
In lift TIG welding, the arc is ignited by gently touching the electrode - without any high frequency. The process reduces EMC interference (Class A), is rich in fine welding properties and is correspondingly good for thin-walled components or stainless steel.
What role does the digital display play in modern welding machines?
A digital display shows all important welding parameters such as current, voltage and wire feed in real time. This makes setting easier, improves control over the process and supports precisely repeatable welding results thanks to synergy programs.
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