A 400 kVA (P-50%) DC power welding station with replaceable tools was designed to join the components of the car exhaust system. The use of a several different tools enables the welding of a wide range of details on one device. After change of the tooling, the control system automatically invokes the set of parameters previously entered for the tooling. Thanks to this, and thanks to the fast changeover system, the machine retooling process is done in an easy and quick way.

sensors, Poka-Yoke system, and Keyence vision systems have been used to control the correct assembly of parts. TECNA welding controller and Siemens PLC main control system were used to control the welding station.