Extra thin and soft wire electrodes are sensitive to distortion and deformation. In conventional push-pull systems, very often the wire is being deformed, inevitably resulting in wire failure in the welding torch. The Master-Feed System developed by ABICOR Binzel delivers highly precise wire feed to the welding arc, significantly increasing the quality of production as well as the productivity of the automated cell. From wire spool to contact tip, the Master Feed System, MFS-APD, is a complete unit for continuous wire feed in aluminum welding.

Digitally controlled wire feeding - The heart of the system is the two high-quality four-roll wire drives with digital motor control. The digital drive motor control guarantees precise, repeatable and flexible wire feed process. The motor control receives the actual speed data from the digital encoder sensors. The control processor precisely calculates the actual and programmed wire feed speed and makes the necessary adjustments.

Push-pull system - Two wire drives are precisely synchronized - mechanically and electronically. This eliminates wire tension at all points of the system. All wire drives push the wire and there is always a sufficient amount of wire in the cable assembly near master drive to prevent any tension while feeding.

High quality four-roll wire drives - The high quality four-roll wire drives utilized in the Master Feed System transfer relatively high torque to the wire with the lowest possible pressure. Consequently, there is less wire deformation caused by rubbing or excessive roll pressure. Modern welding power sources and lasers require high dynamic wire supply especially for the process starting and ending. Within a few seconds, the wire is drawn forward without slippage. A pre-adjusted and reproducible contact pressure prevents time-intensive malfunctions.

Service friendly and easily available - The wire de-reeling system is able to hold all wire spools and is therefore universal and expandable depending on the requirement. A heating element, located inside the Master Feed System cabinet, controls the temperature and maintains a moisture-free environment for the wire spool. This protects the wire from oxidation and prevents the introduction of moisture into the weld pool. A highly visible warning light signals when the wire spool is nearly empty.

The MFS-APS system utilizes a separate drive for de-reeling the wire spool. The drive is synchronized with wire feed speed through a balancing arm which senses wire tension variations. The combination of the two wire drives provides precision wire feeding not achievable with conventional systems. Easily changeable wire spools, mobile cabinet and quick replacement of all the system components are only a few of the many convincing advantages of MFS-APD systems.