Description

We design and manufacture various spot welding transformer and gun accessories, these include:

Transformer / gun quick couplers 

These couplers were specially designed and manufactured for the motor industry to save on production breakdown time when changing welding cables. Couplings are made to suit any transformer and gun. 

Water and Air Quick Release Couplings 

These brass male and female couplings are fitted to the air and water hoses on secondary looms and save time in determining water and air flow, without damaging hoses by clamps. 

Loom Straps 

These revolutionary straps with their quick release stainless steel buckles are used for binding the secondary loom instead of tape and cable ties. They save time, can be reused again and are regarded as a cost saver. 

Secondary Loom Push-Lock Hoses

These hoses allow for the transport of filtered air and cooling water on conventional welding stations. Various sizes are available as well as technical data sheets on the various applications. 

 

Description

Z-Flex copper strands can be manufactured and supplied to carry up to 2000 amps with wire sizes ranging up to 1100mm. This type of strand is used extensively for large motor windings, transformer connectors, heavy current shunts or furnace droppers. Various types are offered depending on the environment conditions and our sales team can help recommend the optimal coverings depending on temperature, gas fumes, location etc.

A Z-Flex circular strand is designed using a unique rope type construction that prevents the copper strands from being in contact with the inner rubber tube of a kickless cable. Our experience has shown that a small bend in a normal cable tends to braise through the rubber with continual usage. However, the unique Z-Flex strand design allows the customer greater flexibility with less abrasion and, thus, a longer product lifespan. 

Z-Flex Flat Braids and Connectors 

These highly robust and flexible straps are designed using tin plated or copper tube terminals which are formed and pressed in a unique way to allow maximum conductivity at the current transfer area; with a minimum voltage drop and no loss of flexibility in the connector. 

A Z-Flex flexible braid has the option of having a crimped ferrule end to allow a high voltage/high current carrying capacity and can be manufactured and supplied to each customer’s particular requirements. 

Purchasing guidelines

Please provide us with the following information:

• Type
• Outside length 
• Width 
• Thickness (less clip)
• Hole pattern 
• Hole location
• Hole diameter 

Description

Kick and Kickless Cables 

 

The kickless cable is a world leader in the welding industry as it is unique in design and manufactured under strictly controlled processes. The product is able to last longer and withstand more wear and tear than other competitive products in the industry. Our cables are uniquely designed with a double clamping system to give the least possible impedance and greatest flexibility, which enhances operator productivity and cable life. 

The product is used extensively in manufacturing plants around the world and the product can be customised to fit each individual customer’s specifications ranging from 257 M.C.M – 1200 M.C.M (128.5mm - 600mm), to meet your exact specification. The cable offers unique features, which have been extensively developed by the testing of cables in our specially developed in-house test facility. These features include, redesigned head assembly, enclosed separators, improved water flow, a smaller cable diameter, new cable configuration, and a new construction hose. This in return has allowed us to achieve more cable flexibility and higher durability and thus, offer increased productivity, lower downtime and cost savings.

 

Quality 

Before the cable is supplied to the customer, each individual cable undergoes vigorous quality checks and inspections to ensure that the product meets the highest possible standards. 

 

Testing includes: -

insulation testing,

high pressure testing (10 bar water pressure for 3 minutes) and 

durability testing ( 40C @ 8500 amps).

 

Our experience in this industry also has shown that knowing each cable’s water flow rate is the single most important factor for establishing premature cable failure and we have adapted our product and its process to accommodate this. 

 

Purchasing guidelines

Please give us the following information:.

 

• Conductor rating (MCM)
• Length between holes
• Terminal orientation style 

Description

Our company specialise in the manufacturing of resistance welding consumables and relevant products.

We are able to manufactured and assemble anything you may need at our facility, so please do not hesitate to contact us and enquire about your general engineering requirements. 

Description

Z-Flex specialize in the development and manufacture of nozzles. Many of our manufactured nozzles are used in body shop and paint shop applications in motor manufacturing plants across the world. Each individual nozzle is designed specifically for each individual application.

Variable Nozzles:

This single nozzle is designed to work on both the right and left hand side of the assembly line as one can rotate the nozzle 180 degrees to operate on the opposite side of the application. This helps stabilize inventory control and improve sealer line productivity. 

Universal Adaptors:

These highly durable stainless steel universal adaptors can be fitted to most sealer guns. These universal adaptors are considered as a cost saver as the overall cost of nozzle purchases is reduced as only the nozzle end needs replacing when a new application is needed. We work closely with customers to ensure that each nozzle that we design and manufacture, meets our customer’s objective in the most effective and efficient manner. 

We also design various customized nozzles for automotive:

• Hoods, front and back.
• Doors
• Load Boxes. 

These nozzles all allow a controlled flow of application to a certain area in a specific way. Waste becomes minimized and productivity increases. 

 

We have developed shunts for applications that require high flexibility with high current demands that cannot necessarily be achieved with braided shunts. 

Three different lengths are required to be able to manufacture a shunt, and the automobile industry has standard sizes for the product. However, we are able to manufacture these high quality laminated copper sheets to any length and size for projection welders, spot welding guns and integral guns.

These connectors are produced to perform the same function as the flexible braided connectors with exception of having very little sideward movement. By increasing the number of copper sheets within the shunt, the current carrying capacity may be increased to a maximum cross section of 5000mm? or 4250 amps.