Plastics Welding Technology in Perfection
Wegener – Advanced Technology Based on Experience
Quality and Reliability
Wegener International GmbH is the leading provider of thermoplastics welding technology. Since 1957 welding equipment made
by Wegener have been standing for highest quality and absolute
reliability. Through continuing development of our product range
we guarantee our customers superior technical expertise for their
applications and individual markets.
The Best Solution for Every Application
Today, products and components made of thermoplastics are used
Wegener is the only manufacturer worldwide to pro-
in many industrial sectors, from the packaging industry to venti-
vide a complete product range for the plastics fabri-
lation technology or the construction industry. Precision welding
cation industry. Wegener develops and produces hot
and fusion of these plastics demand the highest level of technology
air welding tools, hand held and automated extrusion
and materials. The welded plastic components are often exposed to
welders, butt welding and bending machines. With
extreme loads. Rigidity, density and longevity of the welding seams
machines made by Wegener, thermoplastic materials
must be of consistent high quality – for each component and
can be welded at high production rates – faster, user-
during each welding process.
friendly and at high quality. Wegener equipment
always ensures our customers to be competitive in
their industries. In addition, Wegener possesses extensive expertise in developing individual solutions
tailored to our customer’s individual requirements.
The high technological level of our production and
custom machines is ensured through continuous research and development. Wegener provides the optimum machine for every application.
Service Worldwide
Our service teams guarantee qualified maintenance and service for
all our machines, no matter what the year of manufacture, at any
Motivation and Expertise
time. We provide all necessary spares and support for technical
A company can only be as effective as the people
questions or possible problems – fast, easy and almost everywhere.
working for it. With their experience and expertise
Wegener Welding LLC, based in Chicago, ensures our presence in the
our employees stand for the success of Wegener and
American markets and carries our comprehensive product range for
its products. The team can solve the most complex
plastic welding and fabrication. Worldwide a network of experien-
customer requirements – fast and efficiently.
ced distributors and sales representatives offer the best
Their technical know-how is the key for our world-
local support.
wide success. The Wegener experts work highly motivated to ensure the high standard of our products.
A commitment our customers can rely on.
Development and Engineering
Technological Leadership
Our philosophy is to provide our customers with the best and most
efficient solution for their application. For this reason, the continuous optimisation of our product range is of special importance to us.
This progressive philosophy is a tradition in the history of our company. Wegener has always been the technological leader in the development of plastics welding technology. We were the first worldwide to manufacture butt welding and bending machines. The first
Teflon® coated stainless steel heating elements also originate from
Wegener – a technology eventually established worldwide.
Unequaled, Wegener remains the technological leader due to our
commitment to ongoing research and development. Wegener continues to further expand our leadership position within the field of
plastics welding through the highest possible technology and new
solutions for the future.
Our technical know-how,
extensive experience and
highest manufacturing quality
guarantee the best machines
and equipment on the market.
Research for New Processes
Our standard product range is based on the many years of our engineers’ experience. Starting with the foundation of the company in
1957, they have developed a broad spectrum of different types of
machines and new processes. Using this knowledge as a basis, our
employees cooperate with numerous research facilities to develop
new solutions and future standards. An example is the continuing
improvement of welding parameters based on long-term studies
of plastic welding seams.
Employee Training
We help our customers to get the best out of their
equipment. In most cases, the quality of the welding
Wegener is the leader in optimisation and automation of welding
process is highly dependent on the knowledge and
processes. For many of our customers, the automation of their pro-
skill of the welding personnel. This specifically applies
duction provides them with the necessary advantage over their
to hot air and extrusion welding where handling of
competitors. Our focus is the practicality of the application:
the equipment and knowledge of the process is cru-
From conceptual drawings to turn key installations, our engineers
cial. Therefore we offer, in cooperation with renowned
cover project planning, design engineering, machine manufactu-
training institutions, comprehensive training classes.
ring and final commissioning.
Guided by our specialists your employees turn into experts for the Wegener plastics processing technology.
Customised Solutions
Specialists in Customised Solutions
Wegener provides a large and technologically advanced standard
product range covering most of the processes for thermal fusion
technology. Sometimes however, a standard product does not meet
customers requirements. No problem for Wegener, we enjoy the
challenge to provide the solution. The extensive know-how gained
over years allows us to modify an existing machine to customer
specifications or to develop a machine or system for a specific production purpose. You name the task and the application – we design
the best solution – with you and for you.
Circular Welding System KBS 4002 –
for automatic fabrication of large
cylindrical structures
Clamping systems are custom designed
for your application
Bead cutter –
fast and precise removal of weld beads
Design and Development of a Molded Parts Welding Machine
Especially for precise welding of plastics molding parts made
from injection-molded ABS Wegener has developed a molded component welding machine allowing for the first time to weld 18 ABS
modules in up to three lines. The entire component is built-up stepby-step and with a precision of +/- 0,1° per welding.
No tolerances due to fully mechanical
synchronisation of tables
Development of a
Polyethylene Pipe Bending System
Wegener’s specially developed RBA is based on the
Molded Parts Welding Machine
requirement to design a machine for automated
bending of plastic pipe into pipe elbows. The solution
was an entirely new machine concept: The pipe ends
remain "cold" during the bending process, thus preventing deformation and allowing immediate use in
further fusion processes. The RBA operates fully automatic and produces pipe elbows of different diameters up to a 90°angle.
Pipe bending machine RBA –
worldwide the first fully
automatic system for the
bending of elbows out of
extruded pipe
Automatic, economic bending of profiles
Machines for Any Application
Additional Wegener developments are a vertical welding machine to process large-surface components,
the profile bending machine for efficient bending of
profile strips for frame production or butt fusion
machines for the welding of plastic pallets.
All the above are only a few examples of the large
Profile Bending Machine
spectrum of individual engineering solutions successfully accomplished by Wegener in the past. You can
rely on Wegener’s expertise even for out of the ordinary tasks – from the idea and the concept to the
finished product. There is hardly any problem we cannot solve, no matter if you want to weld completely
new products from plastics or if you are using entirely
new materials without existing processing parameters so far.
Profile Butt Welding Machine
Welding of profiles –
special clamping system
for fine profiles
Butt Welding Machines
One Process – A Multitude of Applications
During butt welding, thermoplastic sheets are heated
at their edges by a heating element and joined and
cooled under pressure. Performed correctly, the weld
zone is extremely low in stresses. Plastic components
welded with this technology stand out for special durability and material load capacity. Weld quality, production speed and the ability to process a wide variety
of materials are the reasons why this technology is
found in numerous fields and applications.
Applications include ventilation and air conditioning,
packaging, water and wastewater treatment systems,
galvanising, plating and chemical tank fabrication,
pipe insulation, concrete protective liners, just to
name a few.
Butt Welding Machine –
for welding UHMW-PE
Butt Welding Machine SM x60
World Leader
As variable as the range of application may be, most butt welded
components have one common feature: They have been produced
with a Wegener machine. Worldwide, Wegener sells more butt welding machines than all their competitors combined. And for a good
reason, Wegener’s expertise is based on decades of experience with
this technology which enables us to provide unrivaled machinery.
History proves that Wegener’s butt welders operate exceptionally
reliable and consistently efficient even after many years of use.
maximum
working width
material
thickness
SV x20
SM x40
SM x60
2 to 4 m
2 to 6 m
2 to 6 m
up to 15 mm up to 40 mm up to 60 mm
min. cylinder
dimension (mm) 360 x 210
^ working width
x=
280 x 300
300 x 380
Outstanding Product Features
Our patented welding tables combined with their parallel travel
mechanism guarantee a unique, durable, maintenance free mechanical synchronisation, free from offset or distortion. This technology
developed by Wegener achieves for an even and precision welding
seam along the entire working width, from 1 to 6 m with a sheet
thickness of up to 100 mm.
Our VARIO clamping system allows for easy movement of the
clamping beams to the inner table edges. Even thin sheets can be
tightly clamped on the table edge by variable clamping beams in
order to ensure precision and offset free butt fusion. Additional
product features are the extremely even temperature consistency
across the heating bar and a high welding accuracy over the entire
life cycle. All Wegener machines can be equipped with reliable,
trouble free and operator friendly microprocessor controls and
offset compensation.
90° degree corner welding
system with vacuum clamping, independent setting
bar, fully adjustable heating
element positioning and
VARIO clamping system
SMS
· Operator friendly and maintenance
free locking system for clamping
beams
· Support roller for an easy
unloading of the material
Sheet rolling Device – RV 4 – automated and quick fabrication of cylindrical tanks
Accessories and Machine Types for all Requirements
The different application possibilities for butt welding technology
require individual technical solutions. Production of cylinders made
Butt Welding Machine
with Sheet Rolling Device
of thermoplastics used to require extra personnel and auxiliary
equipment which proved to be expensive and sometimes dangerous in the past. Today the rolling process of the sheet into a cylinder and insertion underneath the clamping beam is extremely
simplified due to Wegener’s sheet rolling systems. As a supplement
to Wegener’s butt welding machines they make the rolling of cylinders faster, safer and trouble free. Where numerous personnel were
required in former times, one skilled employee now easily rolls and
welds any cylinder on a Wegener butt welder.
For the welding of concrete protective liners Wegener developed a
butt welding machine to accommodate an overall material height
of 20 mm. Wegener’s model KSM butt welder is the result of a customer’s requirement to easily produce PE cylinders with a maximum wall thickness of up to 5 mm.
Another area of expertise are the Wegener series of SMS butt welders which originally challenged us to design a precision machine
to apply low fusion forces for heavy material gauges, a requirement
for foamed PE or PVC materials.
KSM
Our table synchronisation design
is the most effective on the market –
it guarantees even pressures along
the entire weld seam
Bending Machines
BV
Quality in Production
Wegener bending machines are unrivaled when fast, efficient and
reproducible high production quality are an issue, such as in the
field of ventilation and air conditioning technology. In the manufacturing of rectangular channels Wegener’s bending machines
have a clear advantage compared to a 90° welded joint. In addition
to production speed other benefits are high stability and short distance capability from bend to bend. In the chemical, plating and
galvanising industries bending machines are synonymous for
highest quality construction of containers, processing tanks, hoods,
housings, covers or any other structures which require any type of
corner profile – not a chance for leaks.
Vacuum clamping system –
for smallest dimensions
Fully Automatic Bending Technology
Wegener provides the only fully automatic bending
machine worldwide, with automated sheet transport
between the operation steps. Just one operator
handles large production quantities without a problem. During cooling of the first bend, the second one
BM 305 A – the only fully automatic bending machine worldwide
is in the heating process assuring shortest production
times. The BM 305 A is the ideal machine for production runs of rectangular profiles or U-channels.
Hand Held Extrusion Welders
Light Weight with Great Performance
Extrusion welding is a technology which uses an extruded, fully plasticised welding rod applied to the welding surface. During the welding process, the base material is typically heated with hot air travelling in front of the extruded rod.
Hand held Wegener extrusion welders are top of the line in the
market. The combination of compact design, a superior weight
to welding capacity ratio and sturdy construction make them very
user friendly, an advantage every operator will appreciate. Additional features are very accurate temperature consistency, superior
reliability, lowest maintenance requirements and the multitude
of thermoplastic materials they can process.
Technical Advantage in Every Detail
An excellent cost-performance-ratio at best output capacities are
the key to their popularity. The weight reduction is accomplished
by using light weight metals. State-of-the art technology inside:
Rod feed system with Wegener patented worm gear geometry for
highest extrudate quality. This unique design allows for easy pro-
EXWELD sigma SC
cessing of challenging materials such as CPVC.
Wegener’s extensive range of extrusion welding machines is complemented by a large number of accessories. These include tailored
shoes for special applications, rotating and angled welding heads
just to name a few. Oil and moisture free clean air, imperative for
the quality of a weld is offered through dedicated blowers which
are lowest in maintenance, lowest in operating cost and lowest in
noise generation. These blowers are designed to provide the correct
air volume for optimum extrusion welding.
EXWELD alpha2 SC
EXWELD alpha2 EC
EXWELD beta2 EC
welding capacity (PE)
weight
EXWELD sigma SC
up to 1,9 kg/h
5,8 kg
EXWELD alpha2 SC
up to 2,6 kg/h
7,0 kg
EXWELD alpha2 EC
up to 2,6 kg/h
5,9 kg
EXWELD beta2 SC
up to 4,6 kg/h
9,9 kg
EXWELD beta2 EC
up to 4,6 kg/h
8,9 kg
EXWELD gamma2 EC
up to 6,2 kg/h
9,2 kg
EXWELD hydro
up to 4,8 kg/h
4,5 kg
EXWELD 322
up to 1,4 kg/h
4,8 kg
EXWELD 322 F
up to 1,4 kg/h
5,6 kg
EXWELD mini C
up to 0,7 kg/h
2,5 kg
EXWELD mini F-C
up to 0,7 kg/h
2,9 kg
"Twisty" extrusion welding shoe – the possibility of 360° rotation allows welding
in any direction and access into thightest spaces
EXWELD 322 F
EXWELD – a Solution for Any Application
Wegener’s EXWELD series of extrusion welders offers a multitude
EXWELD beta2 SC
of models to suit every application. Wegener customers can choose
from a wide variety of extrusion welders and select the most suitable design in capacity and air supply for their application. Regardless
of factors such as sheet thickness, pipe diameters, weld geometries,
environmental conditions, in shop or field locations or polymer
types – Wegener has the right machine to fulfill your needs.
The choice is yours: EXWELD mini for small welds, thin materials
and tacking, the proven and economic EXWELD 322 and 322 F, the
high-performance EXWELD alpha2 and the high capacity machines
EXWELD beta2 and EXWELD gamma2, designed for thick sheets and
EXWELD gamma2 EC
heavy wall pipes. The output/weight ratio of the EXWELD alpha2 is
unrivaled in the industry.
Only Wegener provides the EXWELD hydro, the patented maintenance free high production unit with hydraulic drive. Ideal for automation, continuous use and high production applications.
EXWELD hydro
EXWELD mini F-C
Hot Air Welding Tools
Compact and with High Performance
Hot air hand welding is the oldest and most proven process for
welding of thermoplastics. It is used for thin walled components
and is perfect to join sheet for containers, channels and floor coverings. Plastic pipes for air, drinking water and other fluids, gutters
and window profiles and tank linings can be fabricated using
Wegener’s hot air welding tools.
Wegener has always been an influencial leader in this technology.
Since the company was founded Wegener provides a complete line
of products for hot air welding. Over the years Wegener hot air
welding tools have been continuously improved to always meet
the highest performance in quality requirements.
Duratherm
Hot air welding tools made by Wegener are among the finest in
the world. Their ergonomic design, compact size and low weight
produce best results in tacking, free hand and high speed welding
operations.
Autotherm2
Airtherm 1600
Airtherm 3000
Precision Temperature
Wegener’s Duratherm, Duratherm SC, Autotherm2 and Airtherm
models provide optimum performance for all modern thermoplastic hand welding operations. With a unique rotating handle, the
Duratherm is ideal to weld in close quarters and in any position.
The Autotherm2, with its ergonomic handle and close loop tempe-
Welding Nozzles and Blowers for All Applications
rature regulation is the preferred choice of professional welders
The technically advanced design and construction of
across the globe. Companies in the field of fluoropolymers appre-
Wegener welding nozzles is appreciated worldwide.
ciate the precision temperature control and consistency within a
Wegener offers highest quality stainless steel preci-
range of up to 600 ºC. Airtherm is the most universal equipment
sion nozzles for tacking, free hand welding and high
among the Wegener hand welding tools. Airtherm, with its integra-
speed welding. Combination tacking and high speed
ted blower, is the perfect choice for assembling and field welding
welding nozzles are a Wegener innovation.
applications.
Nozzles for triangular shapes, cap strips or other profiles are part of the Wegener program. Our cast stainless steel nozzles are preferred for welding PVC and
fluoropolymers.
Clean air at constant volume is a must for quality hot
air welding. Wegener industrial blowers reliably supply the appropriate amount of clean, oil and moisture
free air with a minimum of noise and weight.
DT 6L
DT 14
Welding nozzles for any application
Geosynthetics / Geomembranes
Easy to use and handy in Operation
Welding of membranes in landfill and similar applications demands high quality and longevity of the
welded seams. The Wegener Geoweld Power and
Geoweld Plus are two extremely reliable welding
machines for this market. Even extremely difficult
tasks such as overhead welding in tunnels, tight
radius seams, extreme humidity or welding in tight
areas are easily accomplished.
These hot wedge welders allow welding of thinnest
gauges to material thicknesses of up to 4 mm.
For quick verification of weld quality on site Wegener
offers the handy Minitest peel tester. Pressure testing
of a double seem is easily performed using Wegener’s
Airtest clamp.
Geoweld Plus
Geoweld Power
Testing Equipment
An Essential Must for your Quality Management
Quality control and quality assurance make a critical difference in
all fabrications. The customer has to be assured of the integrity of
the welded joint. Wegener provides a full line of high performance
testing units. These include high frequency AC spark testers,
DC testers and testing machines for geomembrane welds.
The WEG 24 and WEG 100 can check welded seams, liners and
WEG 100
coatings fast and trouble-free. The top of the line PHD testers allow
high precision adjustment of the output voltage with visual and
audible alarms for optimum verification of integrity. All test units
are available with a wide variety of accessories and electrodes to
meet even the most stringent requirements.
PHD
WEGENER International GmbH
Das Wegener Programm:
The Wegener product range:
Ernst-Abbe-Str. 30
· Sonderlösungen
· custom designed solutions
D-52249 Eschweiler
· Schweißmaschinen
· butt welding machines
Phone: +49 2403 70484-0
· Biegemaschinen
· bending and edging machines
Fax: +49 2403 70484-99
· Extrusionsschweißgeräte
· extrusion welding equipment
www.wegenerwelding.de
· Warmgasschweißgeräte
· hot air welding equipment
info@wegenerwelding.de
· Geotechnik und Prüftechnik
· geotechnical and testing equipment
Design: Suna Niemetz Photo: www.bildkonzepte.de / Fotostudio Arnolds Text: M. Schneiberg · 2011
Im Sinne des technischen Fortschritts behalten wir uns Änderungen vor. / Subject to technical modifications.