The HFDB-100 combines copper braid feeding, resistance welding, compacting and cutting in one machine. Before each piece is cut, the selected area is welded and pressed into a compact section. This helps hold the individual copper strands together and produces an end that is easier to handle in the next assembly process.
Although this equipment is sometimes described as a copper braid crimping and cutting machine, it does not simply apply a mechanical crimp. It uses a 1000 Hz medium-frequency welding system to heat and compact the braid before cutting.
The HFDB-100 is intended for small copper braid cross-sections from 4 to 8 mm². It should not be confused with a copper diffusion welding machine for large laminated busbars or a terminal crimping machine that attaches lugs to cables.
Technical Specifications
|
Parameter |
Specification |
|
Equipment Name |
Automatic copper braids crimping and cutting machine |
|
Model |
HFDB-100 |
|
Rated Duty Cycle |
20% |
|
Transformer Capacity |
160 KVA |
|
Cylinder Bore / Stroke |
160 mm / 110 mm |
|
Max. Working Pressure |
10,000 N |
|
Max. Primary Current |
100 A |
|
Current Adjustment Range |
0% ~ 99% |
|
Transformer Insulation Class |
Class F |
|
Throat Depth |
425 mm |
|
Max. Secondary Short-Circuit Current |
38 KA |
|
Lower Electrode Arm Deflection |
< 0.1 mm (At max. cylinder pressure) |
|
Max. Copper Platform Spacing |
250 mm |
|
Welding Area Range |
4sqmm - 8sqmm |
How the HFDB-100 Works?
Copper Braid Feeding
Continuous copper braid is loaded onto the feeding section. The material is guided toward the welding and cutting position.
01
Length Positioning
The control system feeds the braid to the set position. The required finished length should be confirmed according to the customer's copper shunt drawing.
02
Resistance Welding and Compacting
The welding head applies pressure to the selected section. The 1000 Hz MFDC power supply provides the programmed preheat, welding and tempering stages, compacting the copper strands at the cutting area.
03
Cutting
The compacted area is cut to form an individual copper braid section. Welding before cutting helps prevent loose strands at the cut end.
04
Part Discharge
The finished copper braid piece leaves the working position for collection or the next production process.
05
Why Weld the Copper Braid Before Cutting?
Loose copper braid can spread or fray after cutting. This makes part handling, positioning and later assembly more difficult.
The HFDB-100 first welds and compacts the cutting position. The compact section holds the strands together while the braid is cut into the required length. The result depends on the braid cross-section, strand structure, surface condition, welding current, pressure and heating time.
This process is mainly used to prepare copper braid sections for later forming, terminal connection or assembly. The machine does not replace all subsequent manufacturing steps.
Machine Protection Functions
Water Flow Monitoring
If cooling-water flow becomes abnormal, the machine issues an alarm and stops the cycle. This protects water-cooled welding components from operating without the required cooling.
Current Monitoring
An abnormal current alarm identifies a welding cycle that does not follow the configured current condition. The affected part should be inspected before production resumes.
Pressure Monitoring
The pressure alarm stops the process when the detected pressure is outside the permitted condition. This helps prevent welding with insufficient or unstable force.
Copper Braid Products Made with the HFDB-100
Low-Voltage Switchgear Flexible Shunts
The HFDB-100 can prepare small copper braid sections used as flexible electrical connections in switchgear. The compacted end makes the braid easier to position during later assembly.
Circuit Breaker Connections
Copper braid shunts are used between fixed and moving conductive parts. The machine prepares the braid to the specified length while keeping the middle section flexible.
Contactors and Electrical Switching Devices
Small copper braid connectors can carry current between components that move during operation. Welding and cutting the braid helps control the condition of the cut end before connection or forming.
Power Distribution Components
The machine can prepare copper braid sections for low-voltage power distribution assemblies where a flexible conductor is required between two electrical parts.
The HFDB-100 processes the copper braid itself. Whether the finished part requires later drilling, terminal welding, mechanical forming or surface treatment depends on the customer's product design.
What Makes the HFDB-100 Different?
HAIFEI has several types of equipment for copper braid and flexible conductor production. The HFDB-100 has a specific processing range and should be selected for the correct application.
| Equipment | Main Function | Typical Workpiece |
| HFDB-100 | Automatic feeding, MFDC compacting and cutting | 4–8 mm² copper braid |
| Copper braid terminal welding machine | Welds braid to a terminal or conductive part | Finished connector assembly |
| Copper diffusion welding machine | Bonds foil or braid under heat and pressure | Larger flexible busbars |
| Terminal crimping machine | Mechanically crimps a terminal onto a conductor | Cable and lug assembly |
This distinction prevents the HFDB-100 from competing with HAIFEI's diffusion welding machines and other copper braid production equipment.
why Choose Our Automatic Copper Braided Wire Shunt Cutting And Squaring Machine ?
Haifei Intelligent Equipment Co., Ltd. specializes in high-end resistance welding and automation solutions. We provide:
high quality
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One-Stop Solution
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Deep experience in E-E-A-T-driven industrial manufacturing.
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Fast Technical Support
Quick-response service ensures reliable long-term operation.
Custom Solutions
Machines tailored to your wire size, length, and production requirements.
Customization process
Comprehensive, professional and considerate service.
01
Requirements Consulting
02
Prototype Testing
03
Solution Development
04
Selection and Design
05
Manufacturing Inspection
06
Installation Training
07
Production Acceptance
08
After-sales Maintenance
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We have served over 5,000+ customers worldwide, and our long-term partners include Tesla, BYD, and Siemens.Over 50+ Fortune 500 companies.
Haifei Customer Site
FAQ
01.Is the HFDB-100 a crimping machine or a welding machine?
02.What copper braid size can the HFDB-100 process?
03.Can the HFDB-100 cut loose copper braid directly?
04.Can the machine process tinned copper braid?
05.Can different copper braid products use different settings?
06.Does the machine attach terminals to the copper braid?
Wuxi Haifei Intelligent Equipment Co., Limited is one of the leading manufacturers and suppliers of Automatic Copper Braided Welding and Cutting Machine in China. With abundant experience, we warmly welcome you to buy advanced Automatic Copper Braided Welding and Cutting Machine for sale here from our factory. Quality products and reasonable price are available.
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