Manufacturer of Capacitor Discharge Welding (CD/KES) systems with series and job fabrication for the automotive industry
Manfred Schlemmer GmbH
GermanyNew on Amplifa
About Manfred Schlemmer GmbH
Manfred Schlemmer GmbH is an internationally active company since 1971, specializing in Capacitor Discharge Welding (CD/KES Welding). The company designs and manufactures its own KES welding systems in portal/double portal and C-frame designs, develops and adapts welding fixtures, and manufactures welding tools in its own tool laboratory. Before investment, the process selection is secured through functional proof testing in its own welding laboratory. In addition to system construction, the company offers series and job fabrication with up to 10 million welds per year on a base of 15 KES systems operating in 3-shift (24/7) mode. The system control ProTIA© is based on Siemens SIMATIC S7 with Fail-Safe, Profinet in real-time, operating data acquisition, and IO-Link integration. Other mastered processes include laser, resistance, MIG/MAG, and electron beam welding, as well as automation. Customers include Daimler, Audi, VW, Ford, DAF, ZF, Magna, and GM. Since 2018, there has been a partnership with Lincoln Electric (Cleveland), whose company, the Lincoln Electric Automation Group, takes over the global service of Schlemmer systems.
- Site
- Germany
- Processes
- Capacitor Discharge Welding (CD Welding / KES), Laser welding (Laserschweißen), Resistance welding (Widerstandsschweißen), MIG/MAG welding, EBW Electron Beam Welding (electron-beam welding), Automation (Automating, fully automated lines), Series and job fabrication of welds, Development and adaptation of welding fixtures, design and manufacturing
- Materials
- Capacitor Discharge Welding (CD Welding), Laser Welding, Resistance Welding, MIG/MAG Welding, Electron Beam Welding
- Certificates
- ISO 9001:2015, CE Certification of Systems, UL Certification of Systems
- Founded
- 1971
- Industries
- Automotive Industry
- 01
Consulting and selection of welding process
- 02
Functional proof testing in own welding laboratory
- 03
Development and adaptation of welding fixtures
- 04
Tool manufacturing in own tool laboratory
- 05
Design and manufacturing of the KES welding system
- 06
Project launch including pre-series and sampling
- 07
Series and job fabrication (3-shift, 24/7)
- 08
Pre- and Aftersales service including spare parts warehouse and global service
Processes and Technology
Capacitor Discharge Welding (CD Welding)
High-pulse welding process with net welding time under 10 ms and cycle times over 0.8 s; stored energy 2–160 kJ depending on system type, with currents up to 2,000,000 A.
Laser Welding
Precise joining process for demanding welding tasks alongside the core KES process.
Resistance Welding
Complementary welding process in the company's process spectrum.
MIG/MAG Welding
Gas-shielded arc welding for structural and sheet metal components.
Electron Beam Welding
High-energy vacuum welding process for precision-critical joining tasks.
Site
Germany
DESystem construction, tool laboratory, welding laboratory, series and job fabrication
- Lot size
- Individual systems up to large series (up to 10 million welds/year)
- Materials
- Steel, stainless steel (weld joint varies by component)
- 15 KES welding systems (Inventory)
- KES system Portal/Double Portal (18–160 kJ, 2,000,000 A, up to 160 mm ring buckle diameter)
- KES system C-Frame (2–24 kJ, 400,000 A, up to 95 mm ring buckle diameter)
- Control ProTIA© (Siemens SIMATIC S7, Fail-Safe, Profinet Real-time, IO-Link ifm)
- Own welding laboratory
- Own tool laboratory
Systems and Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Capacitor Discharge Welding (CD Welding / KES)Joining | – | – | – | 10,000,000 welds/year | – |
| Laser welding (Laserschweißen)Joining | – | – | – | – | – |
| Resistance welding (Widerstandsschweißen)Joining | – | – | – | – | – |
| MIG/MAG weldingJoining | – | – | – | – | – |
| EBW Electron Beam Welding (electron-beam welding)Joining | – | – | – | – | – |
| Automation (Automating, fully automated lines)Assembly | – | – | – | – | – |
| Series and job fabrication of weldsJoining | – | – | – | 10,000,000 welds/year, 3-shift | – |
| Development and adaptation of welding fixtures, design and manufacturingEngineering | – | – | – | – | – |
4 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| KES Capacitor Discharge Welding System Portal/Double Portal Design | Schlemmer | – | Stored energy 18–160 kJ; Current up to 2,000,000 A; Ring buckle diameter up to 160 mm; Cycle time > | – | – |
| KES Capacitor Discharge Welding System C-Frame | Schlemmer | – | Stored energy 2–24 kJ; Current up to 400,000 A; Ring buckle diameter up to 95 mm; Cycle time > 0.8 s | – | – |
| KES Welding Systems (Inventory for Series/Job Fabrication) | Schlemmer | 15 | – | – | – |
| Control Operator Interface ProTIA© (Siemens HMI Simatic S7, Fail-Safe, Profinet Real-time, IO-Link) | Schlemmer / Siemens / ifm ProTIA© | – | – | – | – |
Additional services
Reference customers
Quality
The series and job fabrication operations are certified according to ISO 9001:2015. All welding-relevant process data are processed, managed, visualized, and stored via the operating data acquisition system (ProTIA©); the KES systems are CE and UL certified.
| Evidence | Germany |
|---|---|
| ISO 9001:2015 | |
| CE Certification of Systems | |
| UL Certification of Systems |
History
- 1971
Company founded; globally active in CD-Welding ever since
- 1990
Cooperation with PECO (Process Equipment Company) from Ohio for the North American market
- 2018
Partnership with Lincoln Electric (Cleveland); Lincoln Electric Automation (Wayne Trail, Coldwater, Tennessee Rand, Robulution) takes over the global service of Schlemmer systems