Design and manufacture of customised welding systems, jigs and special-purpose machinery for specific production tasks
Sondermaschinenbau Zok
35756 Mittenaar, GermanyNew on Amplifa
About Sondermaschinenbau Zok
Sondermaschinenbau Zok is a special-purpose machinery manufacturer based in Mittenaar (Hesse), specialising in process engineering. The company designs and manufactures custom systems and jigs for solving individual production tasks, in particular welding systems for TIG, MIG/MAG, submerged arc and resistance welding as well as assembly, clamping and testing fixtures. The service portfolio also includes technical consulting, operations consulting, development of production concepts, rationalisation of operating processes, repairs and conversion of used machines with modernisation as well as system and machine inspections in accordance with BG and UVV regulations. Reference systems have been built, among other things, for welding tasks on truck axle spindles, propeller shafts, climate chambers, heating boilers, steel girders, exhaust gas control flaps and stator packages for wind turbines. The systems are used in industries such as automotive supply, HVAC technology, heating boiler construction, structural steelwork, wind and solar technology and coal mining. The location is Dernbacher Str. 4 in 35756 Mittenaar.
- Site
- Mittenaar
- Processes
- Special-purpose machinery construction - design and manufacture of customised systems and fixtures, Conversion of used machines with simultaneous modernisation, Repairs of existing machines, Development of production concepts / operations consulting / rationalisation of operating processes, System and machine inspections in accordance with BG and UVV regulations, TIG welding, MIG/MAG welding, Submerged arc welding (SAW)
- Materials
- Stainless steel (high heat-resistant stainless steels), Steel (steel girders, truck axle spindles), Films (plastic), High heat-resistant stainless steels, Steel
- Industries
- Special-purpose machinery construction, Welding technology, Automotive supply (passenger cars/trucks), HVAC technology, Heating boiler construction, Structural steelwork
- 01
Technical consulting and production concept development
- 02
Design and manufacture of the special system or fixture
- 03
Conversion and modernisation of used machines
- 04
Repair and service
- 05
System and machine inspection in accordance with BG/UVV
Materials and Processes
High heat-resistant stainless steels
Processed in the special welding system for exhaust gas control flaps, as the workpieces are exposed to high exhaust gas temperatures.
Steel
Material for steel girders, truck axle spindles and propeller shafts, welded by submerged arc or MIG/MAG.
Films (plastic)
Printable films up to 3 mm thickness are converted on the cross and longitudinal cutting system.
Locations
Mittenaar
DEHead office with design and manufacturing
- Part weight / size
- Components up to 500 kg, workpiece lengths up to 24,000 mm
- Lot size
- One-off production to customer specification
- Materials
- Steel, stainless steel, plastic/films
- Integrated manufacturing cell TIG cold wire (spacer rings)
- Spot welding machine PSA 2/6
- Circumferential seam welding machine MIG/MAG up to 300 A
- Corner seam welding machine (TIG/MIG/MAG/plasma/laser)
- Special welding machine for truck axle spindles (2 x 350 A)
- Longitudinal seam welding machine for steel girders (submerged arc/MIG/MAG, 2 x 1000 A, up to 24,000 mm)
- Assembly and welding fixture for propeller shafts up to 3500 mm
- Tube bundle assembly fixture RBMV 4000 / 900
- Special drilling fixture up to Ø 200 mm
- Cross and longitudinal cutting system for films
- Register welding-in press
- Conveyor trough welding system, submerged arc, 4 x 1000 A
- Welding machine for stator packages for wind turbines
- Welding system for climate chambers (TIG, forming gas)
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Special-purpose machinery construction - design and manufacture of customised systems and fixturesEngineering | – | – | – | – | – |
| Conversion of used machines with simultaneous modernisationEngineering | – | – | – | – | – |
| Repairs of existing machinesEngineering | – | – | – | – | – |
| Development of production concepts / operations consulting / rationalisation of operating processesEngineering | – | – | – | – | – |
| System and machine inspections in accordance with BG and UVV regulationsTesting | – | – | – | – | – |
| TIG weldingJoining | – | 2200 mm (longitudinal seam fixture) × 1600 mm × 1600 mm | – | – | Edelstahl |
| MIG/MAG weldingJoining | – | 24000 mm (steel girder) × 2400 mm × 2000 mm | 500 kg (propeller shafts) | – | Stahl |
| Submerged arc welding (SAW)Joining | – | 24000 mm × 2400 mm × 2000 mm | – | – | Stahl |
| Spot welding (resistance welding)Joining | – | – | – | – | – |
| TIG cold wire weldingJoining | – | – | – | – | – |
| Plasma weldingJoining | – | – | – | – | – |
| Laser weldingJoining | – | – | – | – | – |
| Plasma coatingSurface | – | – | – | – | – |
| Drilling (special drilling fixture, holes up to 200 mm diameter)Machining | – | 2000 mm (working height) | – | – | – |
| Assembly of tube bundles for heat exchangers (assembly fixture RBMV 4000 / 900)Assembly | – | 4000 mm × 900 mm | – | – | – |
| Assembly and testing of case lid closures (4-station automatic machine)Assembly | – | – | – | – | – |
| Cross and longitudinal cutting of films up to 3 mm thicknessPlastics | – | – | – | – | Folien/Kunststoff |
| Winding of stator packages for electric motorsAssembly | – | – | – | – | – |
| Assembly and welding fixture for propeller shafts (joining + pressing, axial pressing force up to 18Joining | – | 3500 mm × 280 mm (max. pipe diameter) | 500 kg | – | – |
| Welding-in of registers for heating boilers (register welding-in press)Joining | – | – | – | – | – |
| Testing fixture (testing fixtures as a product group)Testing | – | – | – | – | – |
| Rotary tables, clamping, positioning (product groups)Engineering | – | – | – | – | – |
23 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Integrated manufacturing cell for welding spacer rings | – | 1 | Cycle time 12 seconds | – | – |
| Spot welding machine PSA 2/6 (resistance welding machine) | PSA 2/6 | 1 | Cycle time 42 seconds per set of parts (6 pieces) | – | – |
| Welding system for manufacturing climate chambers (TIG, forming gas) | – | 1 | – | – | – |
| Circumferential seam welding machine (shuttle version, MIG/MAG up to 300 A) | – | 1 | Workpieces Ø 200 x 200 mm max. length, 40 kg max., 2 independent rotary tables, 1 pneumatic | – | – |
| Corner seam welding machine (TIG, automatic) | – | 1 | Seam lengths up to 300 mm | – | – |
| Special welding system for exhaust gas control flaps (TIG spot welding) | – | 1 | – | – | – |
| Special welding machine for truck axle spindles (MIG/MAG, 2 torches) | – | 1 | Workpiece diameter 800 mm, length 1200 mm, max. 200 kg; 2 x up to 350 A per torch | – | – |
| Circumferential seam welding fixture for T-pieces (internal clamping, internal diameter 10-154 mm) | – | 1 | T-pieces with internal diameter 10 - 154 mm | – | – |
| Welding machine for steel girders (longitudinal seam welding machine, submerged arc or MIG/MAG) | – | 1 | max. length 24000 mm, width 2400 mm, height 2000 mm, camber max. 1500 mm, lateral bow max. | – | – |
| Production system for climate chamber housings (clamping/welding system) | – | 1 | max. component size length 2000 mm, width 1600 mm, height 1400 mm, load capacity up to 500 kg | – | – |
| Longitudinal seam clamping and welding fixture for climate chambers (TIG) | – | 1 | Working length 2200 mm, sheet thickness up to 2 mm, container cross-section max. 1600 x 1600 mm | – | – |
| Assembly and welding fixture for heating boiler inserts | – | 1 | Boiler shell section with dished end, tube wall plate | – | – |
| Assembly and welding fixture for propeller shafts (circumferential seam up to 450 A) | – | 1 | up to 3500 mm length, pipe Ø min. 80 / max. 280 mm, max. 500 kg, axial pressing force up to 18 t | – | – |
| Conveyor trough welding system (submerged arc process, 4 power sources of 1000 A each) | – | 1 | – | – | – |
| Register welding-in press (heating boiler registers, welding-in under press force) | – | 1 | – | – | – |
| 3-station welding machine for door catch strap holders | – | 1 | – | – | – |
| Welding machine for stator packages (wind turbines) | – | 1 | – | – | – |
| Special drilling fixture (4-speed drilling machine with electronic speed control) | – | 1 | Holes up to 200 mm diameter, working height 300 - 2000 mm above floor, manual drilling feed 200 | – | – |
| Tube bundle assembly fixture RBMV 4000 / 900 | RBMV 4000 / 900 | 1 | Tube bundles for heat exchangers | – | – |
| Cross and longitudinal cutting system for films | – | 1 | Film thickness up to 3 mm | – | – |
| 4-station automatic machine for assembly and testing of case lid closures | – | 1 | – | – | – |
| Special fixture for winding stator packages for electric motors | – | 1 | – | – | – |
| Triplex internal clamping fixture (variant II) with rotary-tilting table (manual welding | – | 1 | – | – | – |
Additional services