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CHAPTER 4:  INTRODUCTION TO FEEDBACK MODES AND MONITORING 

 

 

 

HF28 DC RESISTANCE WELDING SYSTEM 

4-2 

990-372 

Power Mode 

Application 

 

Breaking through surface oxides and plating 

 

Automated applications where part or electrode surface conditions can vary over time. 

 

Description 

This mode precisely varies the weld current and voltage to supply consistent weld energy to the 
parts.  The power mode has been shown to extend electrode life in automated applications. Set 
monitoring limits on current or voltage. 

 
 
 

Summary of Contents for 1-288-01

Page 1: ...990 372 REV E DC RESISTANCE WELDING SYSTEM HF28 OPERATION MANUAL...

Page 2: ...B 34461 12 09 Updated technical information specifications C 42840 10 13 Updated to Miyachi America name and logo D 43480 11 14 Updated to Amada Miyachi America name and logo E 43808 8 15 Updated to...

Page 3: ...splay 1 4 Display Controls 1 5 SCHEDULE Key 1 5 Weld Period Selector Keys 1 5 Time Energy Selector Keys 1 5 Front Panel Data Entry and Mode Keys 1 6 Key Pad 1 6 Mode Keys 1 6 RUN Key 1 6 MENU Key 1 6...

Page 4: ...ion Section I Menus 3 1 Before You Start 3 1 Overview 3 1 Main Menu 3 1 1 Setup 3 1 2 Weld Counter 3 2 3 Copy A Schedule 3 3 4 Calibration 3 3 5 System Security 3 3 1 Schedule Lock 3 4 2 System Lock 3...

Page 5: ...inition 3 19 Weld Sequence Timing 3 19 Welding Applications 3 20 Single Pulse Weld Profile 3 20 Upslope Downslope Weld Profile 3 21 Dual Pulse Weld Profile 3 21 Chapter 4 Introduction to Feedback Mode...

Page 6: ...Pulse Weld Schedule 5 7 Section III Using the Weld Monitor 5 9 Section IV Active Part Conditioning 5 13 Section IV Resistance Set 5 15 Section VI Pre Weld Check 5 17 Section VII Weld To A Limit 5 19 S...

Page 7: ...ppendix A Technical Specifications A 1 Appendix B Electrical and Data Connections B 1 Appendix C Calibration C 1 Appendix D System Timing D 1 Appendix E The Basics of Resistance Welding E 1 Appendix F...

Page 8: ...rovia CA 91017 7133 Telephone 626 303 5676 FAX 626 358 8048 e mail info amadamiyachi com The purpose of this manual is to supply operating and maintenance personnel with the information needed to prop...

Page 9: ...dvantage of the full capabilities of the weld head and power supply please read these instruction manuals before attempting to use them Procedures other than those described in these manuals or not pe...

Page 10: ...HF28 DC RESISTANCE WELDING SYSTEM x 990 372...

Page 11: ...TY WHETHER EXPRESS OR IMPLIED BY LAW COURSE OF DEALING COURSE OF PERFORMANCE USAGE OF TRADE OR OTHERWISE Notwithstanding the foregoing in the event of the failure of any Third Party Product Seller wil...

Page 12: ...replace such Goods or the defective part or ii credit or refund the price of such Goods at the pro rata contract rate provided that if Seller so requests Buyer shall at Buyer s expense return such Goo...

Page 13: ...itions for Additional Acceptance Tests either at Seller s or Buyer s facility shall be mutually agreed in writing prior to issuance or acceptance of the Acknowledgement Performance Warranty The system...

Page 14: ...efect in material and workmanship which are apparent upon receipt by Buyer The foregoing warranty is negated after the initial use No warranty made hereunder shall extend to any product whose serial n...

Page 15: ...phase state of the art inverter power supply for joining precision small parts at high speed with controllable rise times The delivered welding energy is in the form of DC welding energy High speed 40...

Page 16: ...n Screen The MONITOR screen provides instant visual feedback on the actual current voltage or power used to make each weld It permits you to program adjustable limits for both weld pulses Monitor Scre...

Page 17: ...e operator s controls and indicators and the rear panel which contains fuses circuit breakers and power and signal connectors The rear panel connections are discussed in Chapter 2 Front Panel Display...

Page 18: ...active mode of the Control In the run mode the display permits you to View the entire weld schedule profile individual weld periods and weld energy parameters View individual weld parameter program ch...

Page 19: ...press the RUN key Weld Period Selector Keys Select individual weld periods and weld energy fields in the weld schedule profile for programming See Front Panel Data Entry and Mode Controls Time Energy...

Page 20: ...or the schedule key The keys allow you to increment up or decrement down numeric values on the display to change states such as OFF to ON up or ON to OFF down and to scroll the schedule number up and...

Page 21: ...ed Pressing the kW key selects power as the control mode for this schedule The control will output the power waveform shown on the LCD Monitor Keys These keys allow you to view the results of the last...

Page 22: ...t an alarm when the limits are exceeded Pressing this key selects either peak welding energy or average welding energy to be monitored by the energy limits monitors WELD NO WELD Switch When the switch...

Page 23: ...tely at the postal or e mail address or telephone or FAX number shown in the Foreword of this manual Space Requirements Allow ample workspace around the Control so that it will not be jostled or struc...

Page 24: ...tions Input power requirements for the Control are as listed below Power Input Specifications HF28 Model Input Voltage 50 60 Hz 3 phase Vrms Ckt Brkr Current A rms Copper Wire Gauge 7 strands AWG Wire...

Page 25: ...nections to External Equipment All connections other than the weld cable connections between the Control and external equipment are made through the rear panel Rear Panel Components and Connectors The...

Page 26: ...Connect one end of the second weld cable to the positive welding transformer terminal on the Control 3 Connect the other end of the weld cables to the weld head 4 Attach the voltage sensing cable conn...

Page 27: ...se either the or 1 8 diameter clip as appropriate to the electrode diameter 7 Attach a clip directly to each electrode as shown on the right 8 Put a strain relieve on each voltage sensing lead to its...

Page 28: ...nnector to the Control firing switch cable connector 3 Adjust the weld head force adjustment knob to produce 5 units of force as displayed on the force indicator index 4 Connect the weld head firing s...

Page 29: ...rical and Data Connections for circuit details 8 Set the WELD NO WELD switch on the Control front panel to the NO WELD position In this position the Control cannot deliver weld energy but it can contr...

Page 30: ...head firing switch cable connector to the Control firing switch cable connector 3 Connect a normally closed approved emergency stop switch across the two leads of the operator emergency stop switch ca...

Page 31: ...rol front panel to the NO WELD position In this position the Control cannot deliver weld energy but it can control the weld head 9 Set the circuit breaker on the rear panel of the Control to the ON po...

Page 32: ...ESISTANCE WELDING SYSTEM 2 10 990 372 Non EZ AIR Weld Head Connections Non EZ AIR heads may be connected to the Control as shown below however you should refer to the manual provided with the weld hea...

Page 33: ...e menu screens have similar prompts that tell you how to go to a function on the menu and or get to the next menu MAIN MENU 1 SETUP 6 RELAY 2 WELD COUNTERS 7 RESET DEFAULTS 3 COPY A SCHEDULE 8 CHAIN S...

Page 34: ...made in any weld schedule WELD COUNTERS 1 TOTAL WELDS 0000000 2 OUT OF LIMITS HIGH 000000 3 OUT LIMITS LOW 000000 4 WITHIN LIMITS 000000 Number Select an item RUN or MENU NOTE The Control breaks down...

Page 35: ...y to copy the schedule and exit the screen 6 Press the MENU key to return to the main menu The contents of Weld Schedule 1 will be copied to Weld Schedule 2 overwriting the previous contents of Weld S...

Page 36: ...the calibration settings NOTE All security options use the same procedure to enter a security code and to turn the security code OFF 1 Press the 1 key to select SCHEDULE LOCK This will bring up the C...

Page 37: ...2 WHEN ALARM Number Select Page RUN or MENU 4 Press the 2 key to select the WHEN menu shown at the right WHEN 1 ALARM 6 P1LOW 2 OUT OF LIMITS 7 P2HIGH 3 WELD 8 P2LOW 4 END OF WELD 9 MG3 SYNC 5 P1HIGH...

Page 38: ...etting System Parameter Default Setting Foot Switch Weld Abort OFF Weld Counters All 0 Switch Debounce Time 10 ms Communication Role SLAVE Firing Switch AUTO Baud Rate 38 4K Display Contrast 50 ID Num...

Page 39: ...unt creating a chain of schedules that can accommodate a variety of welding needs For example A single work piece requires four welds two weld points require the same weld schedule each of the other t...

Page 40: ...E SETUP SCHEDULE NUMBER WELD COUNT NEXT 1 1 1 2 1 2 3 1 3 4 1 4 Scroll SCHEDULE Select MENU 4 Use the Up Down keys on the front panel to scroll vertically through the schedules to highlight the weld c...

Page 41: ...a foot switch a force firing switch or a programmable logic control PLC Any of these switches could be the weld initiation switch in your system setup ON means that the welding process is initiated b...

Page 42: ...Weld Force Control 3 The SWITCH DEBOUNCE TIME line will now reflect your switch debounce time selection 3 Firing Switch With the SETUP 1 screen displayed press the 3 key to select this function The f...

Page 43: ...turn to the SETUP PAGE 2 of 3 screen 3 End Of Cycle Buzzer 1 With the SETUP 2 screen displayed press the 3 key to toggle the end of cycle buzzer ON or OFF This function is normally used with manually...

Page 44: ...ze response to varying weld conditions Press 1 to bring up the following choices 1 ALWAYS A test weld will be done if The voltage level changes The time in any element of the schedule changes If the w...

Page 45: ...e Use the no weld state when adjusting the air regulators on air actuated weld heads Menu State Pressing the MENU key puts the Control in the menu state It brings up menu screens that enable you to se...

Page 46: ...d was 1 014 volts and the total weld count since the weld counter was last reset is 5 237 The weld profile trace is an analog display of the electrical parameters programmed with the weld period selec...

Page 47: ...f four actions for PULSE 1 and one of two actions for PULSE 2 depending on the selection made with the MONITOR display as shown at the right Also an alarm message will be displayed and any relay set f...

Page 48: ...M 3 16 990 372 Alarm State The Control automatically recognizes many alarm conditions The example WELD SWITCH IN NO WELD POSITION alarm screen shown at the right is displayed when you attempt to initi...

Page 49: ...eld energy amplitudes for the weld period segments you can program an appropriate weld schedule profile to perform the above applications Typical applications and recommended weld schedule profiles ar...

Page 50: ...ted weld head closes Manual Weld Heads For manually actuated weld heads SQUEEZE TIME begins when the force firing switch closes Using SQUEEZE TIME is optional depending on the welding process you have...

Page 51: ...may be programmed for single pulse upslope downslope or dual pulse operation Weld schedules may also use special monitoring features of the Control such as Energy Limit Active Part Conditioner and Pre...

Page 52: ...t flat spring steel parts or heavily plated or oxidized parts Dual Pulse Use for spot welding parts with plating First pulse can be used to displace plating or oxides and the second pulse to achieve t...

Page 53: ...ed to displace plating and or oxides reduce flashing and spitting or reduce thermal shock when welding parts containing glass to metal seals Downslope annealing assists in the grain refinement of cert...

Page 54: ...weld current is typically greater than the Pulse 1 weld current by a factor of 3 as the first pulse significantly reduces the resistance of the interface between the parts The only use for the downslo...

Page 55: ...ctrode to part contact is controlled and consistent Description This mode delivers the programmed current regardless of work piece resistance changes This compensates for slight changes in part thickn...

Page 56: ...ace oxides and plating Automated applications where part or electrode surface conditions can vary over time Description This mode precisely varies the weld current and voltage to supply consistent wel...

Page 57: ...y the time periods for these limits during the weld pulse These limits can be used for several purposes Common uses for out of limits welds are to stop a weld or to trigger a relay to remove parts wit...

Page 58: ...le pulse must be in the same units such as kW Process Tools These tools are proven methods to use the monitor and limit functions described above in order to achieve specific results There are five co...

Page 59: ...d in their ability to deal with varying levels of part contamination and oxide If constant current feedback were used the power supply would ramp the voltage to very high levels in order to achieve cu...

Page 60: ...Set is very similar to APC except that there are applications where you do not want a high voltage at the beginning of the pulse Instead you want to start both voltage and current low and build on an...

Page 61: ...be an unacceptable weld and or damaged electrodes When using a Pre Weld Check Pulse 1 should be very short 1 2 milliseconds and the current should be low about 10 of the Pulse 2 current Pulse 1 should...

Page 62: ...he faulty weld piece can be removed The monitor measures the weld energy parameters during the weld period and compares the measurements against the programmed limits If any of the programmed limits a...

Page 63: ...al automation equipment to perform pre programmed actions such as stopping the production line so the faulty weld piece can be removed In the profile above the weld current is exceeding the selected u...

Page 64: ......

Page 65: ...ion on the welding process see Appendix F Quality Resistance Welding Solutions Defining the Optimum Process Pre Operational Checks Always perform these checks before attempting to operate the Control...

Page 66: ...force 2 Set the WELD NO WELD switch on the Control front panel to the NO WELD position In this position the Control will operate the weld head without producing weld energy NOTE When you are ready to...

Page 67: ...n 0 and 99 milliseconds 5 Press the PULSE 1 WELD key again to highlight the middle line of the LCD to enter weld energy Use the numeric keypad to enter the energy level or use the arrows The Control o...

Page 68: ...r use the arrows Enter 0 5 milliseconds 9 Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2 entering the value 0 in each step 10 Press the HOLD key to enter the amount of...

Page 69: ...onds 5 Press the PULSE 1 WELD key again to highlight the middle line of the LCD to enter weld energy Use the numeric keypad to enter the energy level or use the arrows The Control output ranges are Cu...

Page 70: ...r use the arrows Enter 0 5 milliseconds 9 Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2 entering the value 0 in each step 10 Press the HOLD key to enter the amount of...

Page 71: ...1 WELD key again to highlight the middle line of the LCD to enter weld energy Use the numeric keypad to enter the energy level or use the arrows The Control output ranges are Current from 0 1 2 4 kA...

Page 72: ...a time between 0 and 99 milliseconds We recommend at least 2 milliseconds 9 Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2 entering appropriate values for Pulse 2 10 P...

Page 73: ...al weld waveform The LOWER LIMIT line is shorter because it only includes the WELD portion of the waveform If the line of either limit crosses the weld energy waveform the Control can trigger an alarm...

Page 74: ...ode 5 Toggle the Pulse 1 weld time energy selector key to select the lower limit field for the weld period Enter the lower limit value for the Pulse 1 weld period NOTE In order for a Pulse 1 lower lim...

Page 75: ...This will bring up the PULSE 2 OUT OF LIMITS ACTION screen This screen allows you to select the action that the Control will take if the Pulse 2 upper or lower limits are exceeded You PULSE 2 OUT OF L...

Page 76: ...t of time deleted on each end of the limit the limit will appear to move PULSE 1 MONITOR LIMITS 1 LOWER LIMIT IGNORE 1ST 0 0ms 2 LOWER LIMIT IGNORE LAST 2 5ms 3 UPPER LIMIT IGNORE 1ST 0 0ms 4 UPPER LI...

Page 77: ...ance has stabilized and the parts have come into closer contact 6 Push RUN and optimize the energy and time setting of Pulse 1 constant power to provide an adequate tack weld and also a current wavefo...

Page 78: ...rt will reach the current limit sooner and the pulse will terminate early A dirty part will require more time before the oxide is broken down and current can flow 12 Program your second welding pulse...

Page 79: ...ltage waveform 4 From the MONITOR keys section on the front panel press the resistance key and observe the resistance waveform This should appear to begin high then start to drop as a tack weld is mad...

Page 80: ...for the current to rise and reach the limit even with wide variations in initial resistance 11 The power supply terminates the first pulse when your programmed current is reached A low resistance part...

Page 81: ...first pulse peak voltage readings from weld to weld 4 Press the Pulse 1 weld key to highlight the upper limit field for the weld period Use the numeric keypad to enter the upper limit value for the P...

Page 82: ...voltage limits are reached If the voltage limits are not being reached with these conditions present return to the voltage monitor screen and adjust the limits accordingly You may also have to adjust...

Page 83: ...ress the kA current V voltage kW power and resistance keys and observe the resulting waveforms NOTE You can toggle between PEAK and AVERAGE readings by pressing the PEAK AVERAGE key 4 Press the kA cur...

Page 84: ...of the programmed weld time Weld to a Limit Waveform 11 Make several more welds and inspect them for consistency of weld quality and or weld strength NOTE When using the Weld to a Limit function alwa...

Page 85: ...the MONITOR keys section on the front panel press the kA current V voltage kW power and resistance keys and observe the resulting waveforms NOTE You can toggle between PEAK and AVERAGE readings by pr...

Page 86: ...Try making welds with only one part present Also try making welds with misaligned parts Observe that the power supply terminates the weld as soon as the voltage limits are reached If the voltage limi...

Page 87: ...RELAY TO ON 2 WHEN ALARM Number Select Page RUN or MENU 4 Press the 2 key to select the WHEN menu shown at the right WHEN 1 ALARM 6 P1LOW 2 OUT OF LIMITS 7 P2HIGH 3 WELD 8 P2LOW 4 END OF WELD 9 MG3 S...

Page 88: ......

Page 89: ...Correct weld energy and time is set at the Control The equipment is set up properly All electrical connections are tight Electrode alignment allows flush contact with the weld pieces Electrodes are p...

Page 90: ...set at HF28 2 Contaminated electrode surface 3 Slow weld head follow up Weld Piece Warping 1 Excessive weld time set at HF28 1 Excessive weld head force 1 Incompatible weld piece projection design 2...

Page 91: ...D SCHEDULE LOCK ON Operator tried to change a weld schedule or individual weld parameters Press MENU select System Security then enter your access code to turn off System Security NOTE Entering a secu...

Page 92: ...ue EMERGENCY STOP OPERATOR ACTIVATED The Operator Emergency Stop switch has been activated All power to the HF28 is immediately terminated Remove any unsafe operating conditions at the welding electro...

Page 93: ...rogrammed by the user INPUT TOO LARGE The user has attempted to program a weld energy or time that exceeds the capability of the HF28 Re program welding parameters to be within the capability of the H...

Page 94: ...splash can cause the actual weld power to drop below the user set Lower Limit for Weld1 Add upslope to reduce weld splash Reset the Lower Limit for Weld1 to a smaller value POWER 2 LOWER THAN LOWER L...

Page 95: ...ER THAN UPPER LIMIT Actual weld voltage is greater than the user set Upper Limit value for Weld1 Weld splash can cause the actual weld voltage to exceed the user set Upper Limit for Weld1 Add upslope...

Page 96: ...Upper Limit values for Weld1 and Weld2 If the terminated weld energy is not adequate for the weld re set the Upper Limit values for Weld1 and Weld2 WELD SWITCH IN NO WELD POSITION User has tried to a...

Page 97: ...oduction line to using a 400 600 grit electrode polishing disk If you must clean a badly damaged tip with a file you must use a polishing disk after filing to ensure the electrode faces are smooth The...

Page 98: ...ELDING SYSTEM 6 10 990 372 Section III Repair Service If you have problems with your Control that you cannot resolve please contact our service department at the address phone number or e mail address...

Page 99: ...LSE 1 and PULSE 2 Pulse Width of 50 ms 6 0 kW max Maximum Output Current 2400A Max Peak Output Voltage at Max Peak Output Current 5 2V Duty Cycle at Max Peak Output Current 3 Max Load Resistance for M...

Page 100: ...Single Valve Air or Cam Actuated Force Fired EZ Air Kit Plug and Play 24VDC EZ AIR weld head 301 350 Series Electronic Weldheads Weld Energy Limits Monitoring Weld Pre Check Mode Inhibit second weld...

Page 101: ...nhibit RS232 Download software revisions Voltage Weld voltage signal for voltage feedback operation 0 to 10 volt peak Weld Head Plug and play connector with Firing and Foot switch inputs Voltage Sense...

Page 102: ......

Page 103: ...of two jumper plugs One jumper plug is installed on power connector J23 located on the center chassis plate The other jumper plug P22 plugs into welding transformer cable connector J22 The jumper plug...

Page 104: ...SCHEDULE 1 Binary Schedule input terminals used for schedule selection 3 SCHEDULE 2 Binary Schedule input terminals used for schedule selection 4 SCHEDULE 4 Binary Schedule input terminals used for s...

Page 105: ...econd level the Control will automatically return the upper electrode to its UP position so that you may re position the weld pieces If you do not release the foot switch at the first level and procee...

Page 106: ...rectly If a PLC or other means of trigger is used refer to the I O Signal Interface General Description on page B 3 The mating connector is an AMP type 206429 1 using cable clamp AMP type 206358 2 The...

Page 107: ...ead Connector The Weld Head Connector combines all the inputs and outputs necessary to connect a plug and play EZ AIR Miyachi Unitek weld head Weld Head Connector Pin Description 1 HEAD_1 switched 24V...

Page 108: ...anded leads The firing switch cable connector is a 2 pin Amphenol Type 80 MC2FI It mates with the weld head firing switch connector which is a 2 Pin Amphenol Type 80 MC2M Firing Switch Connector Pin D...

Page 109: ...ming Diagram BCD Welding Schedule Selection Scheme Weld Schedule No Bit 20 Pin 1 Bit 21 Pin 2 Bit 22 Pin 3 Bit 23 Pin 4 Bit 24 Pin 12 Bit 25 Pin 5 Bit 26 Pin 14 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 2 0 1 0...

Page 110: ...alarm or weld status contact signal outputs You can access the programming function through the main menu as described in Chapter 3 The events that you can program for each relay and their timing diag...

Page 111: ...UTION Only authorized personnel should perform this procedure Calibration Equipment Required The required equipment for the setup is as follows 2 weld cables No 2 0 1 ft 30 cm long PN 2 0 BB11 1000 co...

Page 112: ...7 RESET DEFAULTS 3 COPY A SCHEDULE 8 CHAIN SCHEDULES 4 CALIBRATION 5 SYSTEM SECURITY Number Select an item 4 Press 1 for HF28 CALIBRATION which will bring up the CAUTION screen on the right Press the...

Page 113: ...top cover and enter the shunt value which is stamped on the copper conductor connected to the transformer Press to continue 8 The next two screens are 1 CALIBRATE D A HIGH and 2 CALIBRATE D A LOW Foll...

Page 114: ......

Page 115: ...sure Maximum D1 time is 10 seconds If the firing switch does not close within 10 seconds the message FIRING SWITCH DIDN T CLOSE IN 10 SECONDS will be displayed D2 Delay time from Firing Switch closure...

Page 116: ...tart of the weld sequence that is start of SQZ Maximum DELAY time is 2 ms plus switch debounce time SQZ Squeeze time Selectable range is 0 to 999 ms UP Up slope time Selectable range is 0 0 to 99 0 ms...

Page 117: ...from Remote Schedule Select Signal ON to the start of the weld sequence that is start of SQZ DELAY time is 23 ms SQZ Squeeze time Selectable range is 0 to 999 ms UP Up slope time Selectable range is 0...

Page 118: ...ch does not close within 10 seconds the message FIRING SWITCH DIDN T CLOSE IN 10 SECONDS will be displayed D2 Delay time from Firing Switch closure and Foot Switch Level 2 closure to squeeze time SQZ...

Page 119: ...pplied to the parts Sufficient weld force is required to contain the molten material produced during the weld However as the force is increased the contact resistance decreases Lower contact resistanc...

Page 120: ...LECT RWMA TYPE MATERIAL ELECT RWMA TYPE Alumel 2 Alumel 2 Beryllium Copper 2 Cold Rolled Steel 2 Alumel 2 Chromel 2 Beryllium Copper 2 Stainless Steel 2 Alumel 2 Dumet 2 Brass 2 14 Brass 2 14 Aluminum...

Page 121: ...2 Cold Rolled Steel 2 Gold 14 Gold 14 Consil 2 Consil 2 Gold 14 Kovar 2 Consil 2 Tinned Copper 14 Hastalloy 2 Titanium 2 Consil 2 Dumet 2 Inconel 2 Inconel 2 Constantan 2 Constantan Inconel 2 Kulgrid...

Page 122: ...l 2 Tantalum 2 Nickel Alloy 2 Nickel Alloy 2 Stainless Steel 2 Stainless Steel 2 Nickel Alloy 2 Tinned Brass 14 Stainless Steel 2 Tungsten 2 Nickel Alloy 2 Beryllium Copper 2 Tantalum 2 Tantalum 2 Nic...

Page 123: ...ded materials apart A satisfactory weld will show residual material pulled from one material to the other Tearing of base material around the weld nugget indicates a material failure NOT a weld failur...

Page 124: ...ower for different weld forces as shown in the illustration on the next page Typical Weld Strength Profile 4 Repeat steps 1 through 3 using a different but fixed weld time Typical Weld Strength Profil...

Page 125: ...welding principles Weld profiles Approach to development Common problems Use of screening DOE s Use of factorial DOE s Resistance Welding A Material World The first consideration in designing a quali...

Page 126: ...e process or present as a plating or coating Soldered joints are typically achieved at temperatures less than 400 C and brazed joints such as Sil Phos materials melt at temperatures above 400 C Solid...

Page 127: ...stance welding today The materials can be grouped into three common categories The types of joints achievable within each of the main groups are detailed below Group I Conductive Metals Conductive met...

Page 128: ...t is therefore preferred The chart below gives some guidance on the type of joint that can be expected and design considerations required when joining materials from the different groups Group I Group...

Page 129: ...t is common for the heat generated at the electrode to part and part to part resistances to cause multiple welding problems when welding resistive materials including Part marking and surface heating...

Page 130: ...n for resistive materials in a fusion weld In the first stage the heat is focused in the part to part and electrode to part contact areas since contact resistance is high relative to bulk resistance I...

Page 131: ...he contact resistances to reduce as the materials start to come into closer contact at their interface A hold time is initiated after current flows to allow the parts to cool under pressure before the...

Page 132: ...he variables as possible in the welding equipment set up Welding variables can be grouped in the following categories Initial Welding Trials The Look See Tests Look see welding tests are a series of m...

Page 133: ...re related to either materials variation or part to electrode positioning Some examples are shown below The changes detailed above generally result in a change in contact resistance and always affect...

Page 134: ...gh low settings of a parameter and will help establish the impact of a parameter on the process A Screening DOE is a tool that allows the user to establish the impact of a particular parameter by carr...

Page 135: ...when the critical or main key variables have been identified and we need to establish the best settings for the process A factorial DOE may also give an indication as to how wide the acceptable weld...

Page 136: ...al return in quality and long term consistency Welding problems can more easily be identified and solved if sufficient experimental work is carried out to identify the impact of common variables on th...

Page 137: ...al Equipment 2 3 Contact Us vii Control Features 1 1 Control Keys 1 6 Control Mode Selection Keys 1 7 Copy A Schedule 3 3 Criteria for Success F 10 F 11 Current Mode 4 1 Current Voltage Power Resistan...

Page 138: ...Interaction of Welding Parameters E 6 Introduction to Feedback Modes Monitoring 4 1 Programmable Feedback Modes 4 1 Current Mode 4 1 Introduction 4 1 Power Mode 4 2 Voltage Mode 4 1 Weld Monitoring 4...

Page 139: ...F 1 Approach to Weld Development F 7 Material Variables F 7 Power Supply Variables F 7 Process Variables F 7 Quality Requirements F 7 Weld Head Mechanical Variables F 7 Basic Principles F 4 Common Pr...

Page 140: ...tate 3 13 Weld State 3 15 Overview 3 1 Setup 1 3 9 Firing Switch 3 10 Footswitch Weld Abort 3 9 Switch Debounce Time 3 10 Setup 2 3 11 Buzzer Loudness 3 11 Display Contrast 3 11 End Of Cycle Buzzer 3...

Page 141: ...lector Keys 1 6 Weld Schedule Definition 3 19 Weld Schedule Development E 5 Weld Sequence Timing 3 19 Weld State 3 15 Weld Stop 4 9 5 21 Weld Strength Profiles E 6 Weld Strength Testing E 6 Weld To A...

Page 142: ......

Page 143: ...chheim Germany TEL 49 89 839403 0 FAX 49 89 839403 10 AMADA MIYACHI TAIWAN CO LTD Rm 5 2F No 9 Dehui St Zhongshan Dist Taipei 10461 Taiwan R O C TEL 886 2 2585 0161 FAX 886 2 2585 0162 AMADA MIYACHI V...

Page 144: ...AMADA MIYACHI AMERICA INC 1820 South Myrtle Ave Monrovia CA 91016 U S A TEL 1 626 303 5676 FAX 1 626 358 8048...

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