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Amada HF2, Operation Manual

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2 KHZ INVERTER WEDLING POWER SUPPLY 

990-057 

B-1 

 
 

APPENDIX B 

RS-485 CONNECTION 

 

Description 

The Power Supply has a single RS-485 SERIAL PORT connector for transmitting weld data to a serial 
data collecting device such as a PC or Host Computer.  Multiple Power Supplies can be placed on a multi-
drop RS-485 communications line for weld data collection by a Host Computer using the ASCII command 
language and protocol listed in the Advanced 

RS-485 Advanced Data Communications Operation Manual 

(AMADA WELD TECH Part # 990-058)

. 

 

Connection 

The 

RS-485 SERIAL PORT

 Connector is a 9 pin TE Connectivity 747052-4 (AMADA WELD TECH Part 

#  250-196) bulkhead connector that mates with a connector assembly consisting of a CINCH DE-9P 
(AMADA WELD TECH  Part # 250-193) plug and an TE Connectivity  748677-11 (AMADA WELD 
TECH Part # 250-194) connector shell. 
 

 

 

1.

 

Connect an RS-232-to-RS-485 Converter between your Host Computer 

COM1

 or 

COM2

 ports and 

the Power Supply 

RS-485 SERIAL PORT

. 

2.

 

Set the DIP switches on the converter for the correct configuration.  In the illustration above the 
Telebyte Model 285 converter settings are shown (the black square 

■

 indicates the ON position). 

 

RS-232-to-RS-485 Converter 

An RS-232-to-RS-485 Converter can be connected between the Power Supply 

RS-485 SERIAL PORT

 and 

into the COM1 or COM2 port on any PC. 
 

Summary of Contents for HF2

Page 1: ...990 057 REV S INVERTER WELDING POWER SUPPLY HF2 HF2S OPERATION MANUAL...

Page 2: ...ration procedure and reference User Calibration Procedure 994 001 2 Miscellaneous corrections 3 Remove SAVE error G 18951 08 01 1 Include EO 17693 in manual 2 Add latest version of Operator Guide H 19...

Page 3: ...s manual is to provide the information required for proper and safe operation and maintenance of the AMADA WELD TECH HF2 2kHz High Frequency Inverter Welding Power Supply We have made every effort to...

Page 4: ...g Power Supply to HF2 Welding Transformer Connections 2 4 HF2 Welding Transformer to Weld Head Connections 2 5 Weld Sentry Option 2 5 Help Screen Languages 2 5 CHAPTER 3 WELDING SYSTEM SET UP Welding...

Page 5: ...Supply Front Panel 4 1 Power Supply Rear Panel Inputs and Outputs 4 3 Power 4 3 Fuses F1 F2 4 3 Sensing Port 4 3 Sensing Port Connector Pin Assignments 4 4 Output 4 4 Foot Switch Connector 4 5 Single...

Page 6: ...ram State 5 4 Alphanumeric Program State 5 5 Output Relays 5 6 Relay 1 Dual Air Head Operation 5 7 CHAPTER 6 ADVANCED WELDING FUNCTIONS Weld Functions 6 1 Basic Weld 6 2 Weld Repeat 6 3 Quench Temper...

Page 7: ...Programming 8 3 Energy Limit Monitor General Description 8 4 Energy Limit Monitor Programming 8 5 APPENDIX A TECHNICAL SPECIFICATIONS A 1 APPENDIX B RS 485 CONNECTION B 1 APPENDIX C RECOMMENDED SPARE...

Page 8: ...described in this manual or not performed as prescribed in this manual may expose personnel to electrical shock or DEATH When operating any welder always wear appropriate personal protective gear Mai...

Page 9: ...E OF THE POWER SUPPLY UNNECESSARILY High Voltages are present inside the Power Supply Enclosure Do not touch the inside of the Power Supply unnecessarily with the power turned ON You may receive an el...

Page 10: ...any cable The power cable and connecting cables may be damaged which can cause electric shock short circuit or fire If any part needs to be repaired or replaced consult AMADA WELD TECH or your distrib...

Page 11: ...rface Keep combustible matter away from the Power Supply Spatter can ignite combustible materials If you cannot remove all combustible materials cover them with a non combustible material Do NOT cover...

Page 12: ...ds within three 3 days of Seller s written notice that the Goods have been delivered to the Shipping Point Buyer shall be responsible for all loading costs including freight and insurance costs and pr...

Page 13: ...date of Seller s invoice If Seller does not have Buyer s financial information and has not provided pre approved credit terms for Buyer the payment must be made in cash with order or C O D in US dolla...

Page 14: ...TABILITY b WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE c WARRANTY OF TITLE OR d WARRANTY AGAINST INFRINGEMENT OF INTELLECTUAL PROPERTY RIGHTS OF A THIRD PARTY WHETHER EXPRESS OR IMPLIED BY LAW COURSE...

Page 15: ...ctly or indirectly separately or as part of any system the Goods or any technical data including processes and Services received from Seller without first obtaining any license required by the applica...

Page 16: ...arbitrator and the two arbitrators so selected shall select the third arbitrator who shall act as presiding arbitrator Notwithstanding the foregoing if the matter under dispute is 500 000 or less ther...

Page 17: ...high speed with controllable rise times using 2 KHz output pulses superimposed on pure DC welding energy High speed 250 micro second digital feedback automatically controls weld current voltage or po...

Page 18: ...ach weld schedule can use any one of 10 different Weld Functions thus matching the appropriate weld energy profile to the application Simple automated welding control is easily accomplished using the...

Page 19: ...Transformer Air Flow Pattern HF2 Welding Power Supply Dimensions Width in cm Height in cm Depth in cm Weight lb kg 10 5 26 7 8 5 21 5 15 0 38 1 42 19 HF2 Welding Transformer Dimensions Model Height i...

Page 20: ...e to select the correct power line circuit breaker and wire gauge size To minimize peak power losses use single unbroken wire lines Note To minimize peak power losses AMADA WELD TECH recommends wire g...

Page 21: ...60 4 5 14 3 44 1 TR 12 1 52 1 TR 10 5 60 1 TR 9 2 68 1 TR 4 000 4 000 4 000 4 000 1 300 1 100 950 825 IT X11A 4000A 230 15 5 10 7 10 0 52 1 TR 8 6 60 1 TR 8 7 8 8 8 9 4 000 4 000 4 000 1 300 1 100 TRA...

Page 22: ...Cables B Shorter length Weld Cables or Figure 2 4 Secondary Resistance Measurement C Copper Bus Bars to connect the HF2 Welding Transformer to the Weld Head If these suggestions do not work then a di...

Page 23: ...tions Figure 2 6 Transformer to Weld Head Connections 6 Do not attach the Firing Switch Cable at this time This procedure is covered in Chapter 3 Weld Sentry Option A small tag displaying the message...

Page 24: ......

Page 25: ...ad 3 2 AMADA WELD TECH Force Fired Single Air Actuated Weld Head 3 4 AMADA WELD TECH Force Fired Dual Air Actuated Weld Head 3 7 Non Force Fired Single Air or Cam Actuated Weld Head 3 16 General Progr...

Page 26: ...in Weld Head Electrode Holders Firing Switch Cable Connection Connect the Weld Head Firing Switch Cable Connector to the matching cable connector on the rear of the Power Supply Figure 3 1 Firing Swi...

Page 27: ...t to make a good weld 9 Press PROG Use the vertical cursor keys to increase the weld CURRENT Use the horizontal cursor keys to increase or decrease the WELD time In this example weld CURRENT has been...

Page 28: ...to the matching cable connector on the rear of the Power Supply Weld Head Valve Driver No 1 Connection Figure 3 2 A single air actuated Weld Head has one Solenoid Valve Driver Cable for automatic act...

Page 29: ...he Power Switch located on the Power Supply rear panel to ON After a series of power up screens the last RUN screen displayed will appear Press the CHNG key to access the Weld Graph RUN screen for the...

Page 30: ...g Guide 1 Press MENU The MAIN MENU screen will appear 2 Select TRANSFORMER MODEL The TRANSFORMER MODEL screen appears 3 Select MULTIPLE HEADS OFF If the display reads ON then press CHNG until OFF is d...

Page 31: ...ead System operation uses sequential action to activate one Weld Head and then a second weld head using a single Power Supply and Transformer The operator must close and release the Foot Switch to ini...

Page 32: ...clip end of the standard Voltage Sensing Cable that is connected to the Weld Transformer front panel Connect one twisted wire cable to the Left Weld Head electrodes and the other twisted wire cable t...

Page 33: ...alve Driver Cable to the matching Air Valve 1 Driver connector located on the Power Supply rear panel 2 Connect the 4 pin black plastic connector on the Right Weld Head Solenoid Valve Driver Cable to...

Page 34: ...Power Supply will automatically return the Upper Electrode to its up position Dual Air Regulator Adjustment Model 188 Figure 3 5 1 Set the Power Supply front panel WELD NO WELD switch to NO WELD 2 Tu...

Page 35: ...ct COPY A SCHEDULE The COPY SCHEDULE screen will appear 13 Select the last flashing 0 of TO SCHEDULE 0 and use the number keys to change the flashing 0 TO SCHEDULE 1 14 Press ENTER to complete the sch...

Page 36: ...items appear 21 Select RELAY 1 NOT USED Press CHNG to select the AIR HEAD 2 option 22 Press SAVE to update Schedule 2 then press CHNG to automatically return to the Weld Graph RUN State You are now re...

Page 37: ...tus message changes from STANDBY to ALARM FIRING SWITCH Press RUN to clear the alarm then repeat steps 24 and 25 26 Re adjust the Air Regulator that feeds the Bottom Right Air Cylinder on the Right We...

Page 38: ...re program WELD time and weld CURRENT as necessary to make a good weld Try to use the minimum time and current necessary to make a good weld so that the weld joint heat affected zone will be minimize...

Page 39: ...ress SAVE to save the updated Schedule 2 14 Press to select SCH 001 BASIC WELD 15 Press PROGRAM once to select the Alphanumeric PROGRAM screen for Schedule 1 Select NEXT 001 Change 001 to 002 so that...

Page 40: ...reference Chapter 5 Programming Modes Output Relays For a complete description on how to connect for RS 485 Data Communications reference Appendix B RS 485 Connection 2 All weld schedules must be ent...

Page 41: ...ramming Guide 1 Set the Power Supply front panel WELD NO WELD switch to NO WELD 2 Turn the Power Switch located on the Power Supply rear panel to ON After a series of power up screens the last RUN scr...

Page 42: ...een 11 Select WELD HEAD TYPE AUTO Press CHNG until the MANUAL option appears NOTE FOOTSWITCH TYPE AUTO will automatically change to NONE 12 Select FOOTSWITCH WELD ABORT ON Press CHNG until the OFF opt...

Page 43: ...weld joint heat affected zone will be minimized Up to 128 different weld schedules can be created and saved To manually recall any specific weld schedule press the up or down vertical arrow keys unti...

Page 44: ......

Page 45: ...cimal values KEYPAD Use the numeric keys to change weld schedules without the need to use the keys For example pressing 1 0 will recall weld schedule 10 In the RUN State press to select a higher numbe...

Page 46: ...to the RUN State SAVE has no function in the RUN State MENU In either the RUN or PROGRAM States press MENU to provide a menu list of user options which are common to all weld schedules HELP Press this...

Page 47: ...apter 2 Power Line Fuse Requirements for complete specifications for Power Line Fuse sizes SENSING PORT The Sensing Port contains both input and output lines for communicating to the Transformer and t...

Page 48: ...d Voltage Measurement Return 12 Black Weld Transformer Select Line 3 For MA 600 13 Black Weld Transformer Thermo Switch Return 14 Black Future Expansion 15 Red Future Expansion 16 Red 230 VAC Weld Tra...

Page 49: ...gle Level Foot Switch The emitter of the opto coupler must be connected to Pin 4 3 When using a non AMADA WELD TECH Foot Switch connect Pin 2 to Pin 3 Two Level Foot Switch Figure 4 4 1 When a Two Lev...

Page 50: ...and contains 2 shielded twisted 22 AWG conductors of high flex stranded wire The Firing Switch Connector is a 2 pin Amphenol 80 MC2FI AWTA Part 520 011 with strain relief that mates with an Amphenol...

Page 51: ...nvoking an Emergency Stop Condition which abruptly terminates the welding process The Control Figure 4 7 Opto coupler Firing Switch Signals inputs and outputs are designed to be used with a Programmab...

Page 52: ...nput PLC input Remote Weld Schedule Selection Control Line 21 CCB input Schedule Up increment number 3 Input PLC input Remote Weld Schedule Selection Control Line 22 CCB input Reset set schedule to po...

Page 53: ...table Pin No Function Description 1 Schedule Down Decrement the schedule number 2 Schedule Up Increment the schedule number 3 Reset Set the schedule number power up schedule number 4 Auto Manual Enab...

Page 54: ...o 250 ma 2 Relay K1 is also used to control the Air Valve 2 Driver for sequentially activating a second Air Actuated Weld Head Refer to Chapter 3 AMADA WELD TECH Force Fired Dual Air Actuated Weld Hea...

Page 55: ...ir Valve 2 Driver outputs Figure 4 11 115 VAC Weld Head Solenoid Air Valve 1 Driver Figures 4 11 and 4 12 The output of Air Valve 1 Driver is 12 VA at 115 or 24 volts VAC The Power Supply automaticall...

Page 56: ......

Page 57: ...zontal cursor key 3 To return to the first page of help information press the left horizontal cursor key Machine States The Power Supply has eight Machine States RUN NO WELD STANDBY ALARM FIRE MENU PR...

Page 58: ...NG will cause the display screen to change from the Basic Weld Monitor RUN screen if this option has been set to ON to the Alphanumeric RUN screen Pressing CHNG again will return the Power Supply to t...

Page 59: ...itch b removing the second level of a two level Foot Switch or c shorting the Emergency Stop Control Signals Input Pin 10 to Pin 11 Completion of the Firing State is indicated by momentary appearance...

Page 60: ...Head is connected to the Power Supply Squeeze Time allows sufficient time for a non force fired Weld Head to apply the required weld force to the work pieces Squeeze Time is not normally used with AMA...

Page 61: ...d corner will automatically scroll during this change process In this example weld CURRENT has been increased to 0 7 kA and WELD time has been increased to 20 ms 5 Press SAVE to save the updated weld...

Page 62: ...ZE WELD and HOLD periods Press CHNG to select ON In this example RELAY 1 will turn on during the WELD period 4 There are four more RELAY 1 options listed under the SQZ period column Press CHNG to sele...

Page 63: ...ter 3 AMADA WELD TECH Force Fired Dual Air Actuated Weld Head System for complete instructions to set up and operate two sequential action Air Actuated Weld Heads 2 When MENU OPTIONS 2 WELD HEAD TYPE...

Page 64: ......

Page 65: ...on Pre Prog Schedule Typical Application BASIC WELD 001 Make single spot welds on simple flat parts without plating WELD REPEAT 002 Make multiple semi automatic spot welds using an operator QUENCH TEM...

Page 66: ...rodes to close and apply the required weld force to the parts before the Weld Period begins Weld current begins when the Squeeze Period ends and both levels of a two level Foot Switch are closed When...

Page 67: ...eld force to the parts before the Weld Period begins Weld current begins when the Squeeze Period ends and both levels of a two level Foot Switch are closed When Weld Repeat is used with any type of Ai...

Page 68: ...ld current by a factor of two or three since the first bond significantly reduces the resistance of the interface between the parts Another use for Quench Temper is to control grain refinement in the...

Page 69: ...3 is pre programmed at the factory for Quench Temper operation The Power Supply automatically recognizes the presence of a Manually or Air Actuated Weld Head before the first weld is made Figure 6 8 Q...

Page 70: ...Switch in the Air Actuated Weld Head closes When Pre Postheat is used with a Non Force Fired Air Actuated Weld Head the Squeeze SQZ Period must be used to allow sufficient time for the electrodes to c...

Page 71: ...ads weld current begins when both levels of a two level Foot Switch are closed and the Force Firing Switch in the Air Actuated Weld Head closes When Up Downslope is used with a Non Force Fired Air Act...

Page 72: ...ze Braze can be used with AMADA WELD TECH Force Fired Manual or Air Actuated Weld Heads For Manually Actuated Weld Heads weld current begins when the Force Firing Switch closes For Force Fired Air Act...

Page 73: ...th an automatic parts feeder are used to make a Rollspot weld Because of the weld current shunting effect after the first weld set the Weld2 Period weld current greater than Weld1 by a factor of 20 to...

Page 74: ...t the factory for Rollspot operation The Power Supply automatically recognizes the presence of a Manually or Air Actuated Weld Head before the first weld is made Figure 6 20 Rollspot Weld Graph Run Sc...

Page 75: ...d Period begins Weld current begins when the Squeeze Period ends and both levels of a two level Foot Switch are closed Weld Current flows as long as all switches remain closed Hold Period has no meani...

Page 76: ...ntly reduces the resistance of the interface between the parts The only use for the Down Slope Period following the Weld2 Period is to control grain refinement in brittle parts by slowing reducing the...

Page 77: ...ses an Air Actuated Weld Head press to scroll the program screen to the right to access the Down and Hold periods Figure 6 27 Dual Pulse Alphanumeric Run Screen PULSATION Figure 6 28 Pulsation allows...

Page 78: ...used to automatically keep the electrodes closed on the parts after weld current has terminated for the purpose of providing additional heat sinking or parts cooling Squeeze and Hold Periods have no m...

Page 79: ...POWER UP SCHEDULE Figure 7 2 This option determines which weld schedule will be used when the Power Supply is switched ON a Schedule Number 0 127 or b the weld schedule which was selected just before...

Page 80: ...ether Exceptions are as follows NEXT SCHEDULE 000 can only be used at the beginning of a chain NEXT SCHEDULE Setting this number to the same weld schedule currently being used prevents chaining from o...

Page 81: ...chedule chain of Schedule 001 through 004 with 001 being the default power up schedule NOTE Only four weld control schedules can be used with the chain schedule control box 1 From the MAIN MENU screen...

Page 82: ...rgy Limit Monitor Once selected the Basic Weld Monitor or Energy Limit Monitor screens apply to all weld schedules For example if Schedule 001 uses the Basic Weld Monitor function Schedules 002 throug...

Page 83: ...OTSWITCH TYPE Figure 7 7 The Power Supply requires the use of a Single Level 1 Level or Two Level 2 Level Foot Switch in order to control an air actuated weld head The Power Supply automatically detec...

Page 84: ...ing the welding process the welding process will terminate FOOTSWITCH WELD ABORT ON is preferred since it allows the operator to abort the welding process by releasing the Foot Switch or Foot Pedal in...

Page 85: ...E Figure 7 8 The RS 485 SERIAL PORT Connector located on the back of the Power Supply can send out welding data to a serial data collection device such as a host computer or serial printer for SPC ana...

Page 86: ...Press MENU from the Run or Program States to select the MAIN MENU screen 2 Select WELD COUNTER The WELD COUNTER screen will appear 3 Select the weld count number for TOTAL NUMBER OF WELDS This counte...

Page 87: ...e destination In this example Schedule 127 is the destination schedule NOTE Schedule information previously stored in Schedule 127 will be over written with new information from the source schedule 4...

Page 88: ...To prevent the operator from changing weld schedules select SCHEDULE LOCK OFF and use CHNG to select ON When ON is selected all other weld schedules are locked out and cannot be used for welding 5 Pr...

Page 89: ...HELP screen Select the desired topic followed by pressing ENTER Use the horizontal cursor keys to review each page WELD SENTRY Weld Sentry option provides access to the optional Built in Weld Sentry...

Page 90: ...ill display the message SYSTEM PARAMETERS ARE RESET SYSTEM PARAMETERS DEFAULT SYSTEM PARAMETERS DEFAULT POWER UP SCHEDULE LAST FIRING SWITCH 2 WIRE END CYCLE BUZZER OFF SWITCH DEBOUNCE TIME 10 ms KEY...

Page 91: ...e best procedure is to follow Chapter 2 General Set up and Chapter 3 Welding Systems Set up in this manual TRANSFORMER MODEL The Power Supply cannot automatically detect what Transformer has been conn...

Page 92: ...both the maximum weld current and weld voltage Select OTHER then program the correct Turns Ratio for your Transformer Model maximum weld current and maximum voltage This example shows a Turns Ratio o...

Page 93: ...pply contains a simple built in Basic Weld Monitor that can be enabled to measure the average peak weld current voltage power or resistance during the WELD1 or WELD2 periods Only one welding parameter...

Page 94: ...Weld power and weld resistance are not transmitted but can be calculated by the Host Computer Weld Monitoring Suggestions Use a Basic Weld Monitor measurement parameter that is different from the weld...

Page 95: ...WELD1 MEASUREMENT should be flashing This example shows the PROGRAM screen for the Dual Pulse welding function 6 Press CHNG to select CURRENT VOLTAGE POWER or RESISTANCE NOTE Select a measurement unit...

Page 96: ...rement unit limits and inhibit options Multiple WELD2 readings must be obtained to see if they correlate with weld quality 10 Press SAVE to save the updated Schedule You are now back in the Basic Weld...

Page 97: ...he weld current is terminated automatically when the measured weld voltage drops below the user set Lower Limit Energy Limit Monitor Programming 1 Press MENU The MAIN MENU screen will appear 2 Select...

Page 98: ...y Limit or the Lower Energy Limit Energy Limit Monitor Measurement and Limit Selections Feedback Measurement Upper Limit Lower Limit Current Voltage none 0 0 9 999 V Voltage Current 0 0 9 999 KA none...

Page 99: ...Hz Output Current peak maximum 4 KA Power Supply Frequency 2 KHz Environment Ambient Operating Temperature 0 C to 45 C 32 F to 113 F Physical Dimensions Height 21 5 cm 8 5 in Width 26 7 cm 10 5 in De...

Page 100: ...80 5 11 8 44 1 TR 10 0 52 1 TR 8 6 60 1 TR 7 5 68 1 TR 4 000 4 000 4 000 4 000 IT X11A 460 460 5 14 3 44 1 TR 12 1 52 1 TR 10 5 60 1 TR 9 2 68 1 TR 4 000 4 000 4 000 4 000 IT X3A 380 380 6 6 5 4 000 I...

Page 101: ...ol 1 2 000 System Parameter Factory Defaults SYSTEM PARAMETERS OPTIONS 1 DEFAULT BASIC WELD MONITOR OFF CHAIN SCHEDULES FEATURE OFF END CYCLE BUZZER OFF KEY CLICK ON POWER UP SCHEDULE LAST SWITCH DEBO...

Page 102: ...e Current Limits Upper 9 999 kA Lower 0 0000 kA Voltage Limits Upper 9 99 V Lower 0 000 V Power Limits Upper 9 999 kW Lower 0 000 kW Resistance Limits Upper 9 999 m Lower 0 000 m Inhibit Weld Power on...

Page 103: ...T Connector is a 9 pin TE Connectivity 747052 4 AMADA WELD TECH Part 250 196 bulkhead connector that mates with a connector assembly consisting of a CINCH DE 9P AMADA WELD TECH Part 250 193 plug and a...

Page 104: ......

Page 105: ...bly Driver Board 4 32875 01 Drives IGBT Transistor Assembly Front Panel Overlay 4 32297 01 Front Panel Touch Switches Power Board 4 32893 01 HF2 Internal Power Supply Assembly Transistor Assembly 208...

Page 106: ......

Page 107: ...n HF2 Welding Power Supply and Weld Head Replace Weld Head Firing Switch ALARM INPUT SWITCH Force Firing Switch closed before the HF2 was in the RUN State Release Foot Switch or Foot Pedal then re act...

Page 108: ...ghten welding process variables Change Lower Limit value LOW POWER Actual weld power is less than the Basic Weld Monitor user set Lower Limit Tighten welding process variables Change Lower Limit value...

Page 109: ...welding process duty cycle SCHEDULE LOCKED System is Protected and all weld schedules are Locked To change the System Security Status to Unprotected enter the original code If the original code was lo...

Page 110: ...All System Parameters are protected To change the System Security Status to Unprotected enter the original code If the original code was lost press and hold and then press SAVE Release both keys WELD...

Page 111: ...factory for current language availability Language Software Version English V1 16 English French V1 17 NOTE The help screen firmware is stored in IC chip U2 on the main printed circuit board The type...

Page 112: ......

Page 113: ...the right hand side of the Power Supply 4 Locate integrated circuits at location U2 and U3 5 Note the location of pin 1 on each IC 6 Examine the labels on the integrated circuits provided with this k...

Page 114: ......

Page 115: ...applied 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 resistan...

Page 116: ...ELECT 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 Aluminu...

Page 117: ...l 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 Kulgri...

Page 118: ...el 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 Ni...

Page 119: ...lded 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 failu...

Page 120: ...e or power for different weld forces as shown in the illustration below Typical Weld Strength Profile 4 Repeat steps 1 through 3 using a different but fixed weld time Typical Weld Strength Profile The...

Page 121: ...e 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 qual...

Page 122: ...ng the 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 S...

Page 123: ...istance 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 me...

Page 124: ...nt 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 Grou...

Page 125: ...It 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 126: ...on 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...

Page 127: ...Squeeze time also allows time for the 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 par...

Page 128: ...the 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...

Page 129: ...are 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 130: ...e high 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...

Page 131: ...d 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 132: ...antial 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 o...

Page 133: ...E 82178 Puchheim Germany TEL 49 89 839403 0 FAX 49 89 839403 68 AMADA WELD TECH 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 AMA...

Page 134: ...AMADA WELD TECH 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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