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CHAPTER 7. CALIBRATION

UB25 LINEAR DC RESISTANCE WELDING CONTROL

7-2

990-665

Calibration Points

The term

Calibration Points

refers to the various values that need to be calibrated in order for the

Power Supply to operate and monitor accurately. There are 12

Calibration Points

. The instructions

Section II, Calibration Procedure

tell you how to perform the procedures, the illustration below

gives a quick overview of the process.

Calibration Points

Summary of Contents for UB25

Page 1: ...990 665 REV J LINEAR DC RESISTANCE WELDING CONTROL UB25 OPERATION MANUAL...

Page 2: ...the United States of America REVISION RECORD Revision EO Date Basis of Revision A 18653 5 01 Original Release B 18860 5 01 Technical changes C 19146 2 02 Technical changes D 42840 10 13 Updated to Miy...

Page 3: ...303 5676 FAX 626 358 8048 e mail info amadaweldtech com The purpose of this manual is to supply operating maintenance and service personnel with the information needed to properly and safely operate...

Page 4: ...trols 1 10 Section V Emergency Stop Switch and 24v Jumpers 1 13 Section VI Related Publications 1 14 Chapter 2 Getting Started 2 1 Section I Planning For Installation 2 1 Space Requirements 2 1 Utilit...

Page 5: ...3 7 Description 3 7 Power Mode 3 7 Applications 3 7 Description 3 7 Section IV Weld Monitor 3 8 Introduction 3 8 Active Part Conditioner APC 3 8 Applications 3 8 Description 3 8 How It Works 3 9 Instr...

Page 6: ...4 11 Normal Stop 4 12 Emergency Stop 4 12 Re Set After Emergency Stop 4 12 Chapter 5 Setup Software 5 1 Section I Introduction 5 1 Overview 5 1 Section II How to Use Menu Screens 5 2 Main Menu 5 2 Se...

Page 7: ...st 5 18 Section VI Relay Settings 5 19 Function 5 19 Programming Instructions 5 19 Section VII Special Functions 5 21 Copy a Schedule 5 21 Reset Defaults 5 21 Reset System Parameters 5 23 Reset All Sc...

Page 8: ...on II Calibration Equipment Setup 7 3 Section III Calibration Procedure 7 4 Appendix A Technical Specifications A 1 Appendix B Electrical and Data Connectors B 1 Appendix C The Basics of Resistance We...

Page 9: ...ystemet Asenna voimanl hdej rjestelm Installer le syst me d alimentation 1ectrique Das Elektroenergieversorgungssystem installieren Installazione del sistema d alimentazione elettrico Instale o sistem...

Page 10: ...rrente di saldatura Use a chave WELD NO WELD para interromper o fluxo da corrente de soldagem Utilice el interruptor de WELD NO WELD para cortar el flujo de la corriente de soldar EMERGENCY STOP Open...

Page 11: ...is manual or not performed as prescribed in it may expose personnel to electrical hazards After reading this manual retain it for future reference when any questions arise regarding the proper and SAF...

Page 12: ...he Goods 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...

Page 13: ...m the 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...

Page 14: ...PROPERTY RIGHTS OF A THIRD PARTY 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...

Page 15: ...ies that none of the Goods or technical data supplied by Seller under this Agreement will be sold or otherwise transferred to or made available for use by or for any entity that is engaged in the desi...

Page 16: ...if the matter under dispute is 500 000 or less there shall only be one arbitrator who shall be mutually selected by both parties If the party selected arbitrators are unable to agree upon the third a...

Page 17: ...ak and average values Up to 99 individual Weld Schedules sometimes referred to as weld profiles can be programmed and stored Weld schedules can be used individually or in sequence with others using th...

Page 18: ...e them for different welding applications The Power Supply requires only single phase input power and can supply weld power up to 1 000 amps The advanced linear control circuit provides instantaneous...

Page 19: ...Crystal Display LCD Descriptions for each button and display are in Section IV of this chapter Controls and Indicators All electrical connectors data connectors and the ON OFF switch are located on t...

Page 20: ...ing the operating parameters of the Power Supply and operating your welding equipment The keys also allow you to program the precise voltage current power and time of each energy pulse into individual...

Page 21: ...showing the waveform of the weld schedule The waveform gives you an easy to see before and after comparison of how you programmed the weld and how the weld was actually performed Alphanumeric Data Al...

Page 22: ...amount of squeeze time should be programmed to allow the weld head to settle before the WELD period begins The default SQUEEZE time is 150 milliseconds NOTE In addition to the debounce time there is...

Page 23: ...e graph to the shaded graph to see if the weld was completed properly The actual weld energy delivered shaded graph is dependent on the load resistance including cables the weld head and parts to be w...

Page 24: ...ft to right and from the top of the panel to the bottom Step by step instructions on how to use the controls and indicators are in Chapter 4 Operating Instructions Operating Instructions will list the...

Page 25: ...ld energy values energy level and feedback mode press the switch to highlight the middle line To enter weld time values in milliseconds press the WELD switch again to highlight the bottom line To sele...

Page 26: ...w the graphic waveform trace of the selected parameter Welding in the MONITOR state allows you to watch and verify welds as they are being made Welding can be automatically interrupted when the progra...

Page 27: ...kA V and kW keys are used to Set the feedback mode for Pulse 1 and Pulse 2 in the weld schedule Set the feedback parameters for upper and lower monitor limits Select the monitor mode to be viewed on...

Page 28: ...ey to highlight the energy field then enter the desired output level with the numeric keypad and then press the kW key to change the feedback mode to power When MONITOR or RUN is displayed in the MONI...

Page 29: ...ing instructions in several languages is not shown here The tag with the complete text is shown in Appendix B Electrical and Data Connectors You may operate the Power Supply with or without an Operato...

Page 30: ...DING CONTROL 1 14 990 665 Section VI Related Publications Related publication which you may wish to obtain from AMADA WELD TECH is SL 300A Fast Response Weld Head System Part Number 990 115 Please con...

Page 31: ...head to avoid contact with weld splash Assure that there are no sources of high frequency energy close by Dimensions and weight are Height 12 75 in 324 mm Width 9 25 in 235 mm Depth 23 5 in 597 mm We...

Page 32: ...wer Supply are 2 Level Foot Switch Weld Head appropriate for the welding application Input Output Mating Connectors For use on cables connecting the Power Supply to external equipment Verify that the...

Page 33: ...ll not function if these plugs are not installed The plug connected to I O Connector A is pre wired with a two wire lead for the Emergency Stop Switch For details see Chapter 1 Section V Emergency Sto...

Page 34: ...ct one end of the second weld cable to the positive weld terminal on the Power Supply 3 Connect the other end of the two weld cables to the weld head 4 Dress the weld cables together with cable ties t...

Page 35: ...ing a cable tie as a strain relieve attach each voltage sensing lead to its corresponding electrode holder so that the lead terminals will not break away under heavy production operating conditions 9...

Page 36: ...ked FOOT SWITCH 2 Connect the weld head air valve solenoid cable connector to the Power Supply connector marked AIR VALVE DRIVER 24V NOTE This connector provides 24 VAC power only It will not drive 11...

Page 37: ...he pulse to compensate for any variation in part resistance The Power Supply also has several monitor functions that give you remarkable control over the welding and production process Together these...

Page 38: ...Weld profiles may be programmed for single pulse upslope downslope or dual pulse operation Weld schedules may also use special monitoring features of the Power Supply such as Energy Limit Active Part...

Page 39: ...sistance Welding Weld Head Applicability The Power Supply is best used with an AMADA WELD TECH force fired manual weld heads or air actuated weld heads For manually actuated weld heads the weld sequen...

Page 40: ...ope allows a gradual application of weld energy which permits the parts to come into better contact with each other reducing the electrode to part contact resistances Upslope can allow a smaller elect...

Page 41: ...Weld Profile Applications Flat to flat parts Round to round parts Round to flat small parts that may or may not be plated Description Adding upslope to the front of both weld periods allows a reducti...

Page 42: ...ulse 2 weld current is typically greater than the Pulse 2 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...

Page 43: ...deal for welding round or non flat parts Description This mode controls the voltage across the work piece during welding It helps to compensate for part misplacement and force problems and automatical...

Page 44: ...ation must be displaced to allow proper current flow through the parts Levels of oxide and contamination vary from part to part over time which can have an adverse effect on the consistency of the wel...

Page 45: ...pose As the power supply tries to achieve constant power to the weld it raises the voltage to high levels early in the output waveform since current cannot flow due to the oxide As the high voltage br...

Page 46: ...n this case the energy limits will prevent blowouts parts damage and electrode damage Limits can be set to terminate the weld if this occurs To stop the weld when a sufficient current voltage or power...

Page 47: ...oltage Example 1 Energy Limit Weld Termination Example 1 In the profile above the weld current is exceeding the selected upper limit before the end of the welding cycle The spike in the current wavefo...

Page 48: ...be used as a measurement pulse and should not perform a weld Pre Weld Check Waveform Example To detect misaligned parts use constant current and set upper and lower voltage limits for Pulse 1 If parts...

Page 49: ...art Conditioning Operation Before operating the Power Supply you must be familiar with the following The location and function of Controls and Indicators For more information see Chapter 1 of this man...

Page 50: ...s connected as described in the appropriate sections of your weld head manual Turn the compressed air ON and adjust it according to the instructions in your weld head manual Initial Setup Instructions...

Page 51: ...ront of the Power Supply 2 Press the SCHEDULE button on the right of the Power Supply 3 Use either of the methods below to select a schedule Use the Up Down buttons to scroll through the list OR Use t...

Page 52: ...gy Use the numeric keypad to enter the energy level or use the arrows The Power Supply output ranges are Current from 0 005 1 000 kiloamps Voltage from 0 100 4 900 volts Power from 0 050 4 900 kilowat...

Page 53: ...energy level or use the arrows The Power Supply output ranges are Current from 0 005 1 000 kiloamps Voltage from 0 100 4 900 volts Power from 0 050 4 900 kilowatts 6 Perform one of the following Pres...

Page 54: ...er Supply output ranges are Current from 0 005 1 000 kiloamps Voltage from 0 100 4 900 volts Power from 0 050 4 900 kilowatts 6 Perform one of the following to program the Pulse 1 feedback mode Press...

Page 55: ...tor limit mode Press the kA key to program current as the limit mode Press the V key to program voltage as the limit mode Press the kW key to program power as the limit mode 6 Toggle the Pulse 1 weld...

Page 56: ...for Pulse 2 can be different than the monitor limit mode for Pulse 1 13 Press the HOLD period key This will bring up the PULSE 2 OUT OF LIMITS ACTION screen This screen allows you to select the action...

Page 57: ...orms for voltage resistance current and power 5 Push the voltage V key and observe the high peak of the voltage waveform 5 Push the MONITOR resistance key and observe the resistance waveform This shou...

Page 58: ...the limit even with heavily oxidized parts 11 Try welds with varying oxide clean and dirty The power supply terminates the first pulse when your programmed current is reached A clean part will reach t...

Page 59: ...WELD position 5 Select the desired weld schedule and begin welding using normal operating procedures Normal STOP When finished welding turn the Power Supply OFF Automated Welding Operation 1 Verify th...

Page 60: ...njury to personnel or damage to weld pieces or the welding system 2 Clear the condition that caused the operator to hit the Operator Emergency Stop Switch Re Set After EMERGENCY STOP 1 Clear the condi...

Page 61: ...ing sections How to Use Menu Screens Main Menu Setup Menus Operator Preferences Display Contrast Buzzer Loudness End Of Cycle Buzzer Update Graph After Weld Buzzer On Weld Stop System Settings Wavefor...

Page 62: ...tion listed on the menu Some prompts display which means that you should use the UP or DOWN keys on the front panel to take the next action Other prompts may highlight a specific key which means you s...

Page 63: ...4 To scroll back through SETUP 2 and SETUP 1 menus press the up key 5 When you have finished programming the desired functions press the MENU key on the front panel to return to the MAIN MENU SETUP 2...

Page 64: ...against shop background noise 4 Press MENU to return to the previous screen or keep pressing the MENU key to return to the MAIN MENU End of Cycle Buzzer 1 Go to the SETUP 2 menu 2 Press the 3 key to t...

Page 65: ...the MAIN MENU Buzzer On Weld Stop This function only applies to weld schedules that have STOP ON PULSE 1 or STOP ON PULSE 2 programmed in the monitor refer to Chapter 4 Section IV Programming the Weld...

Page 66: ...totally independent of Weld Monitor features described in Chapter 3 of this manual Waveform Check ON OFF 1 From the MAIN MENU press 0 to get to the WAVEFORM CHECK menu 2 Press the 1 key to toggle WAV...

Page 67: ...city Limit Setting 1 From the WAVEFORM CHECK menu press the 4 key to access the ENERGY CAPACITY LIMIT screen 2 Use the numeric keypad to enter the capacity limit This limit is the below the set point...

Page 68: ...LICATION FUNCTION ON Human operated welding stations where the operator holds parts Allows you to abort the weld process by releasing the foot switch used with an air actuated weld head Will also term...

Page 69: ...ection NOTE NONE represents a debounce time of 0 msec Use NONE for interfacing with the AMADA WELD TECH SL 320A Electronic Weld Force Control 4 Press MENU to return to the MAIN MENU Firing Switch 1 Go...

Page 70: ...are activated 1 Go to the SETUP 1 menu 2 Press 4 for the INPUT SWITCH SELECT menu Mechanical Selection This selection accepts dry contact single or double pole switch or reed relay devices This is the...

Page 71: ...ated welding system This selection accepts 24 VDC from a PLC as a source for activating the Firing Switch and Foot Switch inputs For detailed electrical interface information on these input switch sel...

Page 72: ...hrough 5 below to reset each counter 2 Press the 1 2 3 or 4 key to select the desired weld counter NOTE The example to the right shows the TOTAL WELDS screen 3 To reset the counter press 0 on the nume...

Page 73: ...he 1 key to select SCHEDULE LOCK This will bring up the CHANGE STATUS screen 3 Enter a 7 digit number from 0000001 to 9999999 in the code field then enter a period This will bring up the SYSTEM SECURI...

Page 74: ...ules OFF Some applications require a lower current for a number of welds after the electrodes have been replaced or resurfaced Once the electrodes have been seasoned the current can be increased as re...

Page 75: ...enter the number of the next schedule in the chain 8 Use the SCHEDULE key to move the highlight horizontally back to the WELD COUNT column Repeat Steps 4 through 8 to program the rest of the chain 9...

Page 76: ...n you want to use The Power Supply will now weld in the chain mode until you turn the Chain Schedules feature OFF NOTE When Chain Schedules is turned ON the LCD screen changes to show the chain inform...

Page 77: ...e and also allows you to specify the length of time at the beginning and end of the weld pulse to be ignored by the Test Weld when calculating the load resistance 1 From the MAIN MENU press 1 to acces...

Page 78: ...t Weld when time values voltage levels or power levels are changed on the schedule 1 From the SETUP 3 menu screen press the 1 key to access the DO TEST WELD screen 2 Press the 1 2 or 3 key to select t...

Page 79: ...y to get the relay menu 2 From the RELAY menu press the 1 2 3 or 4 key to select a relay menu 3 Press the 1 key to toggle the relay contact signal state ON closed or OFF open 4 Press the 2 key to sele...

Page 80: ...0 150 milliseconds after the end of HOLD and will stay energized until the OUT OF LIMITS alarm state is cleared by pressing the RUN button or at the start of the next weld refer to Appendix E LCD Disp...

Page 81: ...to select the destination schedule number field 4 Use the numeric keypad to enter the number of the destination schedule 5 Press the schedule key The contents of the source schedule will be copied to...

Page 82: ...TER DEFAULT SETTING Do Test Weld ALWAYS Ignore First Last 0 2 ms Defaults for Waveform Check and Weld Fire Lockout SYSTEM PARAMETER DEFAULT SETTING Waveform Check ON Stability Check Limit 07 0 0 Stabi...

Page 83: ...FAULTS press the 1 key to go to the RESET SYSTEM PARAMETERS menu 3 Press the 2 key to select YES This will automatically reset the system parameters to the factory defaults and return the screen to th...

Page 84: ...ess the 5 key to go to the COMMUNICATION menu shown with default settings 2 From the COMMUNICATION menu toggle the 1 key to select HOST or CLIENT The COMMUNICATION ROLE line will now reflect your role...

Page 85: ...D NUMBER field 4 Press the MENU key to get the COMMUNICATION menu screen This time the I D NUMBER line will display your I D number entry 5 Press MENU to return to the MAIN MENU Baud Rate The baud ra...

Page 86: ......

Page 87: ...ser priority From time to time however you may run into a problem and need some help to get back to normal operation Reading this Chapter will speed up the process General Kinds of Problems It has bee...

Page 88: ...larm messages what they mean and what to do about them please refer to Appendix E LCD Display Messages Troubleshooting The following Troubleshooting Chart is a comprehensive listing of system and equi...

Page 89: ...aligned parts Excessive weld time set at the Power Supply Contaminated electrode surface Slow weld head follow up EMERGENCY STOP message is displayed on the LCD and fans all stop but the Emergency Sto...

Page 90: ...nsufficient weld head force Misaligned parts Slow weld head follow up Incompatible weld piece projection design Contaminated weld piece surface plating Incompatible weld piece materials Contaminated e...

Page 91: ...Excessive weld head force Incompatible weld piece projection design Incompatible weld piece materials Wrong electrode tip shape Excessive current energy set at the Power Supply Technical Assistance If...

Page 92: ...emove pitting oxides and welding debris from the electrode You should limit cleaning of an electrode on the production line to using a 600 grit silicon carbide electrode polishing disk If you must cle...

Page 93: ...here they will be used as standards for the operational welding parameters NOTE Only authorized personnel should perform this procedure Calibration Equipment Required This equipment is required for ca...

Page 94: ...refers to the various values that need to be calibrated in order for the Power Supply to operate and monitor accurately There are 12 Calibration Points The instructions in Section II Calibration Proce...

Page 95: ...required calibration equipment listed in Section I and set it up as shown below Calibration Setup NOTES The ground of the oscilloscope should be isolated from the ground of the electrical live by an i...

Page 96: ...ro ohm shunt the value is printed on the exterior of the shunt Enter the value using the numeric keypad then go to the next screen NOTE The prompts at the bottom of the screen that tell you how to go...

Page 97: ...hed You must wait a minimum of 2 seconds between firing pulses for calibration to be accurate 11 Continue to follow the instructions on the LCD screens 12 When calibration is complete keep pressing th...

Page 98: ......

Page 99: ...1 5 kVA UB25 230 1 5 kVA To be used for sizing ac input power service Output Capability max available to load Based on load See Appendix G Repetition Rates Output Current Steps Programmable 0 005 1 0...

Page 100: ...t line voltage steady state Rise Time Limited by external secondary circuit Data Communications Remote capability to upload download weld schedule monitor welds set up parameters select schedule and r...

Page 101: ...ION VALUE NOTES Input Output 24 V AC DC inputs and outputs 2500 V RMS optically isolated hardware selectable positive or negative logic Fail safe emergency power off input External or internal power s...

Page 102: ......

Page 103: ...hat connector Connectors are described in the order in which they appear on the rear panel of the DC25 starting at the top left Note The specifications listed in this Appendix may be changed without n...

Page 104: ...IN OUT CONNECTOR SPECIFICATIONS PIN NO DESCRIPTION PIN TYPE 1 Signal Ground Isolated ground 1 kV DC Isolation 2 Not used 3 Not used 4 Transmit RS 485 Driver 5 Transmit RS 485 Driver 6 Not used 7 Not u...

Page 105: ...SCRIPTION PIN TYPE 1 Not Used 2 TX Transmit Data RS 232 Driver 3 RX Receive Data RS 232 Receiver 4 Not Used 5 Signal Ground Analog Ground ISOGND1 6 Not Used 7 Not Used 8 Not Used 9 Not Used PIN 1 NOT...

Page 106: ...13 INOWELD PIN 12 I UNUSED PIN 11 O UNUSED PIN 10 24VGND PIN 9 CGND PIN 8 RELAY4P PIN 7 RELAY4 PIN 6 RELAY3P PIN 5 RELAY3N PIN 4 RELAY2P PIN 3 RELAY2N PIN 2 RELAY1P PIN 1 RELAY1N PIN 25 24 V ac PIN 2...

Page 107: ...Positive 7 RELAY4N 230 VAC or 30 VDC 3 A O Relay output 4 Negative 8 RELAY4P 230 VAC or 30 VDC 3 A O Relay output 4 Positive 9 CGND CGND Chassis ground 10 24VGND GND 24 VDC GND 11 O UNUSED Not used 1...

Page 108: ...e PIN 1 ISCH0 PIN 2 ISCH1 PIN 3 ISCH2 PIN 4 ISCH3 PIN 5 ISCH4 PIN 6 ISCH5 PIN 7 ISCH6 PIN 8 INHIBIT PIN 9 ISTOP PIN 10 IFIRE PIN 11 24VOUT PIN 12 FPOWER PIN 13 24VGND PIN 14 NOT USED PIN 15 NOT USED P...

Page 109: ...Schedule Select 25 7 ISCH6 24 VDC 10 mA I Remote Schedule Select 26 8 IINHIBIT 24 VDC 10 mA I Stop next weld pulse 9 ISTOP 24 VDC 10 mA I User convenience stop function 10 IFIRE 24 V 10 mA I Firing sw...

Page 110: ...ing wires with a cable tie Instructions are printed on the front and back of the tag in several languages full text below EMERGENCY STOP Open electrical circuit to retract weld head DESCONECCION DE EM...

Page 111: ...rn 3 Not Used 4 Not Used Firing Switch FIRING SWITCH CONNECTOR SPECIFICATIONS PIN NO SIGNAL MAX VOLTAGE MAX CURRENT I O COMMENTS NAME TYPE 1 24VGND Digital SGND 20 mA Firing Switch signal ground 2 IFI...

Page 112: ...IONS PIN NO SIGNAL VOLTAGE MAX CURRENT I O COMMENTS NAME TYPE 1 CGND Chassis ground 2 IFOOT1 Digital 24 V 10 mA I Foot switch SW1 Level 1 normally open 3 IFOOT2 Digital 24 V 10 mA I Foot switch SW2 Le...

Page 113: ...SISTANCE WELDING CONTROL 990 665 B 11 AC Input Power Connection AC INPUT POWER CONNECTION SPECIFICATIONS MODEL TERMINAL MAXIMUM VOLTAGE MAXIMUM CURRENT UB25 Hot 132 volts 15 amps Neutral Ground UB25 2...

Page 114: ...TORS UB25 LINEAR DC RESISTANCE WELDING CONTROL B 12 990 665 Weld Terminals WELD TERMINAL SPECIFICATIONS TERMINAL MAXIMUM VOLTAGE MAXIMUM CURRENT COMMENTS 9 9 volts 1 300 amps Variable Return POSITIVE...

Page 115: ...ce 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 resis...

Page 116: ...inum 1 Aluminum 1 Aluminum Alloys 1 Aluminum 1 Cadmium Plating 1 Aluminum 1 Tinned Brass 14 Aluminum 1 Tinned Copper 14 Aluminum 1 Gold Plated Dumet 2 Aluminum 1 Gold Plated Kovar 2 Aluminum 1 Kovar 2...

Page 117: ...14 Gold 14 Kovar 2 Hastalloy 2 Titanium 2 Inconel 2 Inconel 2 Inconel 2 Kulgrid 2 MATERIAL ELECT RWMA TYPE MATERIAL ELECT RWMA TYPE Invar 2 Invar 2 Iridium 2 Iridium 2 Iridium 2 Platinum 2 Iron 2 Iron...

Page 118: ...ks should then be used to ensure that the electrode faces are smooth If this is not done the rough surface of the electrode face will have a tendency to stick to the work piece Weld Schedule Developme...

Page 119: ...ratios greater than 4 to 1 The general rule is that the more resistive material or the thinner material should be placed against the negative electrode Polarity on the Power Supply can only be changed...

Page 120: ...small reduction in pull strength but considerably more tolerance to changes in weld energy Weld heat will vary as a result of material variations and electrode wear The 12 lb electrode force curve is...

Page 121: ...es Basic resistance 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 stage in design...

Page 122: ...during 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 40...

Page 123: ...some of the more common materials used today in micro resistance welding The materials can be grouped into three common catagories The types of joints achievable within each of the main groups are as...

Page 124: ...tate joint 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 Grou...

Page 125: ...o part and part to part resistances to cause multiple welding problems when welding resistive materials see below Conductive materials can be welded by using high contact resistance and fast heating a...

Page 126: ...in the weld Resistive materials benefit from slower heating rates that allow the contact resistances to reduce significantly thus bulk resistances become the major source for heat generation Weld Prof...

Page 127: ...wer supply technology selection is based on both the requirements of the application and process In general closed loop power supply technologies are the best choice for their consistent controlled ou...

Page 128: ...t the key welding variables energy force time in order to identify the likely good weld window The mini experiments should also be used to understand the weld characteristics from both application and...

Page 129: ...d be used to fix further variables from an application and process perspective and also to establish a weld window for energy time and force This part of weld development is critical in order to proce...

Page 130: ...ood multiple Screening DOE S may be required AMADA WELD TECH provides a simple Screening DOE tool that is run in excel and is sufficient for the majority of applications contact us for details Bespoke...

Page 131: ...istency Once the optimum parameters have been established in this series of experiments a validation study can be run which looks at the consistency of results over time It is good practice to build i...

Page 132: ......

Page 133: ...Relay Timing Diagrams General Status messages do not activate the output relays Clearing Alarm Conditions to Resume Operation If an alarm condition occurs you must do the following 1 Take the Correcti...

Page 134: ...he end of the waveform Shorten weld time lower energy setting or reduce repetition rate See Chapter 5 for programming instructions OUT OF LIMITS CAPACITY LIMIT EXCEEDED P2 Pulse 2 is below the limit a...

Page 135: ...ting GENERAL STATUS CURRENT 1 GREATER THAN UPPER LIMIT Actual weld current is greater than the user set Upper Limit value for Pulse 1 Determine the cause of the high current Changes to the welding set...

Page 136: ...E FOOT SWITCH The Firing Switch input has been activated before the Foot Switch has been activated Check the weld head for an improperly adjusted firing switch Automation Only Check the timing on the...

Page 137: ...internal fuse on Capacitor Charging Power Supply contact AMADA WELD TECH for support OUT OF LIMITS NO VOLTAGE READING No voltage measurement was made Possible open circuit or possible voltage lead co...

Page 138: ...the MENU default features There is no way to undo a reset to defaults action GENERAL STATUS STABILITY LIMIT EXCEEDED P1 The average deviation of Pulse 1 is beyond the allowable amount programmed in t...

Page 139: ...s should be set by qualified by personnel and are designed to identify process variations OUT OF LIMITS VOLTAGE 1 LOWER THAN LOWER LIMIT Actual weld voltage is less than the user set Lower Limit value...

Page 140: ...mming information See Appendix G for Repetition Rate and Power Supply capability details ALARM WELD STOP LIMIT REACHED The user set Upper Limit value has been reached and the weld energy has been term...

Page 141: ...N OFF state the SET RELAY TO and the WHEN states WELD END OF WELD ALARM OUT OF LIMITS P1 HIGH LIMIT P1 LOW LIMIT P2 HIGH LIMIT P2 LOW LIMIT The following diagrams show the timing sequence for each rel...

Page 142: ...illiseconds The relay will still close in case of an aborted weld If another weld is initiated within this time the END OF WELD relay will be reset at the start of the next weld ALARM The relay output...

Page 143: ...MIT The relay signal will switch when the Control senses that the Pulse 1 energy is lower than the programmed lower limit It will start 0 150 milliseconds after the end of HOLD and will stay energized...

Page 144: ......

Page 145: ...etermining the duration is the sum of the weld period and the periods of upslope and downslope if any For dual pulse welding the sum of both pulses must be compared to the chart This graph requires th...

Page 146: ...APPENDIX G REPETITION RATES UB25 LINEAR DC RESISTANCE WELDING CONTROL G 2 990 665 Maximum Weld Pulse Duration as a Function of Weld Current...

Page 147: ...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 148: ...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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