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CHAPTER 3:  WELDING SYSTEM SET-UP 
 

 

2 KHZ INVERTER WEDLING POWER SUPPLY 

3-8 

990-057 

 

Weld Head Set-up (Figure 3-4) 

1

 

Connect the Upper Weld Cable from each Weld Head to the Positive Terminal on the 
Transformer. 

2

 

Connect the Lower Weld Cable from each Weld Head to the Negative Terminal on the 
Transformer. 

3

 

Adjust each Weld Head Force Adjust Knob to produce 5 units of force as displayed on the Force 
Indicator.  For a complete description of force control and its effect on the welding process, 
please refer to your Weld Head manual. 

4

 

Install electrodes in each Weld Head Electrode Holder. 

5

 

Parallel two sets of twisted wire cables to the 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 to the Right Weld Head electrodes. 

 

 

Figure 3-4.  Weld Cable and Air Line Connections for Dual Air Actuated Weld Heads 

6

 

Connect a properly filtered air line to the Inlet Air Line on the Weld Head Air Valve Driver 
Solenoid assembly which is located on the back of the Weld Head.  Use 0.25 inch O.D. by 0.17 
inch I.D. plastic hose with a rated burst pressure of 250 psi.  Run separate air lines to each Inlet 
Air Line.  Do not split a single 0.25 O.D. line into two lines or the Weld Heads will not have 
sufficient air flow to work properly.  A lubricator should only be used with automated 
installations.  Turn on the air system and check for leaks. 

 

 

Содержание HF2

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 24: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 44: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 56: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 64: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 104: ......

Страница 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...

Страница 106: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 112: ......

Страница 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...

Страница 114: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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