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70 Series Technical Manual

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1. ELECT ELECT ELECT ELECT MATERIAL RWMA MATERIAL RWMA MATERIAL RWMA MATERIAL RWMA TYPE TYPE TYPE TYPE Chromel 2 Tinned Copper 14 Invar 2 Invar 2 Chromel 2 Dumet 2 Iridium 2 Iridium 2 Chromel 2 Nichrome 2 Iridium 2 Platinum 2 Chromel 2 Cold Rolled Steel 2 Tron 2 Iron 2 Consil 2 Consil 2 Karma 2 Karma 2 Consil 2 Tinned Copper 14 Karma 2 Nickel 2 Consil 2 Dumet 2 Karma 2 Platinum 2 Constantan 2 Constantan Kovar Gold Plate 2 Kovar Gold Plate 2 Constantan 2 Copper 14 Kovar Gold Plate 2 Kulgrid 2 Constantan 2 Tinned Copper 14 Kovar Gold Plate 2 Nickel 2 Constantan 2 Tron 2 Kovar Gold Plate 2 Silver 11 14 Constantan 2 Nichrome 2 Kovar Gold Plate 2 Stainless Steel 2 Constantan 2 Nickel 2 Magnesium 1 Magnesium 1 14 14 Molybdenum 2 Molybdenum 2 Copper 14 Dumet 2 Molybdenum 2 Nickel 2 Copper 14 Invar 2 Molybdenum 2 Tungsten 2 Copper 14 Karme 2 Nichrome 2 Nichrome 2 Copper 14 Manganin 2 Nichrome 2 Nickel 2 Copper 14 Nichrome 2 Nichrome 2 Cold Rolled Steel 2 Copper 14 Nickel 2 Nichrome 2 Stainless Steel 2 Copper 14 Paliney 7 2 Nickel 2 Nickel 2 Copper 14 Silver 11 14 Nickel 2 Cold Rolled Steel 2 Copper 14 Cold Rolled Steel 2 Nickel 2 Stainless Steel 2 Copper 14 Stainless Steel 2 Nickel 2 Tantalum 2 Dumet 2 Dumet 2 Nickel 2 Tungsten
2. iine UM UM Mq 1 4 Controller Front Panel 1 5 Operation BUON OEE REE 1 5 SPEED HOLD TIME Display 1 6 ORG CANCEL Button 1 6 Controller dua E O ARE 1 7 Chapter 2 Installation and Setup Section I Instal D3CIOR EE ERER 2 1 Unpacking esee 2 1 Space BeduitenielllS so dace IN ERAS OS UN I ME 2 1 Power Reg it ments issoria seinen Mss 2 1 Installatron on a Wy OL DENIM pL eu 2 1 2 2 Install Na 2 3 Connect Weld Cables 2 3 Connect Controller and Power Supply Cables 2 5 Secon M 2 6 Adjust Electrode Height M M 2 6 Adj st Weld Forc 2 6 dust Weld Head POSION 2 7 Aene the BIeetrode s GM NE 2 7 Adjust the Electrode Mounting Angle 2 8 Chapter 3 Operating Instructions Section I Before You Start 3 1 Preparation ENERO 3 1 Operator Safety AMET 3 1 Section IM Ope
3. IIA USER S MANUAL 990 143 22 MIYACHI Revision C July 2010 JO E KL OPERATOR MANUAL FOR THE SERIES 70 WELD HEADS MODEL NUMBER STOCK NUMBER 2 241 01 2 241 02 2 241 02 02 E 7 Copyright 2004 2008 2010 Miyachi Unitek Corporation The engineering designs drawings and data contained herein are the proprietary work of UNITEK CORPORATION and may not be reproduced copied exhibited or otherwise used without the written authorization of UNITEK CORPORATION Printed in the United States of America Revision Record Revision EO Date Basis of Revision 20183 11 04 None Original edition 21776 5 08 Update to Miyachi Unitek logo and added new CAUTION information 40496 7 10 Addition of Series 73 models SERIES 70 WELD HEADS 990 143 CONTENTS Page Revision RECOTG il Contact US c Safety Precautions vi Declaraton of x Chapter 1 Description Section l 1 1 Section tsp UNE pH S COME Quoc BOUE UNIS EE be pads be Matres 1 2 Mod l 71 ILI E 1 2 Model 1 3 BOUL Head
4. WELD START WELD Output START Additional Pressing Time Setting Hold Time 1 2 3 Turn the Operation button to light up HOLD Lamp Press the Operation button forl second and the HOLD Lamp will blink The number of the blinking SPEED HOLD TIME Lamp indicates the present Hold Time setting Turn the Operation button clockwise and counterclockwise to change the number of the blinking lamp Select your desired speed number ois Tine may 100 Minimum 200 300 400 NN After selecting the number close thereafter open External Input both 1ST and 2ND Check the Hold Time observing the electrode that moves up and down Press the Operation button when your desired Hold Time is determined NOTE Press ORG CANCEL button to interrupt SERIES 70 WELD HEADS 990 143 CHAPTER 3 OPERATING INSTRUCTIONS Setting Moving Speed from Weld Point to Mid Point 1 Turn the Operation button to light up both MID and WELD Lamp 2 Press the Operation button for 1 second The MID and WELD Lamps will blink 3 The number of the blinking SPEED HOLD TIME Lamp indicates the current speed setting 4 Turn the Operation button clockwise and counterclockwise to change the number of the blinking lamp Select your desired speed Ca p e f SERIES 70 WELD HEADS 990 143 3 11 CHAPTER 3 OPERATING INSTRUCTIONS Section Ill Welding Operation 1 Close External Input 2ND Then the electrode mov
5. 2 Continue to press the button until blinking changes stays on 3 Depress the Operation button and 0 blinks on SPEED HOLD TIME Display Rotate the Operation button to choose one of the following settings 0 means Change of Mode 1 means Change of ERROR signal output means End Changing Mode 1 Press the Operation button while 0 blinks on SPEED HOLD TIME Display 2 Mode blinks on SCH Schedule display Rotate the Operation button to select 0 or 1 3 Press the Operation button to set the Mode No 4 Finally be sure to perform the End of Setting operation below Change of ERROR Signal Output 5 Press the Operation button while 1 blinks on SPEED HOLD TIME Display 6 Mode No blinks on SCH SCHEDULE Display Rotate the Operation button to select 0 or 1 Q means circuit opened in case of error 1 means circuit closed in case of error 7 Press the Operation button to set the ERROR signal output Finally be sure to perform the End of Setting operation below End of Setting 9 Rotate the Operation button to select Press the Operation button to fix 10 Confirm End on SCH SCHEDULE and SPEED HOLD TIME Display which means the completion of setting 11 Turn the power OFF SERIES 70 WELD HEADS 3 4 990 143 CHAPTER 3 OPERATING INSTRUCTIONS Applying Power and Moving to Start Point 1 2 3 Turn the power ON Zero 0 blinks on SCH
6. 32 33 n Moving Speed between Mid Point and 1234 Weld Point 12 34 34 Additional Squeeze Time at Weld Point 12A 13 35 35 CR code 0 x 0D Fixed 14 36 36 LF code 0 0A Fixed SERIES 70 WELD HEADS D 6 990 143 APPENDIX E ACCESSORIES Accessories Electrodes ES0402 EU1000 Operator Manual Operator Manual for the Series 70 Weld Heads 990 143 SERIES 70 WELD HEADS 990 143 E 1 APPENDIX F THE BASICS OF RESISTANCE WELDING Resistance Welding Parameters Resistance welding heat is produced by passing electrical current through the parts for a fixed time period The welding heat generated is a function of the magnitude of the weld current the electrical resistance of the parts the contact resistance between the parts and the weld force 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 resistance requires additional weld current voltage or power to produce the heat required to form a weld The higher the weld force the greater the weld current voltage power or time required to produce a given weld The formula for amount of heat generated is the square of the weld current I times the workpiece resistance times the weld time T Welding Parameter Interaction PROBLEM CAUSE PROBLEM CAUSE Parts Overheating Excessive Parts Overheating Excessive W
7. Place and Date Name Signature Pos tion Note This Declaration certifies conformity with the above mentioned Directives but gives no assurance of properties within the meaning of the Law concerning product liability It becomes invalid if any technical or other modifications are carried out without manufacturers consent SERIES 70 WELD HEADS 990 143 CHAPTER 1 DESCRIPTION Section I Features For the rest of this manual Series 70 Weld Heads will simply be referred to as the Weld Head The Motor Control Unit will simply be referred to as The Controller The Weld Head has the following features Owing to motor driven mechanism the electrode force is always stable even if the part thickness changes No fine gap adjustment is necessary when replacing electrodes The electrode force is 1 8 lbs per electrode for the Model 71 and 72 Weld Heads The electrode force is 15 110 lbs per electrode for the Model 73 Weld Head You can adjust the electrode speed to suit your welding needs The force is adjustable in four steps the electrode up down speed in eight steps You can manually or externally select thirty one different weld schedules The electrode moves down quickly from the start point stand by position to the mid point middle stop position then slowly to contact the workpiece The speed of the electrode can be programmed so as not to cause excessive impact to the parts The start point and the mid point are adjustable
8. CHAPTER 1 DESCRIPTION Controller Rear Panel MOTOR CONTROL Connector I O Connector Weld Force Detecting Sensor Connector Power Switch Fuse Holder Power Supply Connector Ground Terminal SERIES 70 WELD HEADS 990 143 1 7 CHAPTER 2 INSTALLATION AND SETUP Section Installation Unpacking The Weld Head comes fully assembled from the shipping box The only installation requirements are planning the workspace installing the electrodes and connecting the unit to the appropriate Power Supply Welding Control with the cables provided in the Ship Kit Unpack the Weld Head from its shipping box and verify that all components of the Ship Kit are present The Weld Head comes from the shipping box completely assembled except for the electrodes NOTE Carefully put the packing materials back in the packing boxes and store for future shipping Space Requirements Allow enough space so the Operator may safely perform the welding operation and have sufficient space for the welding Control Power Requirements The Weld Head 100 240 VAC 10 50 60 Hz 70VA which may be available from the Power Supply Welding Control In addition the weld head requires welding current from the Power Supply Welding Control Refer to the Power Supply Welding Control Operator Manual for power requirements of that unit NOTE The Weld Head is motor driven therefore it does not require any compressed air to operate Installation on a
9. Group l Conductive Metals Conductive metals dissipate heat and it can also be difficult to focus heat at the interface A solid state joint is therefore preferred Typically resistive electrode materials are used to provide additional heating SERIES 70 WELD HEADS 990 143 G 3 APPENDIX G DEFINING THE OPTIMUM PROCESS Group II Resistive Metals Itis easier to generate heat and trap heat at the interface of resistive metals and therefore it is possible to form both solid state and fusion welds depending on the time and temperature Upslope can reduce contact resistances and provide heating in the bulk material resistance Group lll Refractory Metals Refractory metals have very high melting points and excess heating can cause micro structural damage A solid state 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 Group Group Il Group Ill Group 1 Solid State Solid State Solid State Copper W Mo electrodes Projection on Group I Fine projections on Group III Group Il Solid State or Fusion Solid state or braze of II Steel Projection on III Group Ill Solid State Moly Basic Principles R2 R1 R4 Contact Resistance Resistance R6 Bulk Resistance Time The figure above shows the key resis
10. COM When an NPN transistor sink type on a PLC is used as the input signal of the I O Connector connect Pins 13 and 14 The COM terminal of a PLC connects to COM Pins 1 12 and 15 3 COM 2 XT CO When a PNP transistor source type on a PLC is used as the input signal of the I O Connector connect Pins 14 to the COM terminal of the PLC 0 EXT COM Output Terminal COM 15 i Factory connected to GND OV Input pin for the END signal from welding power supply If Pin 16 is closed the input signal of 2 16 cannot be accepted 17 Input pin for Start Point resuming signal When the circuit of Pin 17 becomes closed the electrode resumes Start Point In case that the motor finishes moving back to Original Point the electrode does not move Input pin for RESET signal If a trouble occurs rectify the trouble and close the circuit of the Pin to turnoff NG signal See 18 Chapter 7 for fault codes Close at least for 2 ms Pin 18 does not work while the circuit of Pin 18 is closed Input pin for prohibiting changing the program When Pin 19 is closed the program of 2 2 cannot be modified 20 Spare pin Do not connect Output pin for an emergency stop of the motor When the circuit between Pins 21 and 22 is opened the motor carries out emergency stop 21 Connect the operation switch for an emergency stop of the motor to Pins 21 and 22 of the I O 25 connector Use the operation switch who
11. Keep combustible matter away from the Weld Head Spatter can ignite combustible materials If you cannot remove all combustible materials cover them with a non combustible material Do NOT cover the Weld Head with a blanket cloth etc Heat generated by the operating Weld Head may ignite a blanket or cover Wear ear protectors Loud noises can damage hearing Keep a fire extinguisher nearby Make sure there is a fire extinguisher in or near the welding shop in case of fire Regularly inspect and maintain the Weld Head Regular inspection and maintenance is essential to safe operation and long life of the equipment If you see any damage make necessary repairs before operation qb D p SERIES 70 WELD HEADS viii 990 143 Installation Precautions Do not install this Welding Head in any of the following Damp places where humidity is 90 or higher Dusty places Places where chemicals are handled e Places near a high frequency noise source e Hot or cold places where temperatures are above 40 C or below 0 C or places where water will condense Do not modify the electrode holders or attach additional mechanisms to the moving parts of the head Doing so may hurt welding performance damage the head and void the warranty Operating Precautions e Do not put anything other than a workpiece tool screw coin etc between the electrodes or on the Weld Head or you may damage
12. 2 Dumet 2 Nichrome 2 Nickel Alloy 2 Nickel Alloy 2 Dumet 2 Nickel 2 Nickel Alloy 2 Tinned Brass 14 Dumet 2 Platinum 2 Nickel Alloy 2 Beryllium Copper 2 Dumet 2 Cold Rolled Steel 2 Nickel Alloy 2 Consil 2 Evanohm 14 Copper 14 Nickel Alloy 2 Tinned Copper 14 Gold 14 Gold 14 Nickel Alloy 2 Nichrome 2 Gold 14 Kovar 2 Nickel Alloy 2 Nickel 2 Hastalloy 2 Titanium 2 Nickel Alloy 2 Cold Rolled Steel 2 Inconel 2 Inconel 2 NiSpan C 2 NiSpan C 2 Inconel 2 Kulgrid 2 NiSpan C 2 Cold Rolled Steel 2 SERIES 70 WELD HEADS 990 143 F 3 APPENDIX F THE BASICS OF RESISTANCE WELDING ELECT ELECT MATERIAL RWMA MATERIAL RWMA TYPE TYPE NiSpan C 2 Stainless Steel 2 Niobium 2 Niobium 2 Platinum 2 Platinum 2 Paliney 7 2 Paliney 7 2 Silver 11 14 Silver 11 14 Silver 11 14 Cadmium 13 Silver 11 14 Cold Rolled Steel 2 Silver 11 14 Stainless Steel 2 Cold Rolled Steel 2 Cold Rolled Steel 2 ELECT ELECT MATERIAL RWMA MATERIAL RWMA TYPE TYPE Cold Rolled Steel 2 Stainless Steel 2 Cold Rolled Steel 2 Tantalum 2 Stainless Steel 2 Stainless Steel 2 Stainless Steel 2 Tungsten 2 Tantalum 2 Tantalum 2 Titanium 2 Titanium 2 Tungsten 2 Tungsten 2 Tungsten 2 henium 2 Zinc 14 Zinc 14 Electrode Maintenance Depending on use periodic tip resurfacing is required to remove oxides and welding debri
13. Input Setting Moving Speed from Mid Point to Weld Point 1 Turn the Operation button to light up all of the MID WELD and FORCE CHK Lamps 2 Press the Operation button for I second The MID WELD and FORCE CHK Lamps blink 3 The number of the blinking SPEED HOLD TIME Lamp indicates the current speed setting Turn the Operation button clockwise and counterclockwise to change the number of the blinking lamp Select your desired speed Maximum 4 After setting the speed close and thereafter open External Input both 1ST and 2ND Check the speed of the electrode that moves forward and backward 5 Press the Operation button when your desired speed is determined Press the ORG CANCEL button to interrupt Setting Downstop Point 1 Turn the Operation button to light up WELD Lamp Press the Operation button for 1 second The WELD Lamp will blink 2 3 Close External Input 2ND to make the electrode move to Downstop Point with beeps 4 Open External Input 2ND and 1ST 5 Turn the Operation button clockwise and counterclockwise to make the electrode move forward and backward in 0 1 mm increment decrement 6 Press the Operation button when the electrode reaches the desired position The WELD Lamp will blink quickly SERIES 70 WELD HEADS 3 8 990 143 CHAPTER 3 OPERATING INSTRUCTIONS In Case the Electrode Cannot Move Beyond the Weld Point Because of a Workpiece 1 Turn the Operation button until the electrode stops then press the
14. Operation button again 2 Downstop Point is set 5mm beyond Weld Point and the WELD Lamp blinks fast 3 Close External Input 1ST The electrode moves to Start Point with beeps to complete Weld Point setting When you want to interrupt the operation 1 Press ORG CANCEL button and the WELD Lamp blinks fast 2 Close External Input 1ST The electrode returns to the previous position with beeps 3 Incase of Mode 1 it works by pressing the operation button in addition to External Input Setting Additional Squeeze time at Weld Point 1 the function of setting the additional squeeze time the additional electrode force can be exerted on the electrode for desired period without stopping the motor Turn the Operation button to light up both WELD and HOLD Lamp Press the Operation button for 1 second and WELD and the HOLD Lamps will blink 4 The number of the blinking SPEED HOLD TIME Lamp indicates the additional squeeze time setting Turn the Operation button clockwise and counterclockwise to change the number of the blinking lamp Select your desired period 95 SPEED HOLD TIME Lamp Number Additional Squeeze time ms 4 Press the Operation button when your desired period is indicated NOTE Press the ORG CANCEL button to interrupt SERIES 70 WELD HEADS 990 143 3 9 CHAPTER 3 OPERATING INSTRUCTIONS Start up END Signal Input Start Point Electrode Mid Point Movement Weld Point
15. Operation button is selecting a function Auto function will set electrode position and movement FORCE CHK Lamp Operation button is selecting a function Weld force can be measured HOLD Lamp Operation button is selecting a function Hold Time can be changed MID Lamp Electrode is at Mid Point Mid Point can be changed Operation button is selecting a function READY Lamp Electrode is at Start Point and completed for Start Point can be changed work Operation button is selecting a function SCH Schedule Display Schedule Nos are displayed There are 31 When power supply is applied zero combinations of Electrode position Speed 0 blinks When trouble occurs fault and Hold Time that can be registered as code is displayed Weld force can be Schedules in the 70 series measured SCH Schedule Lamp Operation button is selecting a function Schedule No can be changed TROUBLE Lamp Trouble is occurring 22277727 WELD Lamp Electrode is at Weld Point Lowest point Downstop Point is Operation button is selecting a function being changed SERIES 70 WELD HEADS 990 143 1 5 CHAPTER 1 DESCRIPTION SPEED HOLD TIME Display Indicates the electrode speed and HOLD Time after the application of weld force is completed The larger number indicates the faster electrode speed and the longer HOLD time The lamp lights up simultaneously with other lamps as shown below When illuminated When blinking READY Lamp an
16. SPEED HOLD TIME Display on the Model 72 a vertical bar on the Model 72 On the Model 72 you can select one from the right and left electrodes to measure The blinking 1 indicates the electrode to be measured Rotate the Operation button to move 1 to the right or left Set up a force gauge Close the External Input 2ND The electrode moves forward When the electrode contacts the force gauge the electrode stops with beeps Open External Input 2ND and measure the weld force Close External Input 1ST The electrode returns to Start Point After the electrode has returned to Start Point press ORG CANCEL button to complete the mode of measuring the weld force In case of Mode 1 it works by pressing the operation button in addition to External Input NOTE When you want to interrupt the operation except at the Start Point press the ORG CANCEL button The FORCE CHK Lamp will blink fast Close the External Output 1ST The electrode returns to Start Point and the Controller beeps SERIES 70 WELD HEADS 990 143 CHAPTER 4 MAINTENANCE Section l Troubleshooting When a problem occurs the TROUBLE Lamp lights up and a fault message is shown on the SCH Display Closing the External Input RESET or continuing to press the operation button can reset the fault signal Electrode force is applied on the way Close External Input 1ST again to make the electrode move to to return to Start Point Original Point Rectify the cause of the pr
17. Workbench The Welding Head base has six 6 holes so that it may be installed onto a work bench Each hole is 1 4 inch 6 5mm in diameter with 43 inch 11mm spot facing and is 4 inches 10mm deep SERIES 70 WELD HEADS 990 143 2 1 CHAPTER 2 INSTALLATION AND SETUP Space Requirements Model 71 Weld Head Model 72 Weld Head 467mm 11 9 inches 301mm le 16 inches gt lt M gt M 8 6 inches gt it t i i 219mm i 406 4 7 inches 3 1 inches 80mm 120mm Model 73 Weld Head lt lt SS 10 8 inches gt t 274mm 6 8 inches 173mm SERIES 70 WELD HEADS 2 2 990 143 CHAPTER 2 INSTALLATION AND SETUP Install Electrodes Do not modify the electrode holders or attach additional mechanisms to the moving parts of the head Doing so may hurt welding performance damage the head and void the warranty Installing and replacing electrodes is essentially the same for all Series 70 heads The picture below shows the Model 72 for reference 1 Loosen the Electrode Screw 2 Insert the Electrode into the Electrode Holder 3 Tighten the Electrode Screw to secure the Electrode in place Connect Weld Cables After installing the Weld Head on the work bench connect the Weld Cables also known as seco
18. arbitrarily The electrode moves up and down between the mid point and workpiece for continuous welding This reduces the weld cycle time as the electrode doesn t need to return to the start point every time it welds This can be useful in automation During welding the workpiece can expand and shrink This Weld Head employs a spring so that the electrode can follow up the deformation of the workpiece quickly which reduces splash The dedicated Controller easily sets the electrode position and speed Since this Welding Head is motor driven the piping for air actuation is not needed enabling an easy installation SERIES 70 WELD HEADS 990 143 1 1 CHAPTER 1 DESCRIPTION Section Il Major Components Model 71 Weld Head 40 11 Cs heren Eeoae ode Voer Seng ate Sw Cometh Vlg ___ 7 Wad Cavie For mounting Weld Head to work bench Two brackets are provided each with 2 10 5 5mm mounting holes Adapter Mounting Screws Secures the bottom Electrode Adapter to the Base SERIES 70 WELD HEADS 1 2 990 143 CHAPTER 1 DESCRIPTION Model 72 Weld Head Description item Name Adjusts the electrode force Locks the Weld Force Adjustment Knob 24 Mounting Serew Secures the Head to the Mounting Post 5 Electrode Screws 00 0 Secures the Electrodes to the Holders 6 Voltage Sensing Cable Screw Co
19. the Weld Head or cause a short circuit or fire Operate the Welding Head only according to the instructions in this manual e Operate the button carefully by hand If it is operated roughly or with the tip of a tool you may damage the Weld Head Disposal Precaution The Motor Controller photo coupler contains GaAs Follow all local environmental regulations for disposal SERIES 70 WELD HEADS 990 143 ix TECHNOS CORPORATION EC Declaration of Conformity i The company manufacturer Technos Corporation 95 3 Futatsuka Noda City Chiba 278 0016 JAPAN Herewith declares conformity of the products Designation Resistance Welding Head Type Serial Number etc MH P20A MH D20A With applicable regulations below EC Directive Machinery Directive 98 37 EC amended by 89 392 91 368 93 44 and 93 68 Low voltage Directive 73 23 EEC amended by 93 68 EEC EMC Directive 89 336 EEC amended by 91 31 EEC and 93 68 EEC Harmonized European Standards applied EN 55011 Group 2 Class A 1991 EN 60204 1 1998 EN 61000 4 2 1995 contact level 3 air discharge level 3 EN 61000 4 3 1995 level 2 EN 61000 4 4 1995 power line level 3 signal line level 3 Importer Distributor in EU TECHNOS EUROPE GmbH Pleldelsheimer Strasse 11 D 74321 Bietigheim Germany Division Miyachi Technos Corporation Japan Noda City M Hasegawa Director Production Oct 02 20
20. to narrow in on the optimal setting for a particular parameter This method is generally used 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 window is in relation to quality requirements We recommend data be gathered from a monitoring perspective so that this can provide a starting point for establishing a relationship between quality and the monitored measurement parameter Criteria for Success Critical parameters should be identified from the list of unfixed variables left from the Screening DOE S A mini experiment maybe required establishing reasonable bounds for the combination of parameters to be tested This will prevent void data and wasted time At this stage it is useful to record multiple relevant quality measurement or inspection criteria so that a balanced decision can be reached For example if part marking and pull strength are the relevant criteria a compromise in ideal setting maybe required As with all experiments the test method should be carefully assessed as a potential source of variation and inconsistency 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 in variables such as electrode changes and cleaning as well as equipment set up
21. Display of the front panel Close the circuit of External Input 1ST or ORG and the electrode after it once returns back to Original Point moves to Start Point If the circuit of External Input is opened while electrode is moving the electrode stops there When the circuit of External Input is closed again the electrode begins to move When the electrode reaches Start Point the READY lamp lights up and the preparation is completed NOTES e The Original Point and Start Point are at the same position when the shipping package is opened and the power is supplied for the first time e Incase of Mode 1 it works by pressing ORG CANCEL button in addition to 1 the use of External Input Auto Set the Electrode Position 1 SO o 11 The electrode position be set automatically by means of the auto setting function Turn the Operation button to light up the AUTO Lamp Press the Operation button for 1 second and the AUTO lamp will blink Close the External Input 1ST and the electrode moves to Original Point Open External Input when electrode stops and the Controller beeps NOTE The Controller beeps when the package is opened and the power is supplied for the first time because Original Point and Start Point are at the same position A numeral blinks on SCH Display Turn the Operation button to change Schedule No When Schedule No is determined press the Operation button The blinking numeral on SC
22. H Display changes to the illuminated one Position the workpiece to be welded Close External Input 1ST and 2ND to make the electrode move forward Hold the External Input 1ST and 2ND closed The electrode presses the workpiece and the Controller beeps When the application of the electrode force is completed the electrode returns to the position before Original Point and the Controller beeps Open External Input 1ST and 2ND to complete the auto setting with a beep The position where the electrode stops is Start Point SERIES 70 WELD HEADS 990 143 3 5 CHAPTER 3 OPERATING INSTRUCTIONS 12 The electrode positions determined by the auto setting are as follows Original Point Position where the electrode has completely returned Between Weld Point and Original Point 2mm before Weld Point 5mm beyond Weld Point NOTE The electrode speed and Hold Time are not set automatically The previous settings are valid Change these settings manually In case of Mode 1 it works by pressing the Operation button in addition to the use of External Input When using the Operation button press the Operation button again because the electrode stops after pressing the workpiece Manually Set the Electrode Position Selecting Schedule No 3 6 1 2 95 So eNO oS 11 12 13 14 Turn the Operation button to light up SCH lamp Press the Operation button for I second SCH Lamp and SCH Display blink Turn the O
23. ICS OF RESISTANCE WELDING Typical Weld Strength Profile The picture on the right illustrates a typical weld strength profile The 14 lb electrode force curve shows the highest pull strengths but the lowest X is n tolerance to changes in weld current voltage power The 12 lb electrode force curve shows a 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 Electrade Force 2 8 2 The 12 Ib electrode force curve is preferred It 20 30 40 50 60 70 80 90 100 shows more tolerance to changes in weld current Energy watt seconds voltage or power and has nearly the same bond strength as the 14 lb electrode force curve Typical Weld Strength Profile A comparison of weld schedules for several different applications might show that they could be consolidated into one or two weld schedules This would have obvious manufacturing advantages SERIES 70 WELD HEADS F 6 990 143 APPENDIX G Quality Resistance Welding Solutions Defining the Optimum Process Introduction A quality resistance welding solution can be defined as one that meets the application objectives and produces stable repeatable results in a production environment In order to define the optimum process the user must approach the application in a methodical way and many variables must be considered In t
24. IST Confirm that a qualified Engineer or Technician has properly installed and setup the equipment according to the instructions in Chapter 2 Installation and Setup Con Set the WELD NO WELD Switch located on the front of the Power Supply Welding trol to the NO WELD position ra Check that the weld power cables are correctly attached at both ends Verify that Firing Switch Cable is attached to the welding control Verify that the Power Supply Welding Control is connected to the appropriate power source and that the power source is turned ON Verify that the Power Supply Welding Control is turned ON Operator Safety e Always wear protective safety glasses when performing any welding operation e Always wear appropriate personal protective gear when welding SERIES 70 WELD HEADS 990 143 3 1 CHAPTER 3 OPERATING INSTRUCTIONS Section Il Operation Overview Welding consists of e Adjusting the electrodes and Weld Head height to match the pieces being welded e Adjusting the welding force if necessary e Using the Controller to program the motor drive settings e Welding using normal shop procedures Before performing the procedures below make sure the WELD NO WELD switch is in the NO WELD position to avoid unexpected sparking or weld current discharge that could damage equipment 2 level Footswitch It is of 2 level type The first level switch is External Input 1 STI The second level switch is Ex
25. Mid Point 28 29 a Moving Speed between Weld Point and 138 Mid Point 30 32 Hold Time 128 32 33 n Moving Speed between Mid Point and 1234 Weld Point 12 34 34 Additional Squeeze Time at Weld Point 12A 13 35 35 CR code 0 x 0D Fixed 14 36 36 LF code 0 0A Fixed SERIES 70 WELD HEADS D 4 990 143 APPENDIX D COMMUNICATIONS Overwrite Command Controller tem GHACTERTRAN DESCRIPTION RANGE 09 14 nnnnn Start Point 00000 05000 nnn nn dimensions in mm 07 15 20 nnnnn Mid Point 00000 gt 05000 nnn nn dimensions in mm 21 26 nnnnn Downstop Point 00000 05000 nnn nn dimensions mm 27 28 n Moving Speed Between Start Point and 1238 Mid Point 29 30 Moving Speed Between Weld Point and Mid Point 33 0 32 Time 33 34 a between Mid Point and Weld Point 3595 35 Additional Squeeze Time at Weld Point Additional Squeeze Time at Weld Point Time at Weld Point 3a4 SERIES 70 WELD HEADS 990 143 D 5 APPENDIX D COMMUNICATIONS Controller Host Computer Corer GHACTERTRAN 08 13 nnnnn Start Point 00000 3 05000 nnn nn dimensions in mm 14 19 nnnnn Mid Point 00000 3 05000 nnn nn dimensions in mm 20 25 nnnnn Downstop Point 00000 05000 nnn nn dimensions in mm 26 27 n Moving Speed between Start Point and 1238 Mid Point 28 29 a Moving Speed between Weld Point and 138 Mid Point 30 31 Hold Time 128
26. Optimum Process F 1 SERIES 70 WELD HEADS iv 990 143 CONTACT US Thank you for purchasing a Miyachi Unitek Series 70 Weld Head Upon receipt of your equipment please thoroughly inspect it for shipping damage before installing it If there is any damage please contact the shipping company immediately to file a claim and notify Miyachi Unitek at 1820 South Myrtle Avenue P O Box 5033 Monrovia CA 91017 7133 Telephone 626 303 5676 FAX 626 358 8048 e mail Info muc Miyachi com The purpose of this manual is to provide the information required for proper and safe operation and maintenance of the Series 70 Weld Heads We have made every effort to ensure that information in this manual is both accurate and adequate If you have any questions or suggestions to improve this manual please contact us at the phone number or addresses above Miyachi Unitek Corporation is not responsible for any loss or injury due to improper use of this product SERIES 70 WELD HEADS 990 143 vi SAFETY PRECAUTIONS Before using this equipment read the SAFETY PRECAUTIONS carefully to understand the correct usage of the equipment e These precautions are given for safe use of the Inverter Weld Head and for prevention of injury to operators or others These symbols denote e sure to read each of the instructions PROHIBITION They are warnings 5 about actions that should not be as they
27. Y and MID lamps will blink 3 The number of blinking SPEED HOLD TIME Lamp indicates the current speed setting Turn the Operation button clockwise and counterclockwise to change the number of the blinking lamp Select your desired speed 4 After setting the speed close and thereafter open External Input 1ST Check the speed of the electrode that moves forward and backward 5 Press the Operation button when your desired speed is determined NOTE Press ORG CANCEL button to interrupt Setting Mid Point 1 Turn the Operation button to light up MID Lamp Press the Operation button for I second MID Lamp blinks 2 3 Close External Input 1ST to make the electrode move to Mid Point with beeps 4 Open the External Input 1ST 5 Turn the Operation button clockwise and counterclockwise to make the electrode move forward and backward in 0 1 mm increment decrement 6 Press the Operation button when the electrode reaches the desired position and the MID Lamp will blink quickly SERIES 70 WELD HEADS 990 143 3 7 CHAPTER 3 OPERATING INSTRUCTIONS 7 Close External Input 1ST The electrode moves to Start Point with beeps to complete Mid Point setting 8 When you want to interrupt the operation press the ORG CANCEL button and the MID Lamp blinks fast 9 Close External Input 1ST The electrode returns to the previous position with beeps 10 In case of Mode 1 it works by pressing the Operation button in addition to External
28. ails see the Unitek Peco slide rule Approach to Weld Development The first stage in developing a quality welding process is to fix as many of the variables as possible in the welding equipment set up The welding variables can be grouped in the following categories e Material variables e Process variables Base material Tooling level of automation Plating Repetition rate Size Part positioning Shape Maintenance electrode cleaning e Weld head amp mechanical variables Quality requirements A Force squeeze hold Pull strength Actuation method Visual criteria Electrode material and shape Test method other weld joint requirements e Power supply variables Energy Time squeeze weld hold SERIES 70 WELD HEADS 990 143 G 7 APPENDIX G DEFINING THE OPTIMUM PROCESS At this stage it is good practice to document the welding set up so that it can be referred to later request Unitek Peco Process Audit Worksheet for an example Once the equipment set up has been documented the next stage is to fix as many of the process and material variables as possible to reduce variation in the subsequent welding trials The main welding parameters such as energy force and time cannot be fixed at this stage but many of the other variables such as repeatable part positioning should be fixed Initial Welding Trials The Look See Tests Look see welding t
29. are all important for safe operation performed because they can damage the equipment and will void The meanings of the words and symbols the warranty are as follows These symbols denote actions which operators must take Each symbol with a triangle denotes that the contents gives notice of DANGER WARNING or CAUTION to the operator These actions can cause electric shock and fire Do not do anything other than the maintenance described in this manual Q NEVER DISASSEMBLE REPAIR OR MODIFY THE WELD HEAD SERIES 70 WELD HEADS 990 143 9 9 Q5 QD QD ab Do NOT put your hands or fingers between the electrodes When welding keep your hands and fingers away from the electrodes Do NOT touch any welded part or electrode during or just after welding The welded parts and electrodes are very hot If you touch them you will be burned Only use specified cables A cable with insufficient capacity or loose connections can cause electric shock or fire Only apply the specified power Application of a voltage or current out of the specified range can cause electric shock or fire Do NOT use a damaged connecting cables or plugs Do not step on twist or tense any cable Connecting cables may be damaged which can cause electric shock short circuit or fire If any part needs to be repaired or replaced consult Miyachi Unitek or your distributor Stop operation if any trouble occurs If you detect a burni
30. by different personnel to ensure that the solution is one that can run in a real production environment Welded assemblies should be tested over time an under real use conditions to ensure that all functionality criteria will be met Validation testing is usually required to prove the robustness of the process under production conditions Conclusion The resistance welding process can deliver a reliable and repeatable joining solution for a wide range of metal joining applications Defining the optimum welding process and best production settings is not a black art and can be achieved through a methodical and statistical approach Time spent up front in weld development will ensure a stable welding process and provide a substantial 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 the quality and variation of the welded assembly Unitek Peco will frequently use the Screening DOE tool to establish the impact of key variables and also to assist customers with troubleshooting Often the testing as described above will provide the information and understanding to predict common failure modes and causes A troubleshooting guide can be requested in the form of a slide rule to assist users in identification of welding problems and likely causes SERIES 70 WELD HEADS 990 143 G 11
31. connected to GND OV Select a schedule number referred to as SCH No below indicating a combination of the circuit closed pins among Pins No 2 3 4 5 and 6 See table below The schedule number selected by I O Connector has priority over the schedule number set on the Controller Before selecting the schedule number by the Operation button on the Controller open the circuits of all the Pins of No 2 3 4 5 and 6 in I O Connector Input SCH signal at least 2 ms before the welding current flows During in operation the schedule number cannot be changed h l2 o2 m ee L 8 1 1 7 Dow 8 60 9 0 6 je 2 je 3 je je 1 E Output pins for 24 VDC through 1000 internal resistor Input pin for start up signal When 1 is closed electrode moves from Start Point to Mid Point When 2 is closed after 1 was closed electrode moves from Mid Point to Weld Point Although only 274 is closed electrode does not move an Spare pin Do not connect a Factory connected to GND OV a Output pins for 24 VDC through 100Q internal resistor SERIES 70 WELD HEADS 990 143 B 3 APPENDIX B ELECTRICAL AND DATA CONNECTIONS Description According to the usage connect pins as follows e When a contact is used as the input signal of the I O Connector connect pins 14 and 15 DELL COM 5
32. d Head Screw firmly Aligning the Electrodes 1 Unplug the AC Cable from the outlet to turn off the power supply 2 Loosen the Holder Mounting Screws 3 Rotate or move back and forth the Electrode Holders to align the upper and lower electrodes as shown at lower right NOTE If you can t align the electrodes loosen the Holder Screw to move the Electrode Holder up down left or right as needed SCREWS HOLDER i gt SERIES 70 WELD HEADS 990 143 2 7 CHAPTER 2 INSTALLATION AND SETUP Adjust the Electrode Mounting Angle 1 Unplug the AC Cable from the outlet to turn off the power supply 2 Loosen the Holder Mounting Screws and turn the Electrode Holders to adjust the mounting angle of the electrode 3 After the adjustment tighten the Holder Mounting Screw securely SERIES 70 WELD HEADS 2 8 990 143 CHAPTER 3 OPERATING INSTRUCTIONS Section Before You Start Preparation Before operating the Weld Head read both this manual and the Operator Manual that came with your Power Supply Welding control Particularly note the specific hazards associated with those components You must be familiar with the general principles of welding programming weld schedules and the operating procedures of your Power Supply Welding Control Use the checklist below to make sure that all connections and settings are correct to ensure that you will achieve the highest quality welds possible PRE WELD CHECKL
33. d Operation button is selecting a function Electrode speed between Start Point MID Lamp and SPEED HOLD TIME Display does not light and Mid Point can be set SPEED HOLD TIME o EM Display Electrode is moving between Start Point and Mid Point MID Lamp and Operation button is selecting a function Electrode speed from Weld Point to WELD Lamp and SPEED HOLD TIME Display does not light Mid Point can be set oar a de 1 ing fi Id Poi Mid HOLD TIME Display ectrode is moving from Weld Point to Mid Point MID Lamp and Operation button is selecting a function Electrode speed from Mid Point to WELD Lamp and SPEED HOLD TIME Display does not light Weld Point can be set FORCE CHK Lamp P Electrode is moving from Mid Point to Weld SPEED HOLD TIME Poi oint Display WELD Lamp and Operation button is selecting a function The desired time for which the HOLD Lamp and SPEED HOLD TIME Display does not light additional weld force is exerted on up after applying the weld force at Weld 2 Point is being set HOLD Lamp and Operation button is selecting a function Hold Time can be set SPEED HOLD TIME SPEED HOLD TIME Display does not light Display up SPEED HOLD TIME In case of Movement Mode 1 electrode Display position is at Start Point and the Display shows A when setting is not performed ORG CANCEL Button This button interrupts the programming changes in progress SERIES 70 WELD HEADS 1 6 990 143
34. d puerta eco ae aang 3 8 In Case the Electrode Cannot Move Beyond the Weld Point Because of a Workpiece 3 9 When you want to interrupt operation ooi ee Unc pee ose RS 3 9 Setting Additional Squeeze time at Weld Point e 3 9 Setting Hold I TO wha cc toa SOLD 3 10 Setting Moving Speed from Weld Point to 4 3 11 Section M TAI rr 3 12 M UTD TUS ENS TES 3 12 Weld Force RED 3 12 Chapter 4 Maintenance Section L Troubleshooting pu usada MERI MET 4 1 Section Maintenance T 4 2 Mog c P 4 2 Blectrode Cleaning eoe 4 2 Appendix Technical Specifications 1 Appendix B Electrical and Data Connections B 1 Appendix C uiii arc TES C 1 Appendix D Communication fies cs sats cep rx ape ER Mu RR HEY MODEL Ua Vd xU t Eu RAN a o ru D 1 Appendix ACCOSSOFIGS oen alpin Sat detente ahdcetaccntannens E 1 Appendix The Basics of Resistance Welding eere F 1 Appendix Quality Resistance Welding Solutions Defining the
35. e negative electrode Polarity on the Control can only be changed by reversing the Weld Cables Weld Strength Testing Destructive tests should be performed on a random basis using actual manufacturing parts Destructive tests made on spot welds include tension tension shear peel impact twist hardness and macro etch tests Fatigue tests and radiography have also been used Of these methods torsional shear is preferred for round wire and a 45 degree peel test for sheet stock Weld Strength Profiles Creating a weld strength profile offers the user a scientific approach to determining the optimum set of welding parameters and then displaying these parameters in a graphical form 1 Start at a low weld current voltage or power making five or more welds then perform pull tests for each weld Calculate the average pull strength Increase weld current voltage or power and repeat this procedure Do not change the weld time weld force or electrode area Continue increasing weld current voltage or power until any unfavorable characteristic occurs such as sticking or spitting Repeat steps through 3 for different weld forces then create a plot of part pull strength versus weld current voltage or power for different weld forces as shown in the illustration on the next page Typical Weld Strength Profile Repeat steps through 3 using a different but fixed weld time SERIES 70 WELD HEADS 990 143 F 5 APPENDIX F THE BAS
36. eak Weld Weak Weld Insufficient Nugget Insufficient Nugget Metal Expulsion Metal Expulsion Warping Warping Discoloration Discoloration Electrode Damage Insufficient Electrode Damage Insufficient FORCE PROBLEM CAUSE Parts Overheating Excessive Weak Weld Insufficient Nugget Metal Expulsion Warping Discoloration Electrode Damage Insufficient Interaction of Welding Parameters SERIES 70 WELD HEADS 990 143 F 1 APPENDIX F THE BASICS OF RESISTANCE WELDING Electrode Selection Correct electrode selection strongly influences how weld heat is generated in the weld area In general use conductive electrodes such as a RWMA 2 Copper alloy when welding electrically resistive parts such as nickel or steel so that the weld heat is generated by the electrical resistance of the parts and the contact resistance between the parts Use resistive electrodes such as RWMA 13 Tungsten and RWMA 14 Molybdenum to weld conductive parts such as copper and gold because conductive parts do not generate much internal heat so the electrodes must provide external heat Use the following Electrode Selection Table for selecting the proper electrode materials ELECT ELECT ELECT ELECT MATERIAL RWMA MATERIAL RWMA MATERIAL RWMA MATERIAL RWMA TYPE TYPE TYPE TYPE Alumel 2 Alumel 2 Ber
37. educe significantly thus bulk resistances become the major source for heat generation Weld Profiles The basic welding profile or schedule consists of a controlled application of energy and force over time Precision power supplies control the energy time and therefore heating rate of the parts The weld head applies force from the start to finish of the welding process SERIES 70 WELD HEADS G 6 990 143 APPENDIX G DEFINING THE OPTIMUM PROCESS The figure on the right Welding Force shows a typical weldin the force is Trigger Force Curent applied to the parts a squeeze time is then initiated which allows the force to stabilize before the current is fired Squeeze time also allows time for the contact resistances to Squeeze Heat Hold reduce as the materials start to come into closer contact at their interface A hold time is the initiated after current flows to allow the parts to cool under pressure before the electrodes are retracted from the parts Hold time is important as weld strength develops in this period of time This basic form of weld profile is sufficient for the majority of small part resistance welding applications Power 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 output and fast response to changes in resistance during the weld for further det
38. es forward to Weld Point e When the electrode contacts the workpiece and the weld force reaches the setting value then the electrode stops Weld Start Signal is output and the welding starts e When Weld Start Signal is once output the weld force of the electrode is maintained although the footswitch is released e When Hold Time has elapsed or End Signal is output from the welding power supply the weld force is released NOTE In case that End Signal cannot be input although Hold Time is set to 8 press ORG CANCEL button while pressing the footswitch The electrode returns to Start Point or Mid Point After the weld force of the electrode is released open External Input both 1ST and 2ND Then the electrode returns to Start Point In case that External Input 1ST is closed the electrode returns to and stops at the Mid Point NOTE When External Input 2ND is closed while the electrode is at Mid Point the electrode starts to apply the weld force again Be sure not to release the electrode while welding current is being applied Measuring Weld Force 1 2 3 12 Turn the Operation button to light up FORCE CHK Lamp Press the Operation button for 1 second The FORCE CHK Lamp blinks and a numeral blinks on SCH Display A minus lights up on SPEED HOLD TIME Display on the Model 72 a vertical bar 1 on the Model 72 Rotate the Operation button to change Schedule No The FORCE CHK Lamp blinks A minus blinks on
39. ests are a series of mini welding experiments designed to provide a starting point for further statistical development of the welding parameters The user should adjust 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 process perspective Key factors in this understanding are listed on the next page Application Perspective Materials Resistivity melting point thermal mass Shape hardness Heat balance Electrode materials shape Polarity heating rate upslope Observation visual criteria cross section and impact of variables on heat balance Process Perspective What are the likely variables in a production process How will operators handle and align the parts What tooling or automation will be required How will operators maintain and change the electrodes What other parameters will operators are able to adjust What are the quality and inspection requirements What are the relevant production testing methods and test equipment Do we have adequate control over the quality of the materials SERIES 70 WELD HEADS G 8 990 143 APPENDIX G DEFINING THE OPTIMUM PROCESS Common Problems During this stage of process development it is important to understand that the majority of process problems are related to either materials variation or part to electrode positio
40. his article we will look at the following key stages and principles to be considered when defining the optimum resistance welding process e Materials and their properties e Basic resistance welding principles e Weld profiles e Approach to development e Common problems e Use of screening DOE S e Use of factorial DOE S Resistance Welding A Material World The first stage in designing a quality welding solution is to consider the properties of the materials to be joined and also the quality requirements of the desired welded joint When considering these properties it is worthwhile to review the way the resistance welding process works and the likely outcome when the parts are resistance welded There are four main types of structural materials e Metals silver steel platinum e Ceramic alumina sand e Plastics polymers PVC teflon e Semiconductors silicon geranium Metals can be resistance welded because they are electrically conductive soften on heating and can be forged together without breaking SERIES 70 WELD HEADS 990 143 G 1 APPENDIX G DEFINING THE OPTIMUM PROCESS Alloys are a mixture of two or more metals as Alloy shown on the right Alloys are normally harder less conductive and more brittle than the parent metal This has bearing on the type of joint one can expect when resistance welding a combination of different metals Metal B Metals atoms are naturally attracted to other metal atoms e
41. impact that welding and process parameters have on the quality of the weld Quality measurement criteria should be selected based on the requirements of the application A Screening DOE will establish a relative quality measurement for the parameters tested and also the variation in the welded result This is important as variation in process is critical in establishing the best production settings Typical welded assemblies are assessed for strength of joint and variation in strength A Screening DOE tests the high and low settings for 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 carrying out the minimum number of experiments to gain the information A five factor screening DOE can be accomplished in as few as 24 welds with three welds completed for each of 8 tests By comparison it would take 96 welds to test every combination It promotes understanding of many variables in a single experiment and allows the user to interpret results and thus narrow the variables for the next level of statistical analysis If many variables are still not understood multiple Screening DOE S may be required Unitek Peco provides a simple Screening DOE tool that is run in excel and is sufficient for the majority of applications contact us for details Bespoke sophisticated software is also available from other vendors designed specifica
42. lectrode is at Start Point and no setting is performed then A is shown on SPEED HOLD TIME Display Change of Schedule Number Changing the Schedule No does not cause the electrode to move The electrode s START POINT stays at the position of the previous schedule In case that Start Point of the new Schedule No differs from the one of the last Schedule No move the electrode to the Mid Point and back to get the new Start Point Start up SCH No Input StartPoint SCH1 Electrode startPoint Movement SCH2 Mid Point SCH2 Electrode Position Output e Incase of continuous operations across several Schedule Numbers set each Start Point the same e When the weld force is exerted on the electrode on the way other than moving from Mid Point to Weld Point then the fault code E is displayed In Case of Mode 0 When a problem occurs between Mid Point and Start Point open External Input 1ST to make the electrode move to Start Point SERIES 70 WELD HEADS 990 143 3 3 CHAPTER 3 OPERATING INSTRUCTIONS When a problem occurs between Start Point and Original Point open External Input 1ST to make the electrode move to Original Point At the Original Point External Output START POINT is output In case of Mode 1 Power to the motor is turned OFF to stop Mode Setting Setting 1 Turn on the power while pushing the Operation button The character of Set blinks on the SCH Schedule display and SPEED HOLD TIME Display
43. lly for this purpose Criteria for Success Before running the series of experiments the user must establish an acceptable window for energy time and force This will prevent voided results It is common practice to include one or all of the above variables in a Screening DOE This is only recommended if sufficient understanding has been established for the other application and process variables that can impact quality Users should first try to screen out all common application and process variables that require further exploration from the results of the look see mini experiments and then include the three key welding variables energy force and time Several Screening DOE S maybe required Results should be interpreted carefully Typically one would look for the highest result in terms of quality with the least variation A Screening DOE provides only a measurement that indicates the relative importance of a parameter and not the ideal setting Factorial DOE S should be used to establish the correct or best setting for a parameter once many of the other variables have been screened and fixed This is the time to also assess the measurement accuracy and consistency of the test method and procedure Variation in test method can invalidate the test and can lead to misinterpretation of results SERIES 70 WELD HEADS G 10 990 143 APPENDIX G DEFINING THE OPTIMUM PROCESS What are Factorial DOE S The purpose of a Factorial DOE is
44. ly as show on the right the contact resistance is lower and bulk resistance now controls the heat generation This type of weld is achieved with a slower heating rate and normally longer time is preferred for welding resistive materials which can generate heat through their bulk resistance Electrode QEON Electrode High Contact Resistance Better Part to part electrode to part fit up The contact resistance present at the weld when the power supply is fired has a great impact on the heat balance of a weld and therefore also the heat affected zone SERIES 70 WELD HEADS 990 143 G 5 APPENDIX G DEFINING THE OPTIMUM PROCESS The figure below shows a weld that is fired The figure below shows a weld that is initiated early on in the weld sequence when the when the contact resistance is lower and in this contact resistance is still quite high example we are using bulk resistance to generate our weld heat Contact Resistance Contact Resistance Resistance Weld Pulse Resistanc Weld Pulse Bulk Resistance Bulk Resistance Time mime Heat Affected Zone NOTE Larger nuggets are possible with longer weld times when using bulk resistance In general conductive materials benefit from a faster heating rate as the higher contact resistances assist heat generation in the weld Resistive materials benefit from slower heating rates that allow the contact resistances to r
45. ndary cables to the head as shown below Model 71 Model 72 SERIES 70 WELD HEADS 990 143 2 3 CHAPTER 2 INSTALLATION AND SETUP Model 71 SECONDARY e CABLES NOTES e These cables are not polarized e The connecting screws on Model 72 are on both the left and right sides of the head SERIES 70 WELD HEADS 2 4 990 143 Conne 1 CHAPTER 2 INSTALLATION AND SETUP ct Controller and Power Supply Cables Connect the Volt Sensing Cable When employing the voltage detecting function of a Power Supply Weld Checker etc connect the Volt Sensing Cables to the Electrode Holders as shown below Model 71 amp 73 Model 72 990 143 NOTE On the Model 72 connect the Volt Sensing Cables on both the right and left Holders Connect the Weld Force Detecting Sensor Cable Connect the Weld Force Detecting Sensor Cable to the Motor Controller Connect the I O Connector Connect the I O Connector to the Motor Controller Connect the operation switch for an emergency stop of the motor to Pins 21 and 22 of the I O connector Use the operation switch whose capacity is more than 24VDC 20 mA Connect the AC Cable Finally connect the AC Cable to the 100 240VAC 50 60 Hz outlet SERIES 70 WELD HEADS CHAPTER 2 INSTALLATION AND SETUP Section 11 Set up Adjust Electrode Height Adjust the electrode height in advance to allow LI L2 when welding a stepped workpiece If the distances to
46. ng off the power or resetting the fault signal resume Start Point Fault occurred in electrode driving After turning off the power or resetting the fault signal SERIES 70 WELD HEADS 990 143 4 1 CHAPTER 4 MAINTENANCE Section Maintenance Service There are no User serviceable parts in the Weld Head or Controller If they need service or if you have problems you cannot resolve contact us at the address e mail or phone number listed in CONTACT US in the front of this book The only maintenance the User can perform is to routinely clean and replace the electrodes Electrode Cleaning Clean the electrode tips periodically to remove oxides and welding debris 1 Use 600 grit sandpaper or finer to clean the electrodes 2 Place the sandpaper beneath electrodes The electrodes should contact with paper with a force low enough to allow the paper to be moved without damaging the electrodes 3 Gently pull the sandpaper forward one or two inches in a straight line only CAUTION Do not move the paper from side to side or in a circular motion or you may damage the electrodes 4 Clean the electrode face with a small cotton swab saturated in alcohol SERIES 70 WELD HEADS 4 2 990 143 APPENDIX A TECHNICAL SPECIFICATIONS Specifications Description 11 9 inches 301mm MODEL 71 Dimensions 8 6 inches i t 219mm 3 1 inches 80mm 18 4 inches 467mm MODEL 72 Dimensions 16 inche
47. ng smell abnormal sounds abnormal heat smoke etc turn power OFF immediately to prevent fire or electric shock Contact Miyachi Unitek or your distributor for help People with pacemakers MUST stay away from the Weld Head When the Weld Head is operating it generates a magnetic field which adversely affects pacemakers People who use a pacemaker must not approach the Weld Head or walk around the welding shop while the Weld Head is operating unless their medical doctor has deemed it safe to do so Wear protective gear Put on protective gear such as protective gloves long sleeved jacket and leather apron to avoid being burned 990 143 SERIES 70 WELD HEADS vii CAUTION Keep water and water containers away from the Weld Head Water spilled on the Weld Head can cause a short circuit electrical shock or fire Use proper tools wire strippers pressure wire connectors etc for terminations of the connecting cables Do not nick the wire conductor Doing so can cause a short circuit electric shock or fire Do NOT damage connecting cables or connectors during use Do not step on twist or tense any cable Connecting cables may be damaged which can cause electric shock short circuit or fire If any part needs to be repaired or replaced consult Miyachi Unitek or your distributor Install the Weld Head on a firm level surface Injury may result if the Weld Head falls over or drops from an uneven surface
48. ning Some examples are shown below Material Control Part To Part Positioning Electrode To Part Positioning The changes detailed above generally result in a change in contact resistance and always affect the heat balance of the weld During weld development these common problems must be carefully monitored so as not to mislead the course and productivity of the welding experiments In summary the look see welding experiments should 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 proceed to a statistical Design of Experiments method of evaluation Random explosions or unexpected variables will skew statistical data and waste valuable time Poor Follow up Sparks Insufficient Force Impact Force Sparks Variation lt lt Wr Variation sparks No Squeeze No Hold Sparks Vs Hold Variation ea queeze The figure above shows common welding problems that can often be identified in the basic set up of the force energy and time welding profile These problems can lead to weld splash and inconsistency and variation contact Unitek Peco for further information and support SERIES 70 WELD HEADS 990 143 G 9 APPENDIX G DEFINING THE OPTIMUM PROCESS What are Screening DOE S The purpose of a Screening DOE Design of Experiments is to establish the
49. nnects the Voltage Sensing Cable Weld Cable Screw Secures the Weld Cable to the Power Bar Mounting Posts Attaches to the Base and supports the Weld Head 10 Base Mounting Holes For mounting the Welding Head on the workbench Six 6 holes are provided Each hole is 4 inch 6 5mm with 43 inch 11mm spot facing and 4 inches 10mm deep SERIES 70 WELD HEADS 990 143 1 3 CHAPTER 1 DESCRIPTION Model 73 Weld Head Description Adjusts the electrode force Locks the Weld Force Adjustment Knob Holds the electrode Electrode Screw Secures the Electrode to the Electrode Holder For mounting the Weld Head to the work bench Two brackets are provided each with 2 10 5 5mm mounting holes 6 Holder Clamping Screw Clamps the Electrode Holder in place Weld Cable Screw Secures the Weld Cable to the Electrode Holder Adapter SERIES 70 WELD HEADS 1 4 990 143 CHAPTER 1 DESCRIPTION Controller Front Panel Operation Button You operate the Weld Head by turning the button clockwise counterclockwise and by pressing it By turning the button the lamp illumination changes as shown below 2 f 2 0 4 12 S 4A 4 A 1 mne eam 12 2 READY 10 Q E NK 1 8 FORCE MID c S 0 MID EWELD NER NN FORCE MID WELD 14 WELD 7 Y gt When Illuminated When blinking AUTO Lamp
50. nt START POINT Electrode Operation ORIGINAL POINT Movement START POINT Electrode WELD POINT Weld Start Start Point Mid Point SERIES 70 WELD HEADS 990 143 C 1 APPENDIX D COMMUNICATIONS Specifications RS 232C RS 232C Asynchronous Teletype procedure RS 485 RS 485 Asynchronous Half duplex Start bit Data Type Data bit Stop bit Parity bit ASCII Character Code CR code is indicated as and LF code as 1 Connections RS 232C RS 232C signals use TXD RXD and GND The communication connector is inside the external connector cover Controller Controller External Connector Host Computer Pin Number Pin No 1 CD TXD RXD RXD TXD Host computer 4d ra Ld 6 DSR GND RTS 9 CTS RI D Sub 9 Pin Female External connector cover D Sub 25 Pin Male NOTE DTR and DSR are not used with the Controller CTS is not checked at the beginning of communication SERIES 70 WELD HEADS 990 143 D 1 APPENDIX D COMMUNICATIONS RS 485 RS 485 signals use RS and RS The communication connector is inside the external connector cover Controller External Connector Pin Number Controller Host Computer RS 11 RS 18 RS 2320 RS 485 Conversion Adapter D Sub 25 Pin Male M External connector Terminal Resistance cover p 1002 E su NOTES e RS 485 operation requires a user provided RS 232C to RS 485 conver
51. oblem Thereafter reset the fault signal and close External Input 1ST E Mode 0 The TROUBLE output is released Electrode force is applied before Close External Input 1ST and 2ND to make the electrode Mid Point return to Start Point Rectify the cause of a trouble Thereafter reset the fault signal and close External Input 1ST The TROUBLE output is released Electrode force is applied on the way After rectifying the cause of a trouble reset the fault signal E Mode 1 to return to Start Point or applied resume Start Point before Mid Point Fault occurred in controller memory Some settings have been lost You must re set again Turn on the power while pressing ORG CANCEL button to clear all the settings Fault occurred in memory s R W Turn off the power and thereafter turn it on again function in controller If the problem continues contact Miyachi Unitek for repair Fault occurred in controller CPU After turning off the power or resetting the fault signal resume Start Point If the problem continues contact Miyachi Unitek for repair motor resume Start Point If the problem continues contact Miyachi Unitek for repair Fault occurred in the control signal After turning off the power check the connector conduction of electrode driving motor between the controller and motor If the problem continues contact Miyachi Unitek for repair STOP Pin circuit is opened Close the circuit of STOP Pin After turni
52. peration button clockwise and counterclockwise to select a numeral 1 to 31 on the SCH Display After selecting Schedule No press the Operation button Press ORG CANCEL button to interrupt the operation Setting Start Point Turn the Operation button to light up READY Lamp Press the Operation button for 1 second and READY Lamp lights up Close the External Input 1ST The electrode moves to Start Point with and the Controller beeps When the electrode has been at Start Point only beeps are given No motion is observed Open the External Input 157 Turn the Operation button clockwise and counterclockwise to make the electrode move forward and backward in 0 1 mm increment decrement Press the Operation button until the electrode reaches the desired position The READY lamp will blink fast Close the External Input 197 The Start Point setting is completed and the Controller beeps SERIES 70 WELD HEADS 990 143 CHAPTER 3 OPERATING INSTRUCTIONS NOTE When you want to interrupt the operation press the ORG CANCEL button and the READY lamp blinks fast 15 Close the External Input 157 The electrode returns to the previous position with beeps In case of Mode 1 it works by pressing the Operation button in addition to the External Input 1 Changing Moving Speed between Start Point and Mid Point 1 Turn the operation button to light up both READY and MID Lamp 2 Press the Operation button for 1 second The READ
53. raatio EEE E E 3 2 OVEIVIE W E 3 2 3 2 SERIES 70 WELD HEADS 990 143 iii CONTENTS Continued Page 3 2 NOS E cdit 3 3 Change of Schedule Number 3 3 l Case of Mode 0 T ees ER EERE EE E ESEE 3 3 In Case OF Mode T 3 4 Mode Setting ge cee careers ae aoa SM SUUM pA UR fU ne em ee 3 4 BSS EUS 3 4 Changing Mode 3 4 Change Of ERROR Signal 3 4 E d of Setting 3 4 Applying Power and Moving to Start Point eerte 3 5 A to Set the Blectrode PO Sit OM aeter secte tend 3 5 Manually Set the Electrode Position Lees pietre rb retos 3 6 Selecting Schedule ER 3 6 Changing Moving Speed between Start Point and Mid Point 3 7 Sel mp Mid POIN 3 7 Setting Moving Speed from Mid Point to Weld Point 22 Ia peo 3 8 S tting Downst p POL a
54. s 406mm 120mm SERIES 70 WELD HEADS 990 143 1 APPENDIX A SPECIFICATIONS Description MODEL 73 Dimensions 18 4 inches 468mm 10 8 inches gt 274mm 6 8 inches 173mm Model 71 Model 72 Model 73 Head Type For Opposed Welding For Series Welding For Series Welding 1 8 lbs 0 45 3 6 kgf 15 110 8 lbs 0 45 3 6 Electrode Force 1 8 lbs 0 45 3 6 kgf ko Weld Force Method Spring Forced Spring Forced Spring Forced Electrodes ES0400 Series 0 125 inch Unibond Electrodes ES0400 Series 0 125 inch diameter diameter Head 15 lbs 6 8 kg Head 17 lbs 7 7 kg Head 35 2 Ibs 16 kg Including Baseplate Including Baseplate Including Baseplate Weight Controller 4 6 lbs Controller 4 6 lbs Controller 4 6 lbs 2 1 kg 2 1 kg 2 1 kg Throat Depth 8 5 inches 216 mm 8 5 inches 216 mm 5 25 inches 133 3 mm Maximum Current Rating 3 000 A At 2 Duty Cycle 3 000 A at 2 duty cycle 7 500 A at 2 duty cycle 8 Speeds between Start Point Mid Point and Weld Point Mid Point Electrode Speed 4 Speeds between Mid Point Weld Point All speeds are selectable for each Schedule Electrode Drive Method Servo Motor SERIES 70 WELD HEADS A 2 990 143 APPENDIX A SPECIFICATIONS Electrode Stroke 1 7 inches 43 mm Maximum Number of Weld S ch edules 31 Schedules Externally Selectable Operating condi
55. s from electrodes Cleaning of electrodes on production line should be limited to use of 400 600 grit electrode polishing disks For less critical applications a file can be used to clean a badly damaged tip However after filing polishing disks 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 Development Developing a weld schedule is a methodical procedure which consists of making sample welds and evaluating the results The first weld should be made at low energy settings Adjustments are then made to each of the welding parameters one at a time until a successful weld is made 1 Install the correct electrodes in the electrode holders the Weld Head See the preceding Table for electrode material recommendations 2 Usea flat electrode face for most applications Use a domed face if surface oxides are a problem If either of the parts is a wire the diameter of the electrode face should be equal to or greater than the diameter of the wire If both parts are flat the face should be at least one half the diameter of the electrodes Pencil point electrodes cause severe electrode sticking to the parts unexplained explosions and increase the weld heat substantially because of the reduced electrode to part contact area 3 Usethe Force Adjustment Knob on the Weld Head to set the Firing Force and adj
56. se capacity is more than 24VDC 20 mA 3 Output pin for current supplying start signal to the welding power supply When the weld force is completed the circuit between Pins 23 and 24 becomes closed Contact capacity is 24 VDC 20 mA Output pin for completion signal of being ready for work READY When the resumption of Start Point is Output completed the Pin becomes closed If the Controller has an emergency the 63 OUT Pin becomes opened or 6 SERIES 70 WELD HEADS B 4 990 143 APPENDIX B ELECTRICAL AND DATA CONNECTIONS 5 00 START POINT Output pin for completion signal of arriving at Start Point When the electrode is at Start Point the Pin becomes closed 08 OUT 6 Output pin for completion MID POINT signal arriving at 5 0 MID POINT Mid Point When the electrode is at Mid Point the COM Pin becomes 4 OUT COM closed or 63 Common terminal to READY START POINT MID POINT and ERROR 5 0 ERROR 29 Output pin for a trouble signal When trouble occurs in MH P20AJD20A the Pin becomes opened until it is reset 08 OUT COM or 6 Conon isto READY START PONT PONT ana ERROR eno Cov Ca meom SERIES 70 WELD HEADS 990 143 B 5 APPENDIX C TIMING Power ON and ERROR Indication Switch or Apparatus Power Suppl ON To Motor OFF Start U p 1st or ORIGINAL ORIGINAL POINT Moveme
57. tances in a typical opposed resistance weld and the relationship between contact resistances and bulk resistances over time during a typical resistance weld SERIES 70 WELD HEADS G 4 990 143 APPENDIX G DEFINING THE OPTIMUM PROCESS 1 amp R7 The electrode resistances affect conduction of energy and weld heat to parts and also the rate of heat sinking from the parts at the end of the weld 2 4 8 The electrode to part and part to part Contact Resistances determine the amount of heat generation in these areas The contact resistances decline over time as the parts achieve better fit up R3 amp R5 The metal Bulk Resistances become higher during the weld as the parts are heated If a weld is initiated when the contact resistances are still high the heat generated is in relation to the level and location of the contact resistances as the materials have not had a chance to fit up correctly 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 see below Conductive materials can be welded by using high contact resistance and fast heating as their bulk resistance is not high and cannot be relied upon for heat generation marking and surface heating e Weld splash or expulsion e Electrode sticking Weak welds If a weld is initiated when both parts and electrodes are fitted up correct
58. ter adapter e Mount a 1000 terminal resistor at both ends of the RS 485 cable as shown above SERIES 70 WELD HEADS D 2 990 143 APPENDIX D COMMUNICATIONS Bidirectional Communication The Schedule data can be read and written by the command on the host computer side When the electrode is at Start Point the schedule data can be read or written When the readout overwrite command is sent from the host computer 2 2 sends back the data When sending the command do not send the next command until the data are sent back or the timeout time elapses When using the overwrite command compare the Schedule of the overwrite command with that of the sent back data to confirm whether or not it has been changed Then if the comparison is done at Start Point Mid Point and Downstop Point confirm the first 4 digit number eliminating the last digit Example In case of 12345 123 45mm at Start Point eliminate the last digit 5 to confirm 1234 123 4 mm Readout Command tem ORDER GHACTERTRAN DESCRIPTION RANGE SERIES 70 WELD HEADS 990 143 D 3 APPENDIX D COMMUNICATIONS Controller Host Computer Corer cHACTERTRAN 08 13 nnnnn Start Point 00000 3 05000 nnn nn dimensions in mm 14 19 nnnnn Mid Point 00000 3 05000 nnn nn dimensions in mm 20 25 nnnnn Downstop Point 00000 05000 nnn nn dimensions in mm 26 27 n Moving Speed between Start Point and 1238
59. ternal Input 2NDJ These two switches allow a variety of operations Electrode Position Model 72 electrodes have five stop positions _ Position Description Original Point The position where the electrode has completely returned Start Point A little bit farther position from Original Point It can be set arbitrarily The READY Lamp lights up when the electrode is at this position Mid Point Just before the position where the electrode contacts workpiece It can be set arbitrarily MID Lamp lights up when the electrode is at this position Weld Point The position where the electrode contacts workpiece The WELD Lamp lights up when the electrode is at this position and causes the welding current to flow Downstop Point A little bit beyond the position from Weld Point It can be set arbitrarily SERIES 70 WELD HEADS 3 2 990 143 CHAPTER 3 OPERATING INSTRUCTIONS Electrode Working Mode Model 72 has two working modes For setting Position or Performed by External Input Performed by External Input measuring Weld Force 1ST or 2ND 1ST or 2ND or pressing the Operation button For resuming Start Point of Performed by External Input Performed by External Input motor 1ST or ORG 1ST or ORG or pressing ORG CANCEL button Electrode is pressed on the way Error indicated Error indicated and the power other than from Mid Point to supply to motor turned off Weld Point In Mode 1 when the e
60. the formation of harmful alloys that could form brittle compounds that are easily fractured In a solid state joint the metals are only heated to 70 80 of their respective melting points This means that the materials are less thermally stressed during heating and subsequent joint cooling in comparison to a fusion weld As there is no real melting of the materials in a solid state joint there is less chance of weld splash or material expulsion A weld nugget can still be achieved with a solid state joint SERIES 70 WELD HEADS G 2 990 143 APPENDIX G DEFINING THE OPTIMUM PROCESS Consider the Material Properties The important material properties to be considered in the resistance welding process are as follows Electrical and thermal conductivity Melting point Hardness It is also important to consider the surface properties of each material such as plating coatings and oxides The figure below gives an idea of the variance in resistivity and melting point for some of the more common materials used today in micro resistance welding The materials can be grouped into three common catagories 1 6 1 4 OFF Scale Inconel Nichrome 800 Group Il es 600 M Resistivity Stainless Steels nano ohm 304 316 etc Group fT 400 j Group III Br Pt Ir MT E 500 1000 1500 2000 2500 3000 3500 Melting Point C The types of joints achievable within each of the main groups are as follows
61. the work pieces are different two built in photo micro switches do not turn on simultaneously resulting in inferior welding This could also damage the equipment Adjust Weld Force e Always stop operation before starting adjustment e The weld force conversion graph represents theoretical values To measure the actual weld force use a force gauge NOTE Weld Force adjustment is the same procedure for both models The Model 72 Weld Head is shown for reference 1 Loosen the Lock Screw using the supplied M2 5 hex wrench Weld force 4 2 scale represents the weld force adjust knob Turn the Weld Force Adjust Knob to CT ZIMIYACHI adjust the center of the Lock Screw to the desired weld force scale Lock 3 Tighten the lock screw to lock the Weld Force Adjust Knob 4 After adjusting measure the weld force using a pressure force gauge 70 SERIES SERIES 70 WELD HEADS 2 6 990 143 CHAPTER 2 INSTALLATION AND SETUP Adjust Weld Head Position Always support the Weld Head when you loosen the screws If you loosen the head without support it could fall causing injury to the Operator and or damage to the equipment 1 Unplug the AC Cable from the Body fixing screws electrical outlet 2 screws each for upper and lower 2 Loosen the Weld Head Screw 3 Move the Weld Head up and down to adjust the mounting height 4 When the head is in the desired position tighten the Wel
62. tions Temperature 0 40 C Humidity 90 or less No condensation Power Supply Voltage 100 gt 240 VAC 10 50 60 Hz 70VA SERIES 70 WELD HEADS 990 112 A 3 APPENDIX B ELECTRICAL AND DATA CONNECTIONS External Input Output Signal Connections 24VDC 1 COM IDEES SCHI x74 7 1 1215 1 ez ie SCH XE H sem 8 COM 1ST pf ft 2ND m Spare Do not connect 12 COM gt 9 16 END Sasa ee ee IDET 19 3 P LOCK 20 Spare Do not connect n START READY me START POINT 6 MID POINT OUT 6 29 ERROR 30 Spare Do not connect 31 OUT COM 32 EXT 24V Do not connect 33 34 Spare Do not connect SERIES 70 WELD HEADS 990 143 APPENDIX B ELECTRICAL AND DATA CONNECTIONS EXAMPLE When contacts are used as the Input Terminal of the I O Connector COM 1ST 2ND COM COM EXT COM COM EXAMPLE When an NPN transistor sink type on a PLC is used as the input terminal of the I O Connector COM 1ST 2ND COM COM EXT COM COM EXAMPLE When a PNP transistor source type on a PLC is used as the input terminal of the I O Connector SERIES 70 WELD HEADS B 2 990 143 APPENDIX B ELECTRICAL AND DATA CONNECTIONS Connector Internally
63. ust an Air Actuated Weld Head F 4 SERIES 70 WELD HEADS 990 143 APPENDIX F THE BASICS OF RESISTANCE WELDING Program a weld schedule then make your first weld Always observe safety precautions when welding and wear safety glasses For a complete procedure on making welds refer to Chapter 4 Operating Instructions Use pliers to peel the welded 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 failure Excessive electrode sticking and or spitting should define a weld as unsatisfactory and indicates that too much weld current voltage power or time has been used If the parts pull apart easily or there is little or no residual material pulled the weld is weak Increase the weld time in 1 msec increments Increase weld current voltage or power if a satisfactory weld achieved using 10 msec of weld time NOTE Actual weld strength is a user defined specification Polarity as determined by the direction of weld current flow can have a marked effect on the weld characteristics of some material combinations This effect occurs when welding materials with large differences in resistivity such as copper and nickel or when welding identical materials with thickness ratios greater than 4 to 1 The general rule is that the more resistive material or the thinner material should be placed against th
64. ven in different parent materials Metals and alloys will bond together once surface contaminants such as dirt grease and oxides are removed Resistance welding generates heat at the material interface that decomposes the dirt and grease and helps to break up the oxide film The heat generated softens or melts the metal and the applied force brings the atoms on either side into close contact to form the bond The strength of the joint develops as the joint cools and a new structure is formed There are three main types of bonds that can be formed using the resistance welding process Solder or Braze Joint A filler material such as a solder or braze compound is either added 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 400 C Solid State Joint A solid state joint can be formed when the materials are heated to between 70 80 of their melting point Fusion Joint A fusion joint can be formed when both metals are heated to their melting point and their atoms mix Many micro resistance welding challenges involve joining dissimilar metals in terms of their melting point electrical conductivity and hardness A solid state joint can be an ideal solution for these difficult joining challenges There is no direct mixing of the two materials across the weld interface thus preventing
65. yllium 2 Cold Rolled 2 Steel Alumel 2 Chromel 2 ES lumel Beryllium 2 Stainless Steel 2 Alume 2 Dumet 2 Copper Aluminum 1 Aluminum 1 Brass 2 14 Brass 2 14 k 2 14 14 Alloys Brass 2 14 Consil 2 Aluminum 1 Cadmium 1 Plating Brass 2 14 Constantan 2 Aluminum 1 Tinned Brass 14 Brass 2 14 14 Aluminum 1 Tinned 14 Brass 2 14 Tinned 14 Copper Copper Aluminum 1 Gold Plated 2 Brass 2 14 Dumet 2 Dumet Brass 2 14 Nichrome 2 Aluminum 1 Gold Plated 2 Kov r Brass 2 14 Nickel 2 Aluminum 1 Kovar 2 Brass 2 14 NiSpan C 2 Aluminum 1 Magnesium 1 Brass at Paliney 7 Aluminum 1 Cold Rolled 2 Brass ae Silver SRSHE Steel Brass 2 14 Cold Rolled Steel 2 Aluminum 1 Stainless Steel 2 Brass 2 14 Stainless Steel 25 Beryllium 2 Beryllium 2 Bronze 2 11 Bronze 2 11 Copper Copper Bronze 2 11 Tinned Copper 14 Beryllium 2 Brass 2 14 Copper Bronze 2 11 2 Beryllium 2 14 Bronze 2 11 Nichrome 2 Copper Bronze 2 11 Nickel 2 Beryllium 2 Tinned 14 Chromel 2 Chromel 2 Copper Copper Beryllium 2 Nickel 2 Chromel 2 Constantan 2 Copper Chromel 2 Copel 2 Chromel 2 Copper 14 SERIES 70 WELD HEADS 2 990 143 APPENDIX F THE BASICS OF RESISTANCE WELDING

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