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Energy
Good Weld
Time
Weld Force
Power Supply
Feedback
Welding Transformer
Weld Head
Upslope/Downslope
Dual Pulse
Linear DC
Power Supply Weld Head
Drive Unit
Capacitor Charging Circuit
Feedback
Voltage Leads
Cap Bank
MOSFET Bank
Current Shunt
Linear DC Attributes
Single Pulse
Characteristics: Energy control in Current, Voltage, or Power Time control in 0.01 millisecond increments (minimum) Low Repetition Rates Closed Loop Feedback Compensates for varying part conditions Built-in Monitor Applications and Use: Ultra stable waveform. Extends electrode life. Best choice for welding fine wires and thin foils.
Upslope/Downslope
Dual Pulse
Capacitor Discharge
Power Supply
SCR Circuit
Pulse Transformer
Weld Head
Cap Bank
Dual Pulse
Applications and Use: Fast rise time with high peak current. Good for welding flat conductive parts. Require good part fit up.
Direct Energy
Power Supply Welding Transformer
Taps
Triac
Weld Head
Timer
% Current Control
Cycle Welding
.018 0.46 mm
.036 0.91 mm
.054 1.37 mm
.072 1.83 mm
.090 2.29 mm
DC HF
CD AC
.001 .025 mm Size of Smaller Part (Thickness) .010 0.25 mm
.020 0.51 mm
.030 0.76 mm
.040 1.02 mm
.050 1.27 mm
Specification Comparison
Closed Loop: DC HF
Input Power Output Range Feedback Modes Feedback Rate Weld Monitoring Time Control in: Repetition Rate Equipment Cost Application and Use Notes 115V; 230V Single Phase 5-4000 Amps I, V, & P >10 micro-sec Built-in I, V, & P .01 msec steps 240V; 400V; 480V Three Phase 50-4000 Amps I, V, & P 40-250 micro-sec Built-in & Sentry 0.1 msec steps
Open Loop: CD AC
115V; 230V Single Phase Up to 875 WS N/A (Open Loop) N/A (Open Loop) Sentry Option Pulse Widths 115V; 230V; 460V Single Phase Up to 16 KVA N/A (Open Loop) N/A (Open Loop) Sentry Option Line Cycles
Fine energy control, smooth waveform. Best choice for welding fine wires & foils.
Best automation supply. Extends electrode life. Welds wide range of applications.
Fast rise time with high peak current. Good for welding conductive parts.
General purpose control with high energy output. Longer weld times useful for brazing.
HF2
2400 CURRENT
1000
10 msec
50 msec
TIME
100 msec
Repeatable Welds
A Closed Loop power supply will keep the programmed parameter constant (Current, Voltage, or Power). It will adjust the non programmed parameter to achieve the programmed value to compensate for changes in part or process conditions.
Weld 1
Weld 2
Weld 1 Weld 2
Weld 1:
Weld 2:
RC1
RC2
RC3
Feedback Modes
Constant Voltage:
Compensates for parts misplacement and force problems Reduces weld splash Ideal for round (non-flat) parts Monitor current Varies current and voltage for consistent energy Breaks up surface oxides and plating Ideal for automation to extend electrode life Monitor current or voltage Delivers same current regardless of resistance changes Compensates for part thickness changes Ideal for flat parts with consistent electrode to part fit-up Monitor voltage
Constant Power:
Constant Current:
Part Challenges:
Surface Roughness Plating Inconsistencies Oxidized Parts Contamination Projections Wire Welds Thickness Inconsistencies
Constant Power
Constant Voltage
Constant Current
Process Challenges:
Part Misplacement Varying Overlap Inconsistent Force Mushroomed Electrodes Oxidized Electrodes Automated Systems Weld Cables
Constant Voltage
Constant Power
Feedback Modes
Feedback Mode Part Challenges
Constant Voltage Projections Wire Welds
Process Challenges
Part Misplacement Varying Overlap Inconsistent Force Mushroomed Electrodes Oxidized Electrodes Automated Systems
Constant Power
Surface Roughness Plating Inconsistencies Oxidized Parts Contamination Constant Current Flat Parts, Thickness Inconsistencies
Weld Cables
Weld Monitoring
Graphic waveform traces (HF25, DC25, UB25) provide: Simple, dynamic weld information for process understanding and diagnostics Easy set limits with programmable relay action Other process tools Pre-Weld Check A.P.C. Resistance Set Weld to Limit Energy Limit
Process Tools
Pre Weld Check
Weld to a Limit
Energy Limit
Process Tools
Note: Welding conductive parts with resistive electrodes may be difficult to monitor electrically.
In these applications, the bulk resistance of the electrodes is much greater than the resistance of the parts. Displacement monitoring is preferred.
Quality Reporting
S.P.C. software packages can generate control charts and provide data summaries