INDUSTRIAL ELECTRONICS - Edge
INDUSTRIAL ELECTRONICS - Edge
INDUSTRIAL ELECTRONICS - Edge
ELECTRONICS
WELDING
The process of joining metals
usually by heat or sometimes
with pressure and sometimes
with an intermediate or filter
material with high melting point.
I. WELDING SYSTEMS
1. BASIC INTERVALS
a. Squeeze Interval
b. Weld Interval
c. Hold Interval
d. Release
e. Standby Interval
2. POPULAR WELDING PROCESSES
a. Arc Welding
TIG Welding
MIG Welding
b. Solid State Welding
c. Resistance Welding
Spot Welding
Seam Welding
Upset Welding
BASIC INTERVALS
a. SQUEEZE INTERVAL
Welding electrode comes
forward and engage the
metal pressing against the
surface.
Typical squeeze time is 1
sec.
BASIC INTERVALS
b. WELD INTERVAL
Welding transformer is
energized, current flows
and creates a weld.
On heat subinterval is a
condition when the current
is on.
On cool subinterval is when
the current is off
Typical duration (2-10 sec).
BASIC INTERVALS
c. HOLD INTERVAL
Weld interval is finished.
Electrode pressure is
maintained.
d. RELEASE
Welding electrode is retracted.
e. STANDBY INTERVAL
The time after release interval
to the next start sequence.
POPULAR WELDING PROCESSES
a. ARC WELDING
It is simply the use of electric
arc to provide heat.
Process of utilizing the
concentrated heat of an
electric arc to join metal by
fusion of the parent metal and
the addition of metal to joint
usually provided by a
consumable electrode.
POPULAR WELDING PROCESSES
a.ARC WELDING
Either direct or alternating
current may be used for the arc,
depending upon the material to
be welded and the electrode used.
Various forms of arc welding
includes electroslag welding,
plasma arc welding, gas metal arc
welding, submerged arc welding,
gas tungsten arc welding, etc.
ARC WELDING MACHINE
POPULAR WELDING PROCESSES
TIG WELDING
Gas tungsten arc welding
An arc is formed between a
non-consumable tungsten
electrode and the metal
being welded.
Some of its benefits includes
superior quality welds,
precise control of heat, free
of splatter and low distortion.
TIG WELDING
GTAW Weld Area
POPULAR WELDING PROCESSES
MIG WELDING
Gas metal arc welding
Commonly used high deposition
rate welding process
Referred to as a semiautomatic
welding process
Benefits include all position
capability, long weld can be
made without start and stops
and minimal post weld cleaning
is required.
GAS METAL ARC WELDING
GMAW WELD AREA
1) Direction of Travel
2) Contact Tube
3) Electrode
4) Shielding Gas
5) Molten Weld Metal
6) Solidified Weld Metal
7) Workpiece
POPULAR WELDING PROCESSES
c. RESISTANCE WELDING
Uses the application of electric
current and mechanical pressure to
create a weld between two pieces
of metal.
Weld electrodes conduct the
electric current to the two pieces of
metal as they are forged together.
Some of its benefits include high
speed, easily automated, suitable
for high rate production and it is
economical.
RESISTANCE WELDING
POPULAR WELDING PROCESSES
SPOT WELDING
Resistance welding in which
the weld is produced by the
heat obtained at the
interface between the work
pieces.
SPOT WELDS
RESISTANCE SPOT WELDING
POPULAR WELDING PROCESSES
SEAM WELDING
Spots are very closed to
each other that they
overlap and make a
continuous seam weld.
SEAM WELDING MACHINE
POPULAR WELDING PROCESSES
UPSET WELDING
Resistance welding process
applicable to small welding
areas.
UPSET WELDING MACHINE
UPSET MOTION
REVIEW
QUESTIONS
1. The time between the first
application of electrode force
and the first application of
welding current.
a. Squeeze time
b. Weld time
c. Hold time
d. Off period
2. Process wherein coalescence is
produced by the heat obtained
from the resistance of the
workpiece to the flow of low
voltage, high density electric
current in a circuit.
a. Forge welding
b. Resistance welding
c. Ultrasonic welding
d. LBW
3. Time when electrode force is
applied but the current is shut
off.
a. Off period
b. Hold time
c. Squeeze time
d. Weld time
4. The time when electrode force
is released.
a. Hold time
b. Squeeze time
c. Off period
d. Weld time
5. The fusion of the grain structure
of materials.
a. Forge
b. Weld
c. Recombination
d. Coalescence
6. Time when current is applied
to the workpiece.
a. Weld time
b. Squeeze time
c. Hold time
d. Off period
7. Heat in resistance welding is
produced by the following factors
except one
a. Time duration
b. Current
c. Electrical resistance
d. Pressure applied
8. Resistance welding machine
component that holds the
workpieces.
a. Electrical circuit
b. Electrode system
c. Mechanical system
d. None of the above
9. Resistance spot welding (RSW)
machine type that is controlled by
hydraulic cylinders.
a. Miniature welders
b. Rocker-arm welder
c. Press-type welder
d. Portable spot welder
10.Machine component made up of
the transformer and the current
regulator.
a. Control system
b. Electrical system
c. Electrode system
d. Mechanical system
11.Welder machine with capacities
up to 500 kVa
a. Miniature welders
b. Rocker-arm welder
c. Press-type welder
d. Portable spot welder
12.Regulates the time of the welding
cycle.
a. Electrode
b. Current regulator
c. Control system
d. Mechanical system
13.Welding machine use for large
workpieces.
a. Miniature welders
b. Rocker-arm welder
c. Press-type welder
d. Portable spot welder
14.Another name for hammer welding
a. Fusion welding
b. RW
c. Maul welding
d. Forge welding
15.Referred to as a
localized coalescence
a. Weld
b. Mold
c. Cast
d. Metal
16.Part of the welding electric circuit
that is used to produce high
amperage current at low voltages.
a. Capacitor
b. Voltage regulator
c. Transformer
d. The secondary circuit
17.The overlapped RSW.
a. RSEW (Resistance Seam Welding)
b. ORSW
c. OSW
d. USW
18.Spot welding are most commonly
used in
a. Ships
b. Automobiles
c. Airplanes
d. Rafts
19.The last step in welding time
control.
a. Off period
b. Weld time
c. Squeeze time
d. Hold time
20.The relative maximum workpiece
thickness where spot welding can
be used.
a. 0.5 in
b. 1 in.
c. 1.5 in.
d. 0.25 in.
21.Resistance welding was developed
by this man in and revolutionized
the welding industry.
a. Isaac Asimov
b. Karel Capek
c. Thomas Seebeck
d. Elihu Thomson
22.The year when resistance welding
was discovered.
a. 1935
b. 1798
c. 1886
d. 1945
23.It is the fusion or growing of
the materials being together.
a. Coalition
b. Coincidence
c. Coalescense
d. Mixing
24.Arc welding requires a voltage
around _______.
a. 60 – 100 V
b. 150 -200 V
c. 400 – 440 V
d. 1000 – 5000 V
25.During arc welding, the
current is in the range of
_______.
a. 1–5A
b. 5 – 50 A
c. 50 – 400 A
d. 500 – 4000 A
26.The body structure of the car
is welded by ______.
a. Gas welding
b. Spot welding
c. Induction welding
d. Arc welding
27.For inspection of welding defects
in thick metals, which of the
following ray is used to
photograph thick metals objects?
a. Gamma rays
b. Cosmic rays
c. Infrared rays
d. Ultraviolet rays
II.INDUSTRIAL ELECTRONIC DEVICES
1. ELECTRON TUBES
a. Thyratron
b. Ignitron
2. THYRISTOR
a. Silicon Controlled Rectifier (SCR)
b. Triac
3. BREAK-OVER DEVICES
a. Shockley Diode
b. Silicon Unilateral Switch
c. DIAC
d. Silicon Bilateral Switch (SBS)
e. Silicon Controlled Switch (SCS)
f. Gate Turn Off Switch
g. Unijunction Transistor (UJT)
h. Programmable Unijunction Transistor (PUT)
ELECTRON TUBES
a. THYRATRON
A gas filled triode
used as an electrode
switch.
IGNITRON
1. Anode
2. Cathode
3. Ignitor
4. Mercury
5. Ceramic Insulators
6. Cooling Fluid
THYRISTOR
Solid state devices used as a switch
in applications that handles larger
voltage and currents.
Have at least four semiconductor
layers.
Regenerative switching devices and
cannot operate in linear manner.
THYRISTOR
SILICON CONTROLLED
RECTIFIER (SCR)
Most commonly used thyristor.
Three-terminal device used to
control large currents to a load.
Four layer semiconductor
device usually used in relay
controls, time delay circuits,
regulated power supply and
phase controls.
SCR Basic Construction and
Equivalent Circuit
SCHEMATIC
SYMBOL
SCR
SCR CHARACTERISTIC CURVE
THYRISTOR
IH - HOLDING CURRENT
Anode current between the
conducting state and non-
conducting state.
SCR GATE CHARACTERISTICS
SCR is fired by a short burst of current
into the gate typically 0.1 – 50 mA.
a. SHOCKLEY DIODE
A 4-layer diode constructed
like an SCR but without gate
terminal.
Unilateral triggering device for
SCR.
SHOCKLEY DIODE Schematic Symbol and
Construction Diagram
SHOCKLEY DIODE CHARACTERISTIC CURVE
ADVANTAGES OF SHOCKLEY DIODE
OVER SCR
b. SILICON UNILATERAL
SWITCH
Solid-state device that
provides a positive pulse.
Also a 4-layer diode with a
typical break-over voltage
of 8 volts.
In terms of firing, it has
faster rate than Shockley
diode.
BREAK-OVER DEVICES
c. SILICON BILATERAL
SWITCH (SBS)
A bilateral or bidirectional
break-over device.
Two SUS connected back
to back in parallel.
Popular in low voltage
trigger control circuits.
Has lower break-over
voltages than diacs.
ADVANTAGES OF SBS’S OVER DIACS
e. SILICON CONTROLLED
SWITCH (SCS)
SCS turn off time is 1-10 µsec.
The higher the anode gate
current, the lower the required
anode to cathode voltage to
turn on device on.
To turn on the device, a
negative pulse must be applied
to the anode gate terminal
while a positive pulse is
required to turn off the device.
ADVANTAGES OF SCS OVER SCR
Thyristors:
(a) Cross-section,
(b) silicon controlled rectifier (SCR) symbol,
(c) gate turn-off thyristor (GTO) symbol
ADVANTAGES OF GATE TURN
OFF SWITCH (GTO)
g. UNIJUNCTION TRANSISTOR
(UJT)
Break-over type switching device
Double-based diode
Semiconductor device consisting
of thin silicon bar on which a PN
junction acting as emitter is
formed near one end
Operates in the negative
resistance region
UJT Symbol and Characteristic Curve
APPLICATIONS OF UJT
Timers
Oscillators
INTERBASE RESISTANCE
Vp = ŋVBB + Vdiode
BREAK-OVER DEVICES
h. PROGRAMMABLE
UNIJUNCTION
TRANSISTOR (PUT)
Similar operating characteristics
as UJT
Programmable because the
internal resistances of UJT are
external for PUT and can be
selected to a certain desired
response.
Anode
Anode
Gate P
N Gate
P
N
Cathode Cathode
FEEDBACK
BASIC SERVO SYSTEM
a. POSITION SERVO
Control the position of the load.
In AC position servo, the
amplitude and phase of the AC
error signal determine the amount
and direction the load will be
driven.
In the DC position servo system,
the amplitude and polarity of the
DC error signal are used to
determine the amount and
direction of the load will be driven.
Potentiometer is one of the
simplest position sensor device
and is generally used because of
its small size, high accuracy and
output which can either be AC or
DC.
Balanced potentiometer in a
closed loop servo system is a
voltage divider that functions as
a position sensor and produces
the error voltage that is fed to
the servo amplifier.
LINEAR POSITION SERVO
BASIC SERVO SYSTEM
b. VELOCITY SERVO
Same principle of error signal
generation as position servo
except that the velocity is being
sensed rather than the position.
BASIC SERVO SYSTEM
c. ACCELERATION SERVO
Similar to velocity and position
servos except that the
acceleration of the load is
being sensed rather than
position or velocity.
The tachometer of the velocity
loop is replaced with an
accelerometer.
HIGH ACCELERATION SERVO
DAMPING
Used to stabilize a system
to minimize or eliminate the
problem of overshot.
DAMPING CONDITIONS
UNDERDAMPED
Provides instant response to an
error signal but results in the load
oscillating about the point of
synchronism.
OVERDAMPED
Takes as excessive amount of
time to reach synchronization.
OVERDAMPED
UNDERDAMPED
TIME LAG
Servo characteristics defined as
the time between the input of the
signal and the actual movement of
the load.
Undesirable and is reduce with the
use of high gain amplifiers.
Damping systems are added to
smoothen the operation.
SERVO DEVICES
a. AC SERVO MOTORS
Used in servo systems that
move light loads.
SERVO DEVICES
b. DC SERVO MOTORS
Control heavy loads and are
widely used in servo systems.
SERVO DEVICES
c. E-TRANSFORMER
Magnetic error detector that
can be used in systems limited
by large angular movements.
CROSSED E-TRANSFORMER
SERVO DEVICES
d. MODULATORS
Used to change a DC error
signal into an AC input error
signal for servo amplifiers.
e. DEMODULATORS
Convert AC error signal to DC
error signal.
Drive a DC servo amplifier.
SERVO DEVICES
f. MAGNETIC AMPLIFIERS
Used when power from a
conventional servo amplifier is
too small to drive a large servo
motors.
SERVO DEVICES
g. RATE GENERATOR
Tachometer
Used in the velocity servo loop.