The document provides an overview of Metal Stop Welding, detailing its working principle, machine components, and electrical standards. It outlines product and process parameters, including specifications for welding strength and defect correction methods. Additionally, it emphasizes compliance with safety standards and the importance of process parameter adjustments for optimal welding performance.
The document provides an overview of Metal Stop Welding, detailing its working principle, machine components, and electrical standards. It outlines product and process parameters, including specifications for welding strength and defect correction methods. Additionally, it emphasizes compliance with safety standards and the importance of process parameter adjustments for optimal welding performance.
The document provides an overview of Metal Stop Welding, detailing its working principle, machine components, and electrical standards. It outlines product and process parameters, including specifications for welding strength and defect correction methods. Additionally, it emphasizes compliance with safety standards and the importance of process parameter adjustments for optimal welding performance.
The document provides an overview of Metal Stop Welding, detailing its working principle, machine components, and electrical standards. It outlines product and process parameters, including specifications for welding strength and defect correction methods. Additionally, it emphasizes compliance with safety standards and the importance of process parameter adjustments for optimal welding performance.
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Metal Stop Welding
Kulraj Singh / Manufacturing
07-2024 Table of Content Slide No.
1. Working Principle 3
2. Current machine 4-5
3. Electrical & Electronics standard 6-8
4. Product & Process Parameters 9-12
5. Defects & Correction 13
2 Working Principle •Metal Stop Welding is a type of resistance stop welding, which follows the principle of Joule’s Law pf heating. This law states that the heat generated (Q) is proportional to the square of the current (I), the resistance (R), and the time (t) the current flows: Q = I² * R * t
•Spot welding uses electric current to produce heat. Electrodes hold the metals together, focusing the current to create intense heat at the contact point. This heat melts the metals, fusing them together for a strong, precise weld.
3 Metal Stop Welding Machine Machine Description
Function: • Designed for welding of piston rod and metal stop • Automates high-production rate welding
Key Components: • FRL Unit is for regulating the air pressure to the pneumatic circuitry. The filter cleans the air of all particles, and removes moisture. The Lubricator lubricates the air entering the cylinder, so as to ensure smooth and long life of cylinder and moving piston in solenoid valve • Solenoid Valve regulates the up and down movement of the cylinder • Pneumatic Cylinder is coupled to the weld head, which moves the electrode up and down • Water cooling manifolds the machine has internal piping to the elements requiring water cooling • Weld Controller used to set welding parameters • Grounding terminal
4 Metal Stop Welding Machine Automated Welding Process
Load: Put Clamping of
Position: The Return: All Metal stop on part: Clamping Weld: The electrodes units retract to the piston rod of the part is electrode forms it initial and load it on done so that it welds the part position positions machine doesn’t move
5 Electrical and Electronics Standard Part List
Sr. No. Part Name Specifications/Models Make Qty
1 SOLONOID VALVE MFH-5-1/8 WITH 24VDC & COIL & INDICATOR FESTO 7 2 MCCB 4P, 160 AMP ABB 1 3 MCB SB203M C6 ABB 1 4 WELDING TRANSFORMER 50 KVA KIRPEKAR 1 5 WELDING CONTROLLER CY-210 MIYACHI 2 6 THRISTOR SKKT-330AMP SEMIKRON 2 7 PUSH BUTTON AND SEL. SW TEKNIC 2 A. SELECTOR SWITCH AUTO/MANUL, WELD OFF/ON B. RETURN SPRING FOR ERROR, CYCLE STOP C. MASHROOM LATCH FOR EMM STOP TYPE-RED D. MASHROOM SPRING TYPE-GREEN E. ILLUMINATED PUSH BUTTON FOR CYCLE START FOR HOME 1 8 RELAY BOARD 8WAY TOUCH TRIENTY 3 9 INDICATOR CONTROL ON-230VAC TEKNIC 1 10 TRANSFORMER INPUT-415VAC; OUTPUT-220VAC; 1.5KVA CAPACITY RAJ ELECTRICALS 1 11 DIGITAL PRESSURE SWITCH ISE-20A-01-P-LA1 SMC 4
6 Electrical and Electronics Standard Part List
Sr. No. Part Name Specifications/Models Make Qty
12 WATER FLOW SWITCH SV5200 IFM 2 13 RELAY MY-4N-24VDC OMRON 1 14 SERVO MOTOR HG-KN-43 MITSUBISHI 1.29Nm, 3000RPM 15 SERVO AMPLIFIER MR-JE-40A MITSUBISHI 1 17 SMPS S8JX-G100-24VCD INPUT-110-240VAC OUTPUT-24VDC, 4.5AMP FESTO 1 18 FRL LOE-D-MINI EQUIP 1 19 REGULATOR LR-D-MINI FESTO 4 20 FILTER БАР EQUIP 1 22 SENSORS A. PHOTOELECTRIC SENSOR M18 P&F 1 B. PROXIMITY SENSOR E2B-M12 OMRON 2 23 PLC-CPU FX-5U-64MT MITSUBISHI 1 24 HMI GS2107-WTBD MITSUBISHI 1 25 TOWER LAMP 3 TIER WITH HOOTER 24VDC GREEN TECHNOLOGY 1 27 CONTROL PANEL FAN 230VAC REXROTH 1 28 CONTROL PANEL TUBE & MACHINE 230VAC STROKE 2 29 PLUG AND SOCKET 5A ANCHOR 1
7 Electrical and Electronics Standard Standard Followed by Kirpekar Engineering PVT. LTD
Safety Standards: ISO 9001-2008 Certified: This is a quality management system standard that ensures a company has a well-defined process for designing, developing, manufacturing, installing, and servicing a product. While it doesn't guarantee specific technical aspects, it signifies a commitment to quality control. CE Regulation Compliant: CE marking indicates compliance with various European Union (EU) directives related to safety, health, and environmental protection. Specific directives applicable to welding machines would depend on the machine type and technology (e.g., resistance welding, arc welding). IEC 60974-1: Arc welding equipment - Part 1: Welding power sources This standard focuses on the welding power source, which is the core component of a welding machine. It specifies the general safety and performance requirements for these power sources. IEC 60974-10: Arc welding equipment - Part 10: Welding consumables This standard focuses on welding consumables, which are the materials used to create the weld joint. In MIG (Metal Inert Gas) welding, the primary consumable is the solid wire electrode. IEC 60898: This is an international standard for Miniature Circuit Breakers (MCBs) set by the International Electrotechnical Commission (IEC). It specifies requirements for rated voltage, rated current, breaking capacity, performance characteristics, and testing methods for MCBs. Following this standard ensures the MCBs meet international safety and performance criteria.
Melting of Metal stop Not allowed (GIL/LS/Strut/05) Visual (WI-ST-PE-03)
Spatter & Metal stop burn Not allowed (GIL/LS/Strut/05) Visual (WI-ST-PE-03)
Crack not allowed Visual (WI-ST-PE-03)
9 Process Parameters Process Parameters PROCESS CHAR. SPECIFICATION MEASUREMENT METHOD Schedule No As Per Annexure STW-03 Weld controller Ram Pressure 2.7-3.4 bar Pressure Gauge Gauges , Tools & Measuring instruments Should be free from dent & damage Visual Squeeze As per AnnexureSTW-03 Weld controller Weld I As per AnnexureSTW-03 Weld controller Cool 1 As per AnnexureSTW-03 Weld controller Slope I As per AnnexureSTW-03 Weld controller Weld II As per AnnexureSTW-03 Weld controller Cool II As per AnnexureSTW-03 Weld controller Weld III As per AnnexureSTW-03 Weld controller Slope II As per AnnexureSTW-03 Weld controller Hold As per AnnexureSTW-03 Weld controller Pulsation As per AnnexureSTW-03 Weld controller Current I As per AnnexureSTW-03 Weld controller Current II As per AnnexureSTW-03 Weld controller Current III As per AnnexureSTW-03 Weld controller Operator awareness of process / skill As per station skill levelWI-ST-PE-03 Skill Matrix F-STRUT-HR-01
10 Process Parameters What if process parameters change? 1.Squeeze: Description: This refers to the time period during which pressure is applied by the welding electrodes before the welding current starts flowing. Effect of Increase: More time allows for better conforming of the sheets and improved electrical contact, potentially leading to stronger welds. Effect of Decrease: Insufficient squeeze time might result in poor contact between the sheets, leading to weak or incomplete welds.
2. Weld 1, Weld 2, Weld 3:
Description: These represent individual welding stages within the overall seam welding cycle. Some machines might have only two or even a single welding stage depending on the desired weld properties and material thickness. Effect of Increase (Time): Longer welding time in a specific stage increases heat input in that zone, leading to deeper penetration but also potentially causing overheating or distortion. Effect of Decrease (Time): Shorter welding time reduces heat input, resulting in shallower penetration but faster welding speed.
3. Cool 1, Cool 2: Description: These define the duration of cooling applied after each corresponding welding stage (Weld 1, Weld 2, etc.). Cooling is crucial for proper weld solidification. Effect of Increase: Longer cooling time allows for slower solidification, reducing the risk of weld cracks but increasing overall process time. Effect of Decrease: Shorter cooling time might lead to faster processing but increase the risk of weld cracking due to rapid solidification.
4. Slope 1, Slope 2: Description: These settings determine the rate of change in welding current at the beginning (Slope 1) and end (Slope 2) of a specific welding stage. Effect: A steeper slope (higher rate of change) can be used to quickly reach the desired peak current or decrease it rapidly after welding. A gradual slope provides a more controlled heating and cooling profile.
11 Process Parameters What if process parameters change? 5. Current 1, Current 2, Current 3: Description: These represent the individual current settings for each corresponding welding stage (Weld 1, Weld 2, etc.). Current is the primary factor determining heat generation in the weld zone. Effect of Increase: Higher current generates more heat, resulting in deeper penetration and potentially stronger welds. However, excessive current can cause melting, burn-through, or distortion. Effect of Decrease: Lower current reduces heat input, leading to shallower penetration and weaker welds. However, it can also improve weld speed and minimize distortion.
6. Welding Ram Pressure:
Description: This defines the force applied by the welding ram to press the workpieces together during the welding process. Effect of Increase: Higher ram pressure improves contact between the sheets, leading to better electrical conductivity and potentially stronger welds. However, excessive pressure can cause indentation in the sheets, shorten electrode life, or even damage the workpieces. Effect of Decrease: Insufficient ram pressure might result in poor electrical contact and weak welds.
12 Defects and correction Operation Problem Causes Immediate Action
13 T H A N K YO U ! I N F O R M AT I O N C O N F I D E N T I A L I T Y N O T I C E The information contained in the presentation is a proprietary property of the Company and cannot be circulated further without the express consent of the Company.
