theme graphic - Resistance Welding Controller

 

 
 

Monitor Settings

Monitor setting example of Resistance Welding Controller-

  • While using current monitor you need to feed upper and lower limit to the controller. This can be done as under :

Example:
Suppose your part requires 10 KA current for 8 cycle .
And your setting is as under

30

00

0

0

00

0

08

0

5

0

sq

Weld1

Co1

Sl1

We2

Co2

We3

Sl2

hold

off

And

0

10

0

Curr1

Curr2

Curr3

(Insure you are putting value in curr2, This can be done by pressing curr2 button and insuring the LED over the button is glowing. Also insure values in curr1 and curr3 by pressing respective buttons. If there is value in weld 1 , it corresponds to curr1 ; value in weld2 and weld3 corresponds to curr2 and curr3 respectively. If you put some value in weld1 and ‘0’ in curr1   this will result in error)      

  • This setting means you need 10 KA current for good weld.
  • Press “MONITOR DISPLAY” button, insure the LED on the button is glowing.
    Monitor display ON will give you actual current flown during the process this value will be displayed at  window immediately above the “curr2 “ button. Its percentage over set value of current will be displayed at the window above “monitor display button.
  • Observe actual current flown ,displayed in the window, and its percentage over set value(10KA)
    If the % difference is  better than +/- 5%, Your setting time is OK ( else try to increase weld time).
    Make destructive test and confirm parameters OK for weld strength. After getting OK result move for next step.

  • Calculate 10 % less of the set value (i.e. 9 KA)

  • Set 09.0 KA in curr2 window.
    Make a weld
    Observe actual current drawn.
    Make destructive test for weld strength.

  • If the test is ok we can conclude 9KA current is also OK for making good weld.
    If you get test fails, increase default value and repeat the procedure or insure your self, by trial and error correct lower value of current.

  • Accordingly set upper value and calculate safe % of upper limt.
  • In this  example Now we have
    9 KA as lower limit .( 10% lower)
    10 KA  set value
    10.5 KA as upper limit ( 5% high )

Now we can set  upper and lower limit on controller monitor.

  • Push ‘prog’ button
    Push lower limit button (- % limit)
    Enter 10

  • Push upper limit ( +% limit)
    Enter 05
    Push prog again

Now the controller is programmed for  upper and lower limits.

  • It will give alarm (error output) at the instant the actual current fall beyond the go - nogo limit.
    Error alarm can be reset by pressing error reset button.

    There are few other errors related to setting and maintenance of the controller . Please read the error no. details from the manual page 36.
  • We can also use other powerful function built in like - 
    - electrode wear compensation
    - Multiple program calling
    - Interlocking with other inputs.
    - Computer interfacing for data download

    Please read Manual for details.

 

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Designed By - Rutuj Worth Concepts