Controls & Transformers

Questions and Answers

A portable resistance welding gun was used frequently in the past but has seen less use with the introduction of the robot transgun. The portable gun is suspended from an overhead trolley by cables which carry most of the weight. The gun consists of the electrodes and force system. The portable gun transformer is located generally overhead and the power is transmitted by kickless cables (low impedance/water cooled) to the gun. These systems are still in use for respot/rework, remote robot and manual guns.

Portable Gun

PORTABLE GUN & TRANSFORMER

Portable Gun Transformer

             PORTABLE GUN TRANSFORMER

Transgun AC transformers are designed to be relatively light and compact with good power to fit on a robot arm for welding applications. These transformers vary in sizes from 35 KVA to 136 kva units (rated at 50% duty cycle). They are lightweight and designed for close couple mounting to welding guns. Their light weight makes them ideal for robotic applications.

Transgun Transformer

          TRANSGUN TRANSFORMER

For many years AC was the system of choice for resistance welding. DC was present for those applications that demanded high power where balanced three phase input and large secondary outputs were necessary.

Over the last twenty years MFDC (mid frequency direct current) offered a means to lighten the weight of the transformer which made robotic welding a practical resistance welding application.

Transgun

Transgun with MFDC Transformer and Servo Actuator

Today MFDC is the largest application of resistance welding transformers. It has found wide acceptance in all industries. It is a balanced three phase, can use less power and has a power factor near unity.

The power factor comparison is:

AC – 0.3-0.8 (Varies with throat configuration)

MFDC- 0.99

 

Reference: Roman Manufacturing - White Paper 2017 “A Comparison of AC to Inverter DC Resistance Spot Welding and the Effects On Dual-Phase 600”

The cascade weld control AC outputs (H1, H2) are wired to the appropriate terminals on the primary side of each transformer. The transformer secondary’s are wired to the weld gun and copper buss bar. The transformer outputs are isolated by the design of and properties of the welding transformer and thus you can connect one leg of each transformer secondary together on a common bus. This connection can also connect to the machine frame or ground. The control, transformer and machine should all be connected to the plant distribution ground.

If a process has been running successfully for some time and one suddenly losses the desired nugget, one of two things has occurred. A process variable has changed or the process was operating on the edge of the weld window. If this has been a long term good process, then process variables are the most likely suspects.

Process variables are anything which can affect the amount of current or the heat being generated. One should look at the variables that control pressure, current and time. Has your part changed? Is the forming of the part different and requiring more force to bring the two surfaces together? Has the cylinder or servo begun to stick or become sluggish? Have you tested the pressure? Is there sufficient plant air pressure and flow, all day? Is the plant power sufficient and consistent all day? Is there sufficient squeeze time to close the electrodes and reach full pressure? Do the electrodes need dressing? Are all electrical connections tight and clean? Have the shunts or cables worn? Some of these are wear items.  Any one of these items can cause a change in weld performance.

Other individual articles describe these topics.

Go back to the basics. Check the current process against the original setup documents.

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