Automatic Double Station High Frequency Spot Welder

Host shape: 1800*1140*1800(L*W*H)

Equipment weight: about 350kg

Input voltage: three-phase AC380V±10% 50/60Hz

Input power: 4.0kw

Rotor outer diameter: φ 20-φ 53mm

Commutator outer diameter: ≤φ 30mm

Rotor shaft diameter: φ 3.2-φ 12mm

Applicable wire diameter: φ 0.08-φ 0.7mm

Automatic loading and unloading: 3s

Welding resistance: ≤0.02 mOhm

Welding efficiency: 12 hooks for 10 seconds/piece, 360*2=720 pieces/hour

Copper hook welding displacement deformation: 0.1~0.8mm can be set and controlled.

Cooling circulation system, water flow ≥ 1000lm/min, water temperature between 25°C~30°C.

The process of automatic duplex high-frequency spot welding machine mainly involves equipment preparation, parameter setting, automatic welding and subsequent processing and so on.

一、equipment preparation

Inspection of equipment: to ensure that the automatic duplex high-frequency spot welding machine is in good working condition, check whether the components are complete, the electrical system, the pneumatic system and the cooling system is operating normally.

Fixture preparation: according to the shape and size of the welded rotor commutator, select the appropriate fixture, and install it on the working table of the equipment. The fixture should have good positioning accuracy and clamping force to ensure the stability of the workpiece in the welding process.

二、Parameter Setting

Welding parameter setting: through the human-machine interface or control system, set the welding current, voltage, time and other parameters.

Path planning: For complex welding tasks, path planning may be required to determine the movement trajectory of the welding torch and the welding sequence. This helps to improve welding efficiency and quality.

三、automatic welding

Workpiece clamping: Place the rotor commutator to be welded into the fixture and adjust its position to align it with the welding gun.

Start welding: Press the start button, the equipment starts to run automatically. The welding gun moves according to the preset parameters and paths to perform high-frequency spot welding of the rotor commutator.

Process monitoring: During the welding process, the equipment monitors the welding parameters and welding quality in real time. If abnormalities are found, such as excessive current, unstable voltage, etc., the equipment will automatically stop and send an alarm signal.

四、follow-up processing

Welding inspection: After the welding is completed, the welding quality is inspected. Check whether the weld is flat and firm, and whether there are cracks, porosity and other defects.

Workpiece unloading: Remove the welded workpiece from the fixture and carry out the necessary follow-up processing, such as cleaning and grinding.

Equipment Maintenance: Regular maintenance and upkeep of the equipment, including cleaning the equipment, replacing worn parts, checking the electrical system, etc., in order to ensure the long-term stable operation of the equipment.

Precautions

During operation, you should strictly follow the operating procedures and wear protective gear to prevent electric shock and other accidents.

Maintain and service the equipment regularly to prolong the service life of the equipment and improve the welding quality.

According to the material of the workpiece and welding requirements, reasonable selection of welding parameters and fixtures to ensure welding quality and efficiency.

To summarize, the process flow of automatic duplex high-frequency spot welding machine includes equipment preparation, parameter setting, automatic welding and subsequent processing and so on.

The overall technical program of automatic duplex high frequency spot welding machine:

一、Equipment Overview

Automatic Duplex High Frequency Spot Welder is a high-quality welding equipment based on the principle of high-frequency current heating, combined with automatic control technology. The equipment adopts double-station design, which is able to carry out welding operation at the same time or alternately, and significantly improve the production efficiency.

二、the technical program

1. System Architecture

Dual-station design: the equipment is equipped with two independent welding stations, each station has a complete welding system and fixture devices to ensure that welding operations do not interfere with each other.

High-frequency power supply system: High-frequency inverter power supply is adopted to provide stable high-frequency current output to ensure the heating speed and welding quality of the welding process.

Automation control system: integrated PLC (programmable logic controller), touch screen human-machine interface, etc., to realize the setting, monitoring and adjusting of welding parameters, as well as the automation control of the welding process.

2. Key components and functions

High-frequency inverter power supply: characterized by energy saving and stability, providing adjustable high-frequency current output to meet different welding needs.

Welding fixture: specially designed for welding rotor commutator to ensure the stability and accuracy of the rotor during the welding process. The fixture can be customized according to the shape and size of the rotor to achieve fast clamping and positioning.

Pneumatic components: high-performance pneumatic components are used to ensure flexible and reliable pressure transfer during the welding process.

Cooling system: the secondary internal welding transformer adopts water forced cooling, effectively reducing the working temperature and prolonging the service life of the equipment.

Microcomputer controller: with multi-specification welding, double pulse, double current control and other functions, as well as silicon controlled temperature monitoring and a number of protection functions to ensure the stability of the welding process.

3. Welding process

Welding principle: using high-frequency current through the rotor generated resistance heat for welding, fast heating speed, high quality welding.

Welding method: support single point, continuous point and other welding methods, can be selected according to the needs of the rotor.

Welding parameters: including welding current, welding time, welding pressure, etc., can be set and adjusted through the touch screen to meet different welding requirements.

4. Safety and environmental protection

Protection matters: the equipment is equipped with protection control box, emergency stop button and other safeguard functions.

Environmental performance: high-frequency welding machine adopts high-frequency current heating, high heating efficiency, low energy consumption, and the welding process produces less waste gas, less waste residue, less pollution to the environment.

三、the application advantages

Improve production efficiency: double station design realizes simultaneous or alternate welding operations, significantly improving production efficiency.

Ensure the quality of welding: high-frequency current heating uniformity, high strength of welded joints, weld quality.

Strong adaptability: can weld a variety of materials (such as steel, copper, aluminum, etc.) and complex shape of the workpiece.

Reduce labor cost: high degree of automation, reduce manual operation, reduce labor cost.

四、maintenance and upkeep

Regular inspection: Regular inspection and maintenance work on the equipment to ensure that the equipment is in good operating condition.

Cleaning and maintenance: keep the equipment clean and dust-free to prevent impurities from entering the equipment to affect the welding quality.

Professional training: professional training for operators to improve operating skills and maintenance capabilities.

In summary, the automatic duplex high-frequency spot welder realizes fast and high-quality welding operation by integrating key technical components such as high-frequency inverter power supply and automatic control system.

Energy spot welding machine is a variety of rectifier hook, groove and enameled wire welding equipment, precision resistance welding does not require consumables, does not need electrodes, welding wire and flux, etc., the heat consumption in the welding process is very small, the smoke and other harmful substances produced are less, no blinding light pollution.

Its working voltage is only a few volts (V), so it is an economical, convenient, reliable and environmentally friendly welding method, special water chiller: rapid cooling circulation system, to ensure that the welding power supply and transformer can work continuously and stably for a long time at room temperature.

This equipment implements double-station spot welding, which greatly improves the production efficiency, and can be continuously grinding by using the positive electrode of tungsten rod up to 150mm, which reduces the procurement cost of the positive electrode.