Microcomputer precision double pulse spot welding machine. High reliability and high efficiency most suitable for battery assembly mass welding PR50

Transcription

1 Microcomputer precision double pulse spot welding machine High reliability and high efficiency most suitable for battery assembly mass welding PR50 Manual

2 Company Profile The company independent research, develop and produce SWM series inverter dc resistance welding machine, PS series can be switch type inverter dc resistance welding used the most advanced inverter power supply technology and microelectronic control technology, is a kind of precision of resistance welding power supply equipment, has the control precision, wide adaptability and process of energy saving, high efficiency, stable and easy operation etc. The company's PR series microcomputer precision welding power source with high reliability and high efficiency and have multiple protection function. The company has a high-quality research and development team, with strong development and design ability, keep on the r&d of new products, push to the market. Companies in strict accordance with the modern enterprise management system production, management, pays more attention to the quality of the products and the quality of service. All major components are used the world first-class products, such as: Germany Siemens, the United States TI company, the United States Microchip companies, ATMEL company. The high quality components, advanced technology, modern management to ensure that the product performance stable and reliable. The products are widely used in electronic connection, electronic products, automobile, battery, medical equipment, lighting, etc. 1

3 1. Notice 1.1 security matters needing attention 1) this machine some connection socket with high pressure, please do not touch socket connection terminal. 2) must ensure that correct grounding machines, avoid the equipment accidents caused by electric shock. 3) the machine and welding head with use, should strictly abide by the operation procedures, avoid head pressure injury. 4) machine maintenance must be in full after power more than five minutes to, or storage capacitor of high pressure cannot be completely released, there is the risk of electric shock. 1.2 before use the matters needing attention 1) before use, please read the instructions carefully. 2) ensure that configuration integrity. 3) to ensure that the correct connection (1) to ensure that the correct input power access. (2) when using PLC and computer control the machine, to ensure the correct connection. (3) transformer output end and head should be of reliable connection between, avoid joint bigger loss. 4) ground: through the grounding line will equipment correct ground. 5) set appropriate welding process parameters. 1.3 use environment matters needing attention 1) avoid in high temperature, high humidity and vibration impact applications. 2) avoid metal dust and welding splash into the inside the case. 3) don't in the corrosive atmosphere or drug environment preservation and use. 4) avoided in high frequency source use nearby. 1.4 installation matters needing attention 1) grounding line connecting the earth. 2) installation position guarantee ventilation cooling, don't jam duct (into the wind and the fan exhaust outlet). 3) and head connection guarantee enough conductive section, use as far as possible short connection. 0

4 2. Overview 2.1 introduction PR series battery assembly microcomputer precision welding power source adopts double pulse welding way, it is the present domestic advanced level high performance inverter resistance welding machine, designed for the production of high-end mobile phone batteries, power battery, digital nimh battery, nickel cadmium battery for and design. PR series precision ac resistance welding power source adopts Japanese thyristor inverter technology, microcomputer control technology and modern power electronic technology development of new power. Since using AC, DC, AC, DC transform technique, time control to achieve millisecond level precision, control response and control accuracy greatly improved; Dc output (below chart) make welding manufacturability significant improvement; Inverter technology still make equipment has small, energy saving efficiency and a series of advantages; Microcontroller (MCU) and electronic technology using the equipment have modern equipment of excellent functions, including digital control, monitoring, fault diagnosis and protection, data transmission, equipment, the function is all ready, agile and convenient, wide adaptability. 2.2 the main technical characteristics: Ac double pulse welding: L double pulse welding, the first pulse used for the workpiece surface coating and oxide removal, and at the same time make in welding electrode contact place to produce slightly deformation and improve the effective contact surface, the second pulse is used for the metal welding on ontology. Can effectively promote the quality of the weld and reduce welding splash. L pulse energy adjustable, welding cycle number adjustable. Power grid voltage automatic tracking compensation, welding stable output current, welding strong, beautiful, splash is little, the operation is simple, safe and reliable. Control mode: L high speed and high precision 8 bit microprocessor (MCU) control, LED digital display, pulse energy precision adjustable (0-999 ), pulse frequency number adjustable (0 to 8), preloading time adjustable (0 to 8), parameter locking function. Easy to operate, save time adjustable machine, it is suitable for different operating environment and operator. Multiple fault protection: L welding machine of the high power circuit and control circuit, is equipped with two sets of different kinds of protection circuit, to prevent overheating equipment, and the external pressure and power supply fluctuation on welder interference; In order to protect in bad environment butt welding machine damage. For some common faults have prompt function, butt welder overheating and damaged, will automatically alarm, and at the same time cut off power supply. Precision welding head design. L the cylinder and spring buffer combine to make the two welding needle in the welding of the pressure when can relative regulation, because spring buffer action, make the cylinder will not direct action in the solder joint, thus effectively protect welding plane. L head internal adopts photoelectric pressure switch, only in two welding needle pressure to achieve the set pressure to discharge welding, the welding protection reliability, and double needle pressure can be 1

5 adjusted. Unique structure: L table stepless lifting, hand screw type locking, the adjustment is convenient accurate position. L unibody design pneumatic operation, the operation is very easy. 2.3 Main Technical Parameters: No. Specification PR50 1 Power 18KVA 3 secondary side welding 3500A current 4 secondary floating voltage 5.5V 5 input voltage 220V 6 input frequency 50HZ 7 max working air pressure 6KG 8 welding control foot switch 10 weight 30KG 11 size L400mm X W220mm X H360mm 3. Power box connection manual 3.1 machine positive: From top to bottom: 1) screen: used for display welding parameter 2) button: 3) power supply switch: 4) output electrode: welding transformer output, connecting head 3.2 machine back: 1) pressure switch interface: connecting head internal pressure switch, pressure switch for Japan imported photoelectric switch, long life, reflect the sensitive. 2

6 2) electromagnetic valve power interface: connect the head of the electromagnetic valve, used to provide a + 12 v power supply to the head of the electromagnetic valve use. 3) foot switch interface: through the pin foot switch, provide power supply start welding signal. 4) insurance tube: 10 a insurance tube 5) power: use 220 v, 50 hz power. 6) power box grounding line: to avoid electric shock, please ensure that the power supply 3.3 pneumatic head: 1, welding pressure adjustment knob: a total of two, regulating pressure size, clockwise pressure increase, decrease conversely. Two independent, to ensure that each welding needle pressure consistent. 2, head sliding body: use linear bearing, guarantee the operation of the flexibility to buy photoelectric pressure switch, only when the two pressure switch are opened, photoelectric switch to a signal to the microcomputer, so as to realize welding, to ensure that the double welding needle pressure balance. 3, double copper electric level: electric level through the high temperature resistant, high voltage insulation material fixed in straight line guide pillar, back end joint welding transformer cable, front end clamp weld needle, the fixed welding needle and conduction current role. Front end clamp weld needle position of special design, positive and negative can be used both to clamp 3.0 or 1.5 welding needle, the user can choose according to need to use. 4, welding needle: can use 3.0 mm or 1.5 mm weld needle, welding needle main material for copper, if want to welding effect good advice to use imported dispersion copper oxide aluminum bronze. 5, cylinder, cylinder for adjustable stroke cylinder, the need to pay attention to is good when regulation must be use after locking nut lock, in order to avoid the adjusting knob for vibration and change the stroke. 6, a cylinder: intake pipe to 8 mm's windpipe, access air. 7, barometer: pressure general adjustment to 0.2 KG KG above, according to the welding piece thickness can be appropriately increased pressure. 8, hand lun: to adjust head lift, but need to loosen the left two lock handle can be adjusted. 9, lock handle: fixed position of authority. 3

7 4. Operating instructions 4.1 LED digital screen display: PR50 1, pulse 1 energy (first heat): the first pulse welding energy (preweld pulse welding energy) from 0-999% adjustable, used for the workpiece surface coating and oxide removal, and at the same time make in welding electrode contact place to produce slightly deformation and improve the effective contact surface. 2, pulse 2 energy (second heat): used to ontology metal welding on. Can effectively promote the quality of the weld and reduce welding splash. 3, pulse 1 cycle number: the first preweld pulse pulse number. From 0 to 8 level adjustable, the biggest eight pulse. 4, pulse and cycle number: the second welding pulse pulse number. From 0 to 8 level adjustable, the biggest eight pulse. 5, preloading time SQT: that is, from welding head down to welding needle pin welding sheet and open photoelectric pressure switch to discharge after the time between when welding. From 0 to 8 level adjustable, pressure time from 0.02 seconds to 0.50 seconds. 6, alarm indication: complete a welding is alarm once, and bright red light. 7, welding instructions: welding indicator (green), said can welding. Green light out is to enter debug procedures, can't welding, can only manual welding. 4.2 Keyboard operation Operating keyboard [setting MODE] key: used for setting the welding parameter [program FUN] key: to choose the stored welding procedure, a total of 10 group. 4

8 [add +] key: used to set welding parameter increase [minus -] key: used to set welding parameters of the reduced; Another role is to enter the welding debugging state. 1, key explanation: L long key: hold key 1 seconds above, and heard long key sound, to execute a long key, then loosen. Long key sound long. L short key: press namely after loosen, and hear the sound button is short key. Short key sound short. 2, welding parameters and machine adjustment state: L welding parameter set condition: used to adjust the current welding parameter L program group copy state: for a program group in terms of the parameters of the copy to another program group L program group selection condition: used to choose a program group L machine debugging state: used for welding machine commissioning before welding parameters and buy object table height, etc. 4.3 welding parameter Settings: Welding parameter setting in turn could be the first pulse energy (current), the second pulse energy (current), the first pulse frequency, the number of the second pulse frequency number, preloading time to adjust. After startup normal display, hold the [setting MODE] key until he heard long key sound, then loosen the key (hereinafter referred to as the long key) into the welding parameter setting procedure, at this time the first pulse energy digital scintillation; Press [setting MODE] the switch to set the second pulse energy, the second pulse energy digital scintillation; Press [setting MODE] the switch to the first pulse frequency count Settings; Press [setting MODE] the switch to set the second pulse frequency count Settings, press [setting MODE] the switch to preloading time Settings; Once again press [setting MODE] is set to return to cycle. Any time long press returned to welding state. [setting MODE] keys will save the current Settings 1, the first pulse welding energy (current) : Enter the Settings, click on the [add +] key is the first pulse current increasing, the press [minus -] key is the first pulse current is added to reduce. From 0-999% according to need adjustment, the main parameters of the preweld role, general set for the second pulse energy (current) 30% - 50%. When this parameter is set to 0, it doesn't work. 2, the second pulse welding energy (current) : From 0-999% adjustable, mainly on welding effect, according to the welding pieces of thick and thin adjust 5

9 this parameter. General for preliminary welding current 2 times the left and right sides. When this parameter is set to 0, it doesn't work 3, the first pulse frequency number: From 0 to 8 case adjustable, each case says a welding pulse, when is 0, it means the first pulse welding doesn't work. If set to "3 case", said the first welding pulse even welding three times. 4, the second pulse frequency number: From 0 to 8 case adjustable, each case says a welding pulse, when is 0, the said the second pulse welding doesn't work. If set to "3 case", said the second welding pulse even welding three times. 5, preloading time SQT: Preloading time refers to: cylinder pressure drop living cell to welding discharge time. From 0 to 8 level adjustable, pressure time from 0.0 seconds to 0.40 seconds, each lattice said 0.05 seconds, grid number, the more the pressure time to grow more, welding speed and more slow. Long press [MODE] key is to quit, and exist in the current program group. Note: if the machine is used for welding battery, had better choose double pulse, namely the first pulse cycle number and the second pulse frequency number all set to 1 case, meet other hardware or wire can be select multiple pulse. This is because the gate number is too much to the battery thermal effect is bigger also. Welding parameter examples illustrate: Such as setting parameters are as follows: the first pulse energy: 130, the second pulse energy 280, the first pulse number 1, the second pulse number 2, preloading time 3 case (0.15 seconds), it is started, the cylinder pressure drop living cell, after 0.15 seconds after the first pulse with 130 of welding energy discharge welding 1 times, the second pulse with 238 energy discharge welding 2 times, cylinder rising complete a welding task. 4.4 program group parameters of the copy In parameters setting state (see 4.3), long press [program FUN] key, enter the program group parameter copy state. At this time it LED digital display "SAV", the flashing LED digital display the current program group. Press [+] key or [-] keys will choose to copy the program group, long press [program FUN] is the current program group of welding parameter copy to choose the program after the group. In this state any time press [setting MODE] key is returned to the parameter Settings state does not save. 4.5 program group selection After startup normal display state, long press [program FUN] key, enter the program group choose state. At this time it LED digital display "Pro", below LED digital display the current program group, through the [+] key, [-] key to program group choice, long press [program FUN] key chooses the current program group and save exit. In the program group choose state, press [setting MODE] key is quit does not save. Can store 10 group program group. debugging First of all access air, boot normal display, welding indicator (green light), said the current in normal 6

10 welding condition, press the buttons the welding light out, then into the machine debugging state. Mainly for the production of former let users machine line head for adjustment and test weld, the battery (or be weldment) height adjustment, the current size of the adjustment, etc., can be adjusted after a large number of welding condition. 1, welding needle height adjustment: first use wrench to loosen the welding needle height adjustment screw, then adjust (or replace) welding needle show electrode the following length (generally mm or so, too long welding needle easy deformation), to lock the screw. 2, electrode (welding needle) width adjustment: first use wrench to loosen the welding needle width adjustment screw, then according to need the width of welding, adjust the two electrode made two welding needle to appropriate distance, and lock the screw. 3, bench height adjustment: table the promise lifting, direct rotating the lock knob carries on the adjustment, general adjustment to welding needle and battery (or other be weldment) distance in 5 mm less than, had better be in 2 mm advisable. 4, welding pressure adjustment: by hand screw welding pressure adjustment screw, clockwise pressure is increased, and it decreases, and according to the welding for the adjustment of the appropriate pressure. 5, cylinder pressure adjustment: general into cylinder pressure adjustment in within 2-4 kg. In general about 3.5 KG can, according to the thickness of the sheet welding adjusted. 6, check welding needle for carbon deposition, need often use file or sandpaper clear welding needle. Garnish with fine sand paper burnish round welding head. If want to welding effect is good, grinding welding needle is little not. 7, test weld: with the foot live foot switch, head down, when welding needle pressure to the welding parts, each time you press the key is welding one time. In the process of welding parameters can be adjusted, according to the welding conditions change welding current and welding needle pressure until welding best. In order to insure good welding quality, must diligently finishing welding needle, with small file will be welding needle tip file level off is smooth, next reoccupy fine sand paper burnish round welding needle. Adjust the loosen the foot switch, cylinder picks up. The key is welding indicator (green light), into the normal welding state. 6, normal welding state After startup screen display normal is entered namely after normal welding state. Such as setting parameters, occurrence hair below the case is not welding: 1, screen have word flash to indicate the still in parameters setting state, now can't welding, to exit to welding. 2, welding light must shine, not bright said machine in debugging state, after the key welding indicator, right now but welding. 7, battery welding parameter Settings note: 1, welding mobile phone batteries, power battery etc must use double pulse, namely the first welding pulse number set as a case, the second welding pulse number set as a case, the first welding energy is the second welding pulse energy about half. 2, in order to guarantee good welding quality, must diligently finishing welding needle, with small file will be 7

11 welding needle tip file level off is smooth, next reoccupy fine sand paper burnish round welding needle Certification of Inspection Name:Microcomputer precision double pulse spot welding machine Model: PR50 Date: 2015 Inspector: No.1 Warranty Card User information: Company: Tel: Add: Product: Model: Date: Guarantee clause L from the date of original shipment maintains for a year, normal use malfunction by my company responsible for maintenance. L all by human's improper operation or not according to the instructions of the damage caused by operation, we shall not be responsible for, if need to service, are the paid service. L use more than a year of equipment (or other equipment), in case of failure to our maintenance, all expenses shall be charged, and the replacement parts guarantee three months. L belong to the following situation, do not belong to free warranty scope: A) because of improper use, operation error, to refit and cause damage. B) with not the company manufacturing accessories and cause damage. C) for accidental factors and cause damage. D) has more than warranty. E) not according to the contract payment date. 8