DeltaSpot Resistance Welding

DeltaSpot Resistance Welding

Boundaries are there to be stretched: For us, at any rate GENERAL REMARKS And with DeltaSpot, that s just what we ve done Shifting the limits is our credo. And we ve definitely lived up to this challenging motto again with DeltaSpot. The absolutely innovative thing about this resistancewelding process is its spooling process tape, and it is this which gives the process its improbable-sounding advantages: Every weld-spot is 100 % reproducible; every spot is, so to speak, welded with an unused electrode; high, indeed unrivaled process reliability; zero surface spatter; any type of join is possible, even aluminum to aluminum or steel to aluminum. As so often with great innovations, the principle is simplicity itself. So you can look forward to getting results that will knock spots off the competition. PROCESS Process reliability that s got it taped The relatively simple yet so radically new principle behind this process is the spooling process tape. This runs between the electrode and the workpiece. After every spot, the process tape spools on to its next position. This means that the contact surface always stays clean. Spot for spot, identically high-quality conditions for starting the process. Spot for spot, a new electrode. This is what makes the quality so 100 % predictable. The surface of the electrode itself stays clean no matter how long it is in use. Depending on the application, you can expect to get up to 21,000 spotwelds per tape. The process tape infl uences the heat balance, with the result that a lower welding current is needed. This means that power sources with a comparatively low power rating can be used for DeltaSpot. Also, the process tape actively infl uences the position of the weld nugget: despite differing material resistances, all the sheets are welded.

The process tape protects the electrode from alloying effects and provides constant, highquality starting conditions. Spot for spot, a new electrode. WELDING PROPERTIES Top Gun with the C-pincer The C-pincer gun is a powerful addition to the pincer gun range, complete with all the familiar advantages of DeltaSpot. Among the merits of the C-pincer gun are its high contact pressure and the good accessibility it allows for special component geometry. It welds challenging 3-sheet joints with complete processreliability, and the high electrode force of 8 kn ensures good spot-welded joins even in the case of super-highstrength steel bimetal joins. Keeping disturbance variables to a minimum There are certain disturbance variables that are very common in resistance spot welding. Electrode wear, a shunt, and batch-related differences in the materials and coatings are all typical disruptive factors. Here too, DeltaSpot is different from other resistance spotwelding systems. The unique process tape is able to greatly minimize the effects of these disruptive factors. The vertical electrode manipulation performed by the C-pincer gun is ideal for visually exposed spot-welds using the Expo electrode. Use of the Q-Master quality assurance system is also possible, of course.

Spot-on, every time UTILIZATION All-rounders DeltaSpot opens up hitherto undreamed-of perspectives in many different sectors. It can weld any material: Steel and coated steel, both high and super-high-strength; aluminum, chrome-nickel, titanium, magnesium, bimetal joins, steel/aluminumjoins. As well as joining materials of differing thicknesses and types, DeltaSpot also welds multisheet joins, with complete process-reliability. Through thick and thin DeltaSpot works with all metallic materials. 3-sheet joins between different materials, thick or thin, can be welded with just the same high process-reliability as aluminum to aluminum. And resistance-welding joins of aluminum have always been a high art in themselves. In multi-sheet joins, the different materials and sheet thicknesses encountered here cause different material resistances to occur. The choice of process tape can be fine tuned to take account of these dissimilarities. 3-sheet join between different steel alloys (1.8 mm / 1.75 mm / 1.0 mm = 0.071 / 0.069 / 0.039 ) Material: H400 1.8 mm (0.071 ) / DX 53 D + Z 140 MB; 1.75 mm (0.069 ) / DX 56 D + Z 140 MB 1.0 mm (0.039 ) Electrode: R+70 Process tape: Parameters: plus PT1200, minus PT3000 8kA 500ms 4kN Aluminum 3-sheet join (3.0 mm / 2.0 mm / 1.0 mm = 0.118 / 0.079 / 0.039 ) Material: AlMg3 3 mm (0.118 ) / AlMg3 2 mm (0.079 ) / AlMg3 1 mm (0.039 ) Electrode: R+70 Process tape: PT1407 Parameters: 17kA 700ms 4kN Super-high-strength steel 2-sheet join (1.35 mm / 1.35 mm = 0.053 / 0.053 ) Material: 22MnB5 1.35 mm (0.053 ) / 1.35 mm (0.053 ) Electrode: R+70 Process tape: PT1200 Parameters: 7.0 ka 590ms 3.6 kn

Suitable for any utilization By developing several different pincer guns, Fronius has opened up a much wider variety of utilizations. The DeltaSpot pincer gun s many different weldingthroat depths make for superior weld accessibility in widely varying areas of utilization. In the automotive and supplier industries, for instance, where it ensures welding with complete process-reliability. Or for highly demanding spot-welded joins in the mechanical engineering, plant construction or railed-vehicle construction fi elds. BASIC DESIGN OF PINCER GUN Maximum Designation Throat depth electrode force Weight X350 350 mm 7 kn 102 kg (13.8 ) (225 lb) X500 500 mm 5 kn 106 kg (19.7 ) (234 lb) X750 750 mm 3 kn 116 kg (29.5 ) (256 lb) C300 300 mm 8 kn 120 kg (11.8 ) (265 lb)

Every spot is documented immediately after welding, and inspected for quality, diameter, size, spot-position and spatter, providing a seamless, traceable data record. SYSTEM QUALITY ASSURANCE Versatile configurability One of the big advantages of DeltaSpot is that it is a perfectly matched, interoperable welding system comprising various different components. These include the pincer welding gun and the gun control. Any standard medium-frequency inverter can be used as the welding power source. The mechanical and electrical interfaces enable the DeltaSpot system to be flexibly connected to all common types of robot and field-bus systems. Controlling with Fronius Xplorer This software was specially developed as an easyvisualization tool for administering networked and automated production areas, and for operating, monitoring, documenting and diagnosing them on a centralized basis. Any number of systems can be controlled from a master control station. When it comes to user-friendliness, Fronius Xplorer is hard to beat. For ease and speed of handling, Fronius Xplorer is also touchscreen-capable, of course. Inspecting with DeltaSpot Q-Master Example of a DeltaSpot system 1. DeltaSpot pincer gun C- or X-pincer gun using medium-frequency technology (1000 Hz). 2. Pincer-gun control With its graphic user interface, the pincer-gun control makes it easy to create the welding parameters. 3. Medium-frequency inverter All common MF inverters with analog addressing can be used here. DeltaSpot Q-Master is a brand-new quality assurance system developed specifically for DeltaSpot. Automated and cost-effective. Q-Master can completely replace the usual destructive testing methods. 100 % inspection is possible at only minimal extra expense. DeltaSpot Q-Master photographs and measures each individual spot, by which we mean every single fingerprint on the tape. The camera that does this sits directly on the pincer-gun arm. 4. Water heat exchanger Cooling unit for cooling the pincer-gun arm and the MF transformer. Fronius Xplorer is very easy indeed to operate: For example, the program lets you create ideal curves for certain characteristics not only by keying in exact fi gures, but also completely intuitively, by drawing the curve yourself.

ECONOMY Surface spatter: None, zero, null, ninguna, nessuno DeltaSpot leaves no surface spatter on the material. Both the weldment itself and the working environment stay clean, and there is no need for laborious cleaning of the workplace. Nor, in most cases, is any post-weld machining of the workpieces needed. Welding on narrow flanges An electrode specifically developed for use on fl anges provides superior weld accessibility, making it possible to reduce the fl ange width by as much as 40 %. This means that less base metal is needed and that the entire weldment can be lighter. The process tape lessens wear-and-tear on the electrode, ensuring long electrode service life. Invisible with the Expo electrode For visually demanding applications, the Expo electrode has been developed. This is arched towards the inside rather than the outside. Thanks to this special shape, the base metal has sufficient space in which to expand before regaining its original shape after the end of the joiningprocess. The result is that the electrode indentation on the workpiece disappears to almost nothing and in turn, so does the post-weld machining: there is no longer any need to regrind the join. The Expo electrode is suitable for all metallic materials such as aluminum, CrNi, steel or special metals. FACTS Process characteristics - process tapes protect the electrodes and the materials to be joined - 100 % reproducible weld-spots - spatter-free spot-welding, with complete process-reliability, even of 3-sheet joins between different types of materials and thicknesses of sheets Recommended base metals - steel, coated steel, high and super-high-strength steels - aluminum materials - CrNi steel, titanium, magnesium - bimetal joins, e.g. steel-to-aluminum Customer segments - automotive and supplier industries - mechanical engineering and plant construction - construction of rail vehicles & rolling stock The special shape of the Expo electrode makes for minimal electrode indentation.

Text and illustrations technically correct at time of going to print. We reserve the right to make modifications. This document may not be copied or otherwise reproduced, whether in part or in its entirety, without the express prior written consent of Fronius International GmbH. www.reklamebuero.at FRONIUS USA LLC 10421 Citation Drive, Suite 1100 Brighton, Michigan 48116, USA Tel: +1 810 220 4414 Fax: +1 810 220 4424 E-Mail: sales.usa@fronius.com FRONIUS INTERNATIONAL GMBH Buxbaumstrasse 2, P.O.Box 264 A 4602 Wels, Austria Tel: +43 7242 241-0, Fax: +43 7242 241-3940 E-Mail: sales@fronius.com www.fronius.com FRONIUS CANADA LTD 2875 Argentia Road, Units 4,5 & 6 Mississauga, ON L5N 8G6, Canada Tel: +1/905-288-2100 Fax: +1/905-288-2101 E-Mail: sales.canada@fronius.com 40,0006,2706 v01 2009 aw03