Powtran Technology’s PI500 Series Medium-Frequency Power Supply Solution for Welding Machines
2018-11-27
I. Overview
A butt welder, also known as a current welder or resistance spot welder, utilizes the electrical resistance between the contact surfaces of two workpieces. By passing a low-voltage, high-current pulse through the contact area, the surfaces of the two metals in contact heat up rapidly to the point of melting and fusion.
Previously, wire rope welding machines used a thyristor-plus-transformer tap method to adjust the welding current, offering a total of eight adjustable levels. During operation, the two sections of wire rope to be welded serve as two electrodes. Under the pressure set by the clamping device, a certain contact resistance is established between the abutting ends of the wires. As the welding current flows from one electrode to the other, a momentary thermal fusion weld is formed at the two points of contact resistance. Due to the inability of earlier models to achieve stepless voltage regulation, the types of products that could be welded were limited, adjusting product specifications and parameters was relatively cumbersome, and the quality of the welded joints could not reach its optimal level.
II. Application Examples
A welding equipment factory in Dongguang is a specialized manufacturer of butt welders. With many years of deep expertise in this field, the company has become an industry leader. Primarily serving the metal products sector, it develops and manufactures products such as the UN series and UN-10V series single-wire automatic welders, as well as DC steel cord wire welders, for welding high-carbon steel wires, stainless steel wires, non-ferrous metals, wires and cables, and copper-aluminum wires. The power ratings of these products range from 1.5 kW to 18.5 kW; future product development will extend the power range up to around 45 kW. The current upgrade involves the UN series butt welders, for which both the PLC control system and the touch screen have been selected from the XINJE brand.
III. Hardware Configuration
The butt welder consists of a welding workbench, a steel wire rope clamping device, welding control buttons, an emergency stop button, a photoelectric switch for adjusting the welding wire melting distance, a touch screen, a PLC control box, a shaping hammer, a grinding wheel, and a steel wire rope torque testing mechanism, among other components.
4. Process Flow
First, the wires are melted and cut. The melting point must be round, smooth, and free of burrs. Next, the two wires are placed on the welding workbench and securely clamped. Select the welding parameters that correspond to the wires, download them into the PLC, and press the “Run” button. The welding machine will then automatically perform the welding process according to the pre-set program. (Welding start, welding stop—heat preservation start, heat preservation stop—tempering start, tempering stop.) After welding is complete, remove the welded wires and inspect the weld points to ensure they meet the required specifications. Then, place the wires onto a torque testing machine for tensile strength testing.
V. System Composition
This renovation involves the UN series butt welder, and both the control PLC and touch screen are from the XINJIE brand.
6. Parameter Settings
The variable-frequency power supply features single-phase or three-phase input and single-phase output, with a relatively simple control method.
Due to the varying process parameters, these parameters are stored in groups according to their sequential numbers. During production, the corresponding process parameters can be retrieved by their sequential numbers based on different wire specifications. If adjustments are needed, they can be fine-tuned on the setup screen and then transmitted to the PLC for welding the products. This system comes preloaded with 30 sets of process parameter recipes, each set containing eight parameters: wire name, welding current, welding time, holding current, holding time, interval time, tempering current, and tempering time. By setting product-specific recipes, the process of adjusting welding parameters has been simplified, significantly reducing the time required for parameter adjustments.
Configuration screen for the welding machine’s touch screen
VII. Conclusion
The entire control system of the butt welder has been upgraded by incorporating a PLC, a touch screen, and a variable-frequency power supply. The upgraded butt welder features convenient and quick recipe functions, enabling a wider variety of products to be welded. Moreover, the overall automation level of the equipment, as well as the welding accuracy and stability of the products, have all been significantly improved.
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