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Pulsed Micro Arc Welding For Coil Terminations Increases Line Throughput

Pulsed Micro Arc Welding for Coil Terminations Increases Line Throughput

Coils with multiple termination points can be welded at one automation station. Article by James Tod, Amada Miyachi UK.

Pulse micro arc welding is a good choice for coil termination applications, especially as coils are getting smaller and smaller. Other processes do not lend themselves as well for these applications. For example, it can be difficult for lasers to target the pins, while resistance welding is not practical due to electrode size, and soldering involves potentially hazardous fluxes. Multiple output pulsed arc welders are available that offer great automation layout flexibility and increase production line throughput.

Pulse Micro Arc Welding Basics

Pulse micro arc welding is a zero-contact process in which an electrical arc is struck between an electrode and target component. The arc generates very high and concentrated energy density, which results in high local temperatures that can be used for welding. Sophisticated closed loop power supplies are used to establish and maintain the arc under precisely controlled electrical conditions.

The micro arc coil termination process requires wire to be wound onto the pin in a uniform fashion and density. The welding process is accomplished by heating the pin and encapsulating the wire in the molten pin material. The wound pin is positioned close to a welding electrode and an arc struck between the pin and the electrode.

Operators profile the energy and current within the arc in terms of rate of rise, period of peak, and downward cooling to control the rate at which the pin begins to melt back. The process of melting the pin back creates a molten ball that causes the wire and its insulation to melt simultaneously, thus welding the wire to the pin.

Material Type is Critical to the Process

With micro arc welding, the materials must flow together based on the heat generated by the welding arc and the surface tension of the materials. Any contamination can cause the materials to fail to fuse with one another.

Wire insulation is critical because it must be broken down by the heat in the weld before the materials can fuse with one another. In the process, the pin is heated directly and the wire indirectly; if the wire insulation remains intact during the weld, the pin will be melted but the wire will not. Pulsed micro arc termination welding works best with wire insulation rated for temperatures of 180 deg C or lower.

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Amada Miyachi Europe: MM-L300A Laser Weld Monitor

Amada Miyachi Europe: MM-L300A Laser Weld Monitor

Amada Miyachi Europe announces the availability of the new MM-L300A Laser Weld Monitor. The compact MM-L300A is designed to detect welding defects and errors such as gaps between parts, missing parts, weld depth over-penetration, incorrect focus point and cover gas absence. It is providing operators feedback on the resultant laser weld quality. The compact, lightweight unit supports laser welding technologies for spot or seam welds.

This high-accuracy monitor is ideal for both process development and quality control for laser welding applications. The MM-L300A indicates weld quality by detecting and recording a thermal signal from the area of laser interaction and converting this into a graphical waveform. Part of the intelligence of this third-generation process monitor is that not only absolute max/min limits can be set but also value envelopes can be drawn around the waveform. Once the limits are determined, the unit compares a new weld waveform in real time to identify a good or bad weld. Providing high temporal resolution – down to 1 microsecond – the MM-L300A, with the SU-N300A dedicated thermal sensor, enables precision monitoring of both continuous wave and pulsed laser processes.

The MM-L300A features easy-to-use software for simple sensor configuration, waveform envelope limit set-up, and real-time or saved waveform analysis on Windows PCs. Additionally, machine-selectable setup schedules enable the unit to monitor different welding conditions. The compact, 3 kg (7 lb) unit reduces set-up space when integrated into a production line or used in a laboratory environment. The sensor can be mounted either on the optical axis of the laser beam trajectory or in an off-axis position.


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Amada Miyachi Europe Releases New Welding Power Supplies

Amada Miyachi Europe Releases New Welding Power Supplies

Amada Miyachi Europe has launched the CD-V Series of Capacitive Discharge Power Supplies and TL-V Series of weld heads. Featuring a fully controllable dual pulse output and a full-colour 3.5 in user interface, the CD-V Series give consistent welding output for repeatable process results.

Typical applications for the power supply series include battery tab welding, interconnects, honeycomb tacking, fine wire to pad processes, and jewellery repair, among others.

Amada’s CD-V series includes built-in peak current indication for immediate weld fire confirmation, pulse shaping with adjustable upslope to reduce expulsion during welds, an ultra-fast rise time for conductive material welding, and the ability to go rapid fire between pulses for quick welding of adjacent locations.

In addition, the CD-V series makes handling a variety of weld schedules easy, as it is able to store up to 8 schedules at one time, giving the operator the ability to easily change between weld schedules. Other ease-of-use features include a weld counter, programmable squeeze time, and a push button rotary encoder for intuitive operation.

The CD-V series is built in the USA and works with the following AMYA weld heads: Models TL-V80F-E2-0A, TL-V88F-E2-0A (manual cable driven); and Models TL-V80A-E2-0A, TL-V88A-E2-0A (standard air solenoid driven).

The weld heads are designed to complement the new power supplies. There are four variants with air actuated and manual actuated motion. The heads are designed for robust usage and come standard with a robust stand and electrodes.


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