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I. Overview
Butt welding machine is also called current welding machine or resistance welding machine. Using the resistance between the contact surfaces of the two workpieces, a low voltage and large current is instantly passed, so that the contact surfaces of the two butting metals instantly heat up to melt and fuse.
The wire rope butt welding machine used a thyristor and transformer tap method to adjust the welding current. There are 8 gears in total. When working, the two sections of steel wire rope to be welded are used as two electrodes. Under the pressure value given by the tightening device, a certain contact resistance is formed between the butt contact surfaces of the broken ends, and the welding current flows between the two electrodes when the welding current flows from one electrode to the other. The contact resistance point forms an instantaneous thermal fusion. Early products were unable to achieve stepless voltage regulation, so the types of weldable products were limited, the adjustment of product specifications and parameters was more troublesome, and the quality of product welding could not reach the best.
Two, application examples
A welding equipment factory in Hebei is a professional manufacturer of butt welding machines. It has been a leader in this industry for many years. Mainly aimed at the metal product industry, welding high-carbon steel wire, stainless steel wire, non-ferrous metals, wire and cable, copper and aluminum wire, developed UN series, UN-10V series monofilament automatic welding machine, DC steel cord welding machine and other products.The power is from 1.5KW-18.5KW, and the power will be extended to about 45KW in the later product development. This transformation is the UN series.Butt welder, The control PLC and touch screen are both of Xinje brand.
Three, hardware composition
The butt welding machine is composed of a welding workbench, a wire rope clamping device, a welding control button, an emergency stop button, a photoelectric switch for welding wire melting distance, a touch screen, a PLC control box, a plastic hammer, a grinder, a wire rope torque test mechanism, etc.
Fourth, the process
First melt the wire, the melting point is required to be round, smooth and free of burrs, then place the two wires on the welding table and clamp them, select the welding parameters corresponding to the wires, download them to the PLC, press the run button, and butt the welding machine Weld automatically according to the preset procedure. (Welding start, welding stop—heat preservation start, heat preservation stop—-tempering start, tempering stop) After welding, remove the welded wire, observe whether the solder joint meets the requirements, and then place the wire Perform a tensile test on a torque tester.
Five, system composition
The transformation is UN seriesButt welder, Both the control PLC and touch screen use Xinje brand.
Six, parameter settings
The variable frequency power input is single-phase or three-phase input, single-phase output, and the control method is relatively simple.
Due to the different process parameters, the parameters are stored in groups according to the sequence number. The corresponding process parameters can be found through the sequence number according to different wire specifications during production. If you need to modify it, you can fine-tune it on the setting screen. Then the process parameters are transmitted to the PLC, and the product is welded. The system presets 30 sets of process parameter formulas, each with 8 parameters, which are wire name, welding current, welding time, holding current, holding time, interval time, tempering current, tempering time, which are set through the product formula , Which simplifies the adjustment process of welding parameters and shortens the adjustment time of welding parameters.
The configuration screen of the welding machine touch screen
7. Conclusion
The entire control system of the butt welding machine was transformed by adopting PLC, touch screen, and frequency conversion power supply. The modified butt welding machine has a convenient and quick formula function, which expands the types of product welding. The automation level of the entire equipment and the welding accuracy and stability of the product are greatly improved.
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